HP Designjet 3D Service Manual
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HP Designjet 3D Service Manual

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Summary of Contents for HP Designjet 3D

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

  • Page 2: Legal Notice

    Rev. C 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 Voltage and Electromagnetic Compatibility Directives: EU 98/37/EEC, EU 73/23/EEC...

  • Page 5: Table Of Contents

    Table of Contents Introduction .....................1 How to use this guide ...................... 1 Safety..........................2 Overview ......................3 What happens when....................3 Powering up: ......................3 Powering Down ..................... 4 Loading Material....................4 Building a Part ....................... 4 Electronics Overview ....................6 Single Board Computer...................
  • Page 6 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: ............... 40 Selecting support style:..................
  • Page 7 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 ....................59 Startup kit tools ......................
  • Page 8 500 Hour maintenance....................60 Tip wipe assembly....................60 Tip shield replacement ..................62 Remove debris from the Filament Present switch ............64 2000 Hour maintenance....................66 Tip replacement and calibration................66 Removing tips: ....................66 Installing tips:....................68 Tip calibration: ....................71 Chamber light bar replacement................
  • Page 9 Part curling ......................142 Part fell over ...................... 143 Part shifting ....................... 144 Rough surface quality ..................146 Rough quality all over ..................147 Model strands on parts ..................148 Witness marks ....................149 Wavy surface ....................150 Wavy parts ....................... 151 Under fill ......................
  • Page 10 Lower Electronics Bay Cover ................171 Opening the electronics bay ................171 Closing the electronics bay................172 Upper Electronics Bay Cover ................173 Removing the upper electronics bay cover ............173 Installing the upper electronics bay cover ............174 Removing the Electronics Bay................175 Removing the electronics bay................
  • Page 11 24VDC Power Supply ..................201 Removing the 24VDC Power Supply ..............201 Installing the 24VDC power supply..............204 5/12VDC Power Supply ..................205 Removing the 5/12VDC power supply ............205 Installing the 5/12VDC power supply.............. 207 120VDC Power Supply ..................208 Removing the 120VDC power supply ..............
  • Page 12 Installing the material tubes ................246 Umbilical Cable ....................247 Removing the umbilical cable ................. 247 Installing the umbilical cable ................248 XY Table Components ....................249 Y Home Sensor ....................249 Removing the Y home sensor ................249 Installing the Y Home Sensor................250 Y EOT (End of Travel) Sensor ................
  • Page 13 Performing part based calibration for HP Designjet 3D from the Service Calibration menu (Firmware version 9.1 or newer)............. 343 Performing part based calibration for HP Designjet 3D with the HP Designjet 3D Diag- nostic Software ..................... 352 Part Measurement Equations ................359 Performing part based calibration for HP Designjet Color 3D from the Service Calibra- tion menu (Firmware version 9.1 or newer)............
  • Page 14 Hard Drive Installation Checklist ................... 420 Toggle Head Assembly Installation Checklist ..............421 XY Table Assembly Installation Checklist ................ 422 Controller Board Checklist.................... 423 HP Designjet 3D Diagnostic Software Help ..............424 Overview ......................424 Select a Modeler....................424 Modeler States....................425 Modeler Setup ....................
  • Page 15 Position and Temperatures................... 426 Versions ......................426 Travel Limits....................... 426 Material ......................427 Door......................... 427 Setting the Serial Number ................... 427 Materials......................427 Adjusting XY Tip Offset ..................427 Gantry ......................428 Temperatures ..................... 428 Temperature Limits....................428 Outputs ......................429 Get Calibration....................

  • Page 17: Introduction

    Introduction HP Designjet 3D and HP Designjet Color 3D are designed with ultimate simplicity in mind. The printer enables you to build parts quickly and easily, even if you’ve never used a 3D printer before. The printers build models with ABSplus material so parts are strong and durable.

  • Page 18: Safety

    Safety The following classifications are used throughout this guide. CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. WARNING: Indicates a potentially hazardous situation which, if not avoided, could result in serious injury. Hot Surface: The hot surface sign indicates the presence of devices with high temperatures.

  • Page 19: Overview

    Overview What happens when... Powering up: Power Switch turned to ON Chamber lights (dim mode), display backlight and fans turn on. Material bay drive homes. Controller BIOS starts and loads the OS Performs Power On Self Test (POST). POST looks at voltages, checksum (operating system) from the and memory, etc.

  • Page 20: Powering Down

    ‘remote’ location or from the display panel at the printer. At Printer ‘Start Model’ - You send a part to the printer from your HP Designjet 3D Software Solution work station. You start the build of the part from the printer.
  • Page 21 Do not press the Wait for Part button b. From your HP Designjet 3D Software Solution work station, send a part to the printer. c. The printer panel displays the name of the first model in the printer queue and Start Model is blinking.

  • Page 22: Electronics Overview

    Once that road is complete, the head will move over the purge bucket, and the Z stage will descend to the bottom of the envelope. In the Pause State the printer can be resumed, material can be loaded and unloaded, the build can be canceled, and printer maintenance may be performed.

  • Page 23: Single Board Computer

    Single Board Computer The single board computer (SBC) is the main processor in the system. See (Figure ) showing the board layout. The TCP/IP network interface connects directly to the RJ-45 connector on the SBC. The network interface supports both 10baseT and 100baseT operation. The hardware differentiates automatically.

  • Page 24: Controller Board

    Controller Board Overview The controller board provides all of the low level hardware control and sensing for the system. The firmware runs on the controller CPU and is flash resident (rather than on the HDD and SBC). Voltage Generation • +/- 1 5 VDC is used for PMD DACs •...

  • Page 25: Liquefier Temperature Control

    Liquefier Temperature Control The liquefier T/C connects to the controller board through the power distribution board. The T/C generates a variable low level current that depends on the temperature of the T/C. This analog signal from the T/C is amplified by the head distribution. It is then sent down the umbilical cable to the PDB, and then to the controller board.

  • Page 26: Safety Devices

    in turn is controlled by the controller board. The following is a list of actuators: • Door solenoid – locks the door to the modeling chamber. • Carrier latches – holds carriers in the material bays. • Material bay solenoids – engage the motor that feeds filament from carrier to the liquefier during auto load.

  • Page 27: Reset Button

    Figure 4: Controller board connection detail Reset Button Located on the lower right side of the board, the reset button will do a hard reset of the controller board. 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.

  • Page 28: Sw2

    Number (in white) Description Default 16-24 Unused Number (in white) Description Default 8- 1 5 Unused Number (in white) Description Default Run built-in self test (BIST) Load Firmware (turn on when using SND- BIN.EXE) Disable door latching Unused Don’t reset controller when in command is issued Disable WatchDog timer Enable use of dc commands...
  • Page 29 controller board, +5 and +12 VDC come from the PDB. One function of the D6-D12 LEDs is that they turn on sequentially to show software 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.

  • Page 30: Power Distribution Board (Pdb)

    Power Distribution Board (PDB) Figure 5: PDB Detail AC Power In Power Switch/Thermostat Chamber Heaters Auxillary 120VDC power supply Z BOT, Z EOT, Chamber Fans, Frame ID, Filament detect sensor (not used) Z motor I/O board connection J1 1 I/O board connection 24VDC input Test points and LEDs (see detail in this section) 5/12VDC input...

  • Page 31: Chamber Temperature Control

    AC line voltage comes into the PDB (Figure 5). The voltage is routed through the solid state relay to an auto switching circuit. The circuit is used to supply the chamber heater voltage: 240 VAC in series, or 120 VAC in parallel. The solid state relay is controlled by the controller board, and turns the heater on/off to regulate the chamber temperature.

  • Page 32: Test Points And Led's

    Test Points and LED’s Test points and LED’s are very useful for troubleshooting the system. The test points and LED’s are listed below with a brief description. Figure 6: Test points and LEDs detail Test Pt. Description Component TP29 Power fail signal from external UPS +5V REF TP24 Head T/C service reference...
  • Page 33 Test Pt. Description Component X EOT TP18 X end of travel sensor (5 VDC), switches are wired normally closed (NC) X Home TP19 X home sensor (5 VDC), switches are wired normally closed (NC) Y EOT TP12 Y end of travel sensor (5 VDC), switches are wired normally closed (NC) Y Home TP13...

  • Page 34: I/O Card

    I/O Card Figure 8: I/O card detail J510 PDB Board connection J51 1 PDB Board connection J507 Chamber thermocouple J501 Y Motor J502 X Motor J503 Y BOT and Y EOT sensors J504 Head blower fan, power on/off switch, left and right chamber lights, LCD display, door solenoid, door switch.

  • Page 35: Head Board

    Head Board Figure 9: Head board layout Rear view Front view J304 Z Sensor J302 Head Motor Power J303 Head Motor Ribbon Cable J301 Umbilical Cable J102 Support Heater U303 X Home Sensor J305 Toggle Sensor Support 120VDC LED (120 VDC present if on) Model 120VDC LED (120 VDC present if on) U304 X EOT Sensor J202...

  • Page 36: Printer Overview

    Software Solution is the preprocessing software 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).
  • Page 37 Figure 1 1: Interior chamber - front view Extrusion Head Tip wipe assembly Purge bucket Z stage platen Modeling base retainers (x2) Modeling base Z stage guide rods Z stage lead screw Extrusion Tips...
  • Page 38 Figure 12: Rear view of printer 1 Model Material Y Connector Support Material Tube 2 Model Material Tube UPS Connection 3 AC Power Cord Connector Material Bay Cable Connector 4 Circuit Breaker RJ-45 Network Connector 5 Material Bay Diagnostics Cable Connector 6 Optional Model Material Tube Material Bay Communications Cable 7 Optional Material Bay...
  • Page 39 Support material carrier Figure 14: Modeling base Modeling base 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.

  • Page 41: Setup

    Set up the printer and material bay(s) per assembly instructions included with printer. Installing software There are two software programs that work with HP Designjet 3D and HP Designjet Color 3D: 1. HP Designjet 3D Software Solution, installed on your workstation, processes the STL files for printing and communicates with the printer from your workstation.

  • Page 42: Establishing Network Communication With The Printer

    HP Designjet printer and commonly used in large networks. In some situations you may need to manually enter a Static IP address for your printer and record the IP address in the HP Designjet 3D Software Solution. Static IP addresses are frequently used for smaller networks.

  • Page 43: Establishing Communication On A Static Network

    Establishing communication on a static network: If you are using a static network or connecting the printer directly to a workstation, you will need to enter the static IP address information into the workstation and the printer. If you are using a static network and your computer already has network access, see “Setting the static network on printer:”...

  • Page 44: Setting The Static Network In Windows 7

    10. Enter the IP address, Subnet Mask and Default Gateway. Contact your IT Administrator or Internet Service Provider for details regarding IP address information. 1 1. Click on the OK button when finished. Close any open networking win- dows. Setting the static network in Windows 7: 1.

  • Page 45: Establish Communication

    1 1. Press Done until Idle is displayed. Establish communication: 1. From your workstation, start the HP Designjet 3D Software Solution. A. From the General tab, click the Manage 3D Printers button. B. Click the Add from Network button in the lower right corner of the window.

  • Page 46: Installing Firmware On Printer

    7. Navigate the HP Designjet 3D 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.

  • Page 47: Adding The Second Hp Designjet 3D Material Bay

    Installing the HP Designjet 3D Material Bay: 1. Remove the HP Designjet 3D Material Bay, material bay cable, material spools and material carriers from the box. 2. Unload the model and support material from the printer.
  • Page 48 Figure 16: Separating the printer and material bay 14. Position the second 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.
  • Page 49 Figure 18: Positioning printer 16. Remove the black plugs from the model and support Y blocks by push- ing in on the coupler rings and pulling outward. 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.
  • Page 50 Figure 20: Connecting the short material tubes 19. Connect the long red striped material tube (M2) from model (M) coupler of lower material bay to right side of model Y block by inserting firmly into red couplers. Gently pull the tube to ensure it is properly inserted. 20.
  • Page 51 Figure 22: Connecting the material bay cables 23. Connect the power cable, network cable and UPS cable if used. 24. Switch the circuit breaker to the ON position. 25. Power the printer ON at the power switch. 26. After the printer has booted up, you may need to reload the printer firm- ware.

  • Page 53: Operation

    Keypad buttons Lower windows The HP Designjet 3D and HP Designjet Color 3D 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.

  • Page 54: System Firmware Overview

    System firmware overview • Idle: If there is no part being built and no part in the build queue, the display will show that the printer is Idle. • Wait for Part or Start Part: If the printer is in Idle and the build queue is empty, you can set it to wait for a part.

  • Page 55: Hp Designjet 3D Software Solution Overview

    • Support style • Clear pack • Printer time • Number of copies • Printer password • STL units • Printer information • STL scale • Update software NOTE: For detailed information refer to HP Designjet 3D Software Solution Dynamic Help.

  • Page 56: Processing Your Stl File For Printing

    4. Navigate to and select the STL file that you have created. Selecting layer resolution: Layer resolution can be changed on the HP Designjet Color 3D printer. Changing layer resolution will affect surface finish and build times. Selecting a smaller layer resolution creates a smoother surface finish, but takes longer to build.

  • Page 57: Selecting Support Style

    Orientation can also affect the ability of HP Designjet 3D Software Solution to repair any problems with the STL file. You can choose to auto orient your part, which allows HP Designjet 3D Software Solution to determine the best orientation for the part for the fastest build time and least material usage, or you can manually change the orientation of your part.

  • Page 58: Adding Your Stl File To The Pack

    The Add to Pack button is found on the General, Orientation and Pack tabs. When you click on the Add to Pack button, HP Designjet 3D Software Solution will add the file that is currently in the preview window (General tab or Orientation tab) to the pack preview window (Pack tab).

  • Page 59: Building A Part

    3. Press Yes. Waiting for Part will now be on the display. 4. From your HP Designjet 3D Software Solution workstation, send a part to the printer. The printer will automatically start to build the part. Starting a build from the display panel:...

  • Page 60: The Display Panel During Build

    The display panel during build The top two lines of the display panel will show the printer status. See Figure The bottom line of the display panel will show the amount of model and support material that remains in the carriers. Figure 26: Display panel during build Single material bay Printer status...

  • Page 61: Pausing A Build

    Pausing a build While building a part, you may want to pause the build to allow for material replacement. To pause the build at any time, from the display panel press Pause. NOTE: The printer will complete the current tool path before pausing.

  • Page 62: Removing A Completed 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 solution. Your part is left with a smooth and clean finish with the fine details intact. The soluble support material can be removed by hand with relative ease, but is designed to be dissolved from your parts for hands free finishing.

  • Page 63: Emptying The Purge Bucket

    Emptying the purge bucket Empty the purge bucket after each build to avoid part quality issues or damage to the printer. GLOVES: Wear gloves when emptying the purge bucket. 1. With a gloved hand, lift up on the purge bucket and pull it off of the two mounts.

  • Page 64: Replacing Material For Dual Material Bays

    6. Remove the material carriers by first pushing them in to unlatch and then pulling them outwards. 7. Place the carrier on a flat stable surface. CAUTION: Do not push the material through the material guide back into the carrier, doing so can cause material to break or become tangled.

  • Page 65: Material Bay Leds

    7. Place the carrier on a flat stable surface. CAUTION: Do not push the material through the material guide back into the carrier, doing so can cause material to break or become tangled. 8. Open the carrier. 9. Rotate the spool to rewind the material, leaving 2 inches (50mm) remaining at the material guide.

  • Page 66: Replacing Material Spools

    Replacing material spools Removing a spool of material from the carrier: 1. Place the carrier on a flat stable surface. 2. Unlatch the carrier and open. 3. Remove the spool of material. Discard any pieces of material that may remain in the carrier. 4.
  • Page 67 Figure 30: Rewinding the material spool 7. Using a cutters, cut the excess 2 inches (50mm) of material from the material guide, leaving a blunt end. 8. Locate the two material retaining clips on the carrier. See Figure 31. Figure 31: Material retaining clips Material retaining clips 9.

  • Page 68: Auto Power Down

    1 1. Cut the excess material from material guide. 12. Place the material retaining clips on the spool before removing the spool from the carrier. See Figure 33. A. Push the material retaining clips over the material and clip on to the material spool. B.

  • Page 69: Powering Off

    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.

  • Page 71: Software

    Software Software Architecture (Figure 35) shows the major software components that control the system. The software that runs on the controller board is EPROM based. The software that runs on the SBC (single board computer) is stored on the hard drive and loaded during power up.

  • Page 72: Comm Server

    The comm server software on the system is the other half of the download software that is part of the HP Designjet 3D Software Solution. Parts to be built (.cmb files) are received by the comm server and saved on the data partition of the hard drive.

  • Page 73: Hp Designjet 3D Software Solution Help

    HP Designjet 3D Software Solution overview HP Designjet 3D Software Solution is an intuitive, user-friendly application designed to interface with HP Designjet 3D printers. It allows you to quickly and easily open a 3D drawing of a part, prepare the drawing for print, and send the print command to create the part.

  • Page 75: Maintenance

    Maintenance Startup kit tools The startup kit contains a set of tools used to help you maintain the printer. The following is a list of the tools contained in the startup kit. • Needle nose pliers • T-Handled allen wrench - 1/8 inch •...

  • Page 76: 500 Hour Maintenance

    500 Hour maintenance Preventive Maintenance Alerts will be displayed on the workstation at the 500 hour time interval as a reminder to perform preventive maintenance. Figure 36. Figure 36: Preventive Maintenance Alert Tip wipe assembly The tip wipe assembly should be replaced approximately every 500 hours. 1.
  • Page 77 Figure 38: Replacing 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: Tip Shield Replacement

    Tip shield replacement Tip shields can become worn or damaged over time. This can have a negative impact on the surface finish and detail of models. Replace the tip shields every 500 hours. Figure 40: Tip Shield damage New shield Worn shield 1.
  • Page 79 3. Position the blade of a small screwdriver between the tip shield and tip plate. Use the blade of the small screwdriver to separate the tip shield from the tip plate. See Figure 42. Figure 42: Tip Shield removal Tip plate Insert small standard Tip shield screwdriver to pry tip...

  • Page 80: Remove Debris From The Filament Present Switch

    Figure 44: Tip Shield installation 6. Exit Maintenance, press Done until back at Idle. Remove debris from the Filament Present switch There may be a time when the Filament Present switch needs to be cleared in addition to the 500 hour maintenance. For example, if a Material Error- Filament blocked message appears on the display panel;...
  • Page 81 Figure 45: Filament Present Switch location Model side Filament Present Switch Support side Filament Present Switch 6. Obtain a can of compressed air. 7. Insert the canned air extension tube to its spray nozzle. 8. Align the canned air extension tube with the entrance hole of the Fila- ment Present Switch.

  • Page 82: 2000 Hour Maintenance

    NOTE: Tips can also be damaged by improper care while performing maintenance in the area around the tips. HP Designjet 3D Software Solution displays the tip time (hrs) - from the Printer Services Tab - Printer Info button (Tip time will reset to zero after replacement).
  • Page 83 Figure 48: Head cover tab locations Press tabs in to remove head cover Head cover 9. Remove tips A. Use 7/64 T-Handle Allen wrench to loosen the heater block screws three to four full turns counterclockwise - or until the top of the screws are flush with the metal cover.

  • Page 84: Installing Tips

    Figure 50: Remove the tips Pull tips down to remove D. Repeat for second tip if necessary. Installing tips: 1. Place the tip shield on the tip. Be sure to install the proper tip. See Figure Figure 51: Tip shield alignment Slotted end Slotted end Align the tip shield so the slotted end is facing...
  • Page 85 Figure 52: Install the tips 3. Use needle nose pliers to grasp the stainless steel shield of the tip. 4. Pull the tip shield toward you, then lift up to install the tip. 5. Push the tip toward the back of the printer once it is all the way up against the heater block.
  • Page 86 Figure 53: Tighten heater block clamp screws. Tighten screws Tighten screws 8. Repeat steps 3 through 7 for the other tip if necessary. 9. Replace head cover and close the printer door. 10. The printer will display Tip Maintenance - Tips Replaced? - press Yes to begin material load.

  • Page 87: Tip Calibration

    Tip calibration: Tip replacement requires Tip Calibration. 1. Select Start Part (flashing) - the printer will run two calibration parts. • The printer will automatically build a Z Calibration part, measure the part and calibrate the Z Axis for tip depth and tip level (approx- imately 5 minutes).
  • Page 88 Figure 54: Example XY Tip Offset Part. This example requires 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.

  • Page 89: Chamber Light Bar Replacement

    Chamber light bar replacement 1. Power down the printer. 2. Locate the wiring harness leading away from the top of the light bar. 3. Disconnect the light bar from the wiring harness by squeezing the wiring harness clip while pulling down. 4.

  • Page 91: Troubleshooting

    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.
  • Page 92 Error message on Recommendation display panel Can’t Find Home – Check 1. Verify a modeling base is inserted. Modeling Base 2. Modeling base may be used or defective – replace. 1. Remove the carrier and verify material is Material Error Filament error coming out of the material guide.

  • Page 93: Fault Determination Codes

    Error message on Recommendation display panel Load Error 1. Remove the carrier and verify material is Purge failed 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.

  • Page 94: Cycling Power

    Cycling power 1. Turn the power switch to the OFF position. The display will show Shutting Down. 2. After the printer has cooled down enough to shut down, the display will go blank. 3. When the display is blank and the printer has shut down, turn the circuit breaker to the OFF position.

  • Page 95: Clogged Tip

    10. Determine if there is a support material extrusion problem by pressing Forward. Watch the support tip (left tip) for any extrusion (material purge). 1 1. Press Stop to stop the extrusion. 12. If material did NOT flow from the support tip, see “Recovering from loss of extrusion”...

  • Page 96: Material Jam

    5. Press Head. The head will heat up to operating temperature which will take approximately 3 minutes. 6. Press Select Drive and choose the drive that may have the clogged tip. 7. Press Forward, the drive wheel will turn the selected drive forward. 8.
  • Page 97 6. Inspect tip inlets for material build up see Figure 58. If there is excess material build up see “Recovering from loss of extrusion” on page 82. there is no excess material build up close the chamber door and con- tinue. Figure 58: Tip inlet locations Support tip inlet Model tip inlet...

  • Page 98: Recovering From Loss Of Extrusion

    Recovering from loss of extrusion NOTE: It is recommended that you read and understand this entire procedure before performing any of the work. 1. Enter Head Maintenance mode. A. From Idle, press Maintenance. B. Press Machine. C. Press Head. The head will heat up to operating temperature which will take approximately 3 minutes.
  • Page 99 Figure 60: Toggle bar in neutral position 4. Remove any excess material found around the head area. NOTE: Material fed to the tip can sometimes jam causing a build- up of material under the head cover. A. Clean out as much of the material as possible using needle nose pliers, a probe, or equivalent tool.
  • Page 100 Figure 61: Create access space for cleaning - model side shown Toggle spring post Idler wheel post Position toggle bar to same side of head as T-Handle. ii. Move idler wheel assembly by pushing with 7/64 inch T-Handle Allen wrench against spring tension. Insert a 1/8 T-handled Allen wrench (from startup kit) into the fixture hole.
  • Page 101 iii. Ease pressure on the 7/64 T-Handle Allen wrench to carefully return the leveraged idler wheel back toward its original position - until the idler assembly is resting against the 1/8 T-Handle Allen wrench. iv. Remove the 7/64 T-Handle Allen wrench. C.

  • Page 102: Service Troubleshooting

    Service Troubleshooting Revised 1 1/15/2010 1.0 How to use this Guide 2.0 Special Notes 3.0 Code Errors 4.0 Non-Code Errors 5.0 Connector Pinouts and Signals 1.0 How to use this Guide 1. Determine what type of error you are experiencing; either a Code Error or Non-Code Error.

  • Page 103: 2.0 Special Notes

    A. Verify that the machine is plugged directly into a wall outlet. Do not use an extension cord or power strip. B. Verify you are running the current HP Designjet 3D Software Solution and printer firmware. Upgrade the software if necessary.

  • Page 104: 3.0 Code Errors

    3.0 Code Errors Major Codes NOTE: These codes are displayed on the system LCD Display. Code Error Definition/Recommendation Unknown Error No data on what error occurred. Cycle power. PUC Error Path, utilities and controller development library (Used for software testing). Cycle power. No Display Process that runs LCD display generated error.
  • Page 105 Code Error Definition/Recommendation Controller Load Unable to load global parameters (Temp values, Failed flow control). Cycle power. Temperature Failed to Liquefier or chamber failed to reach temperature Regulate within 7 min. See 18 error code below. Controller Controller failed to reboot or start. See detailed 19 Initialization Failed error code section below.

  • Page 106: Major Codes With Minor Codes

    Major Codes with Minor Codes NOTE: Currently minor codes exist for major codes 14, 15 17-20, 22, & 23 only. Controller Abort Minor Errors (Code: 14, XX) Code Description Corrective Actions 14,01 Not Used Not Used 14,02 Report: Attempt to raise 1.
  • Page 107 Code Description Corrective Actions 14,05 Abort : Unexpected 1. Power cycle the machine. contact with X axis 2. Check for an obstruction hitting the model. home sensor. 3. Check to make sure the homing sensors are 14,06 Abort : Unexpected clean.
  • Page 108 14,22 Abort : Head 1. Reinstall printer firmware. temperature set-point 2. Verify the head temperature set point using too low. HP Designjet 3D Diagnostic Software. • The model must be above 240 degrees. • The support must be above 240 degrees.
  • Page 109 3. If the frequency of the error is greater than once every three months, replace the controller board. 14,34 Abort : Z axis table Not used on HP Designjet 3D printers. jammed 14,35 Report: Time out while 1. See Load Failed Section (K) in the Non-Error loading carrier.
  • Page 110 Code Description Corrective Actions 14,41 Abort : Motion 1. Check to see if door latch is activating using command while door LED's. open. 2. Check J504 pins 8 and 20 on the I/O card 14,42 Abort : Load cartridge for loose contacts or bent pins. while door open.
  • Page 111 Code Description Corrective Actions 14,55 Abort : Find home 1. Power cycle machine - remember to move failed, X home and X head away from switches. eot both on 2. X errors - Check pins and reseat connector 14,56 Abort : Find home J505 on the I/O Board.
  • Page 112 1. If error occurs more than once a month Checksum error replace the controller board. 14,73 Abort: Head TC Board Not used on HP Designjet 3D printers. Configuration error 14,74 Unexpected contact with 1. Power cycle machine - remember to move unknown limit.
  • Page 113 Code Description Corrective Actions 14,79 Run-time error 1. Cycle power. 2. Check .cfg File for other errors. 3. Replace single board computer. 4. Replace controller board. 14,80 Index out of bounds 1. Cycle power. 14,81 Invalid argument 1. Cycle power. 14,82 Invalid channel 1.
  • Page 114 Controller not ready to 1. Cycle power. build a model 14,106 BOT offset is higher than 1. Use HP Designjet 3D Diagnostic Software to the BOT switch zero the Z offset value. 2. Run tip Z calibration. 3. Check Z home sensor.
  • Page 115 Code Description Corrective Actions 14,1 17 A command failed while 1. Download CFG file - check error code modeling details. 2. Toggle failure - reference 14,129. 3. Check and reseat connectors/pins on J506 on the I/O card and J301 on the head board.
  • Page 116 Code Description Corrective Actions 14,129 Toggle Head failure 1. Check physical position of head at failure. 2. Ensure toggle bar aligns with toggle stops. 3. Inspect top layer of model for part shift. 4. If any of above indicate a failure, Cycle Power and resend part.
  • Page 117 Code Description Corrective Actions 14,133 Head liquefier is not 1. Liquefier T/C may be crushed. Test using heating up meter. • If crushed, reading will be 0 Ohms between pin 1 and ground. 2. If head board with LED’s is present, check model and support 120VDC LEDs at head board.
  • Page 118 Code Description Corrective Actions 14,138 MCB Firmware error: 1. Cycle power. Error upgrading 2. Reinstall upgrade. firmware. (possibly mismatched firmware/hardware versions) 14,139 MCB not present : No 1. Power down. MCB available on the 2. Reseat material bay cables. system. 3.
  • Page 119 Starting Up Failed Minor Errors (15.XX) Code Description Corrective Actions 15,01 Startup state activation Software use only failed 1. See CFG file for additional error details. 15,02 Timeout period expired 2. Replacement controller board or hard drive while starting up is gendered incorrectly.
  • Page 120 1. Liquefier T/C may be crushed. Test using meter. If heat up (its cold). crushed, reading will be 0 Ohms between pin 1 and ground. Use HP Designjet 2. If head board with LED’s is present, check model 3D Diagnostic and support 120VDC LEDs at head board.
  • Page 121 18,01 Chamber 1. Chamber TC has failed. Replace chamber TC. temperature too 2. Chamber temperature offset is incorrect. Correctly high (over 77 set at 77 degrees using HP Designjet 3D degrees) Diagnostic Software. See “Temperatures” on page 428. 18,02 Temperature failed 1.
  • Page 122 Controller Communications Failed Sub Errors (22.XX) Code Description Corrective Actions 22,01 FC_SERVICE event not received. Not used on HP Designjet 3D printers 22,02 Insufficient material to complete job. Universal Device Name Error (23.XX) Code Description Corrective Actions 23,01 UDN controller command failed.

  • Page 123: 4.0 Non-Code Errors

    4.0 Non-Code Errors A. “Build Error” displayed on LCD B. Tip Depth Incorrect C. “Corrupted Upgrade” displayed on LCD D. “Carrier Invalid or Empty” displayed on LCD E. Door Latch “Door Open” displayed on LCD G. Download H. Loss of Extrusion (LOE) Lights Material/Unload Error (failed to load/unload material) K.
  • Page 124 4. Door switch is bad, replace door switch. G. Download 1. Model sent to system, 1. Verify the IP address on the printer and in HP Designjet 3D Software Solution match. but did not appear in queue. 2. Send the file again. Check the lower status bar in HP Designjet 3D Software Solution for error messages.
  • Page 125 Remove head cover and inspect liquefier inlet Are both filaments present at drive wheel? Is there a short Is there excess piece of filament in material inside the the liquefier inlet? head? 1. Filament Missing at Drive 2. Filament Tail Left at 6.
  • Page 126 1. Filament Tail Left at Liquefier 1. Verify that filament tube is connected at all Inlet junctions. - Broken Filament 2. High pull force on the material spool. - Undetected EOF a. Verify spool lid is inserted properly and not rubbing on carrier. b.
  • Page 127 2. Filament Present but Won't 1. High pull force on the material spool. Extrude a. Verify spool lid is inserted properly and not rubbing on carrier. - Spin out b. Remove any debris from bottom of - Head Motor Doesn't turn carrier.
  • Page 128 3. Intermittent LOE 1. Check for loose heater block clamp screws. - Head Motor 2. Make sure the head connectors are seated properly. - Intermittent tip plug 3. Check air plenum for: proper hose connection; properly seating; cracks or damage. 4.
  • Page 129 5. Excess Material Inside Head 1. Check for loose heater block clamp screws. - Filament Buckled / Spaghetti 2. Make sure the head connectors are seated Head properly. - Encased Head 3. Check air plenum for: proper hose connection; properly seating; cracks or damage.
  • Page 130 I. Lights Chamber lights won't come on or 1. Check and reseat connectors to the light bar. are dim. (Unit is otherwise 2. Swap light bars to determine whether bad functioning normally) light bar or bad cable. 3. Lights are burnt out - replace light bars. 4.
  • Page 131 9. Carrier failed to load after 1. Carrier is defective (e.g. material jammed in three tries. carrier, worn drive wheel). Replace 2. Carrier is empty. Replace carrier. 3. Filament left in head or needs to be cleaned. 4. Load solenoid or motor not working. Check connections to motor/solenoid.
  • Page 132 1. System boots, but won't talk to 1. If using static - Wrong IP address, check that network. IP in machine and HP Designjet 3D Software Solution are the same. 2. If using static - Make sure the IP address is static on the customer's network.
  • Page 133 L. Pauses During Build 1. Chamber won't heat up to 1. Verify top and side panels and insulation are at least - 77 degrees installed. 2. Verify chamber fans are operating. 3. Check J3 heater connector/pins on the PDB. 4. Heater bad. Check heater resistance - should be 36 +/- 5 ohms.
  • Page 134 3. Pausing during build and 1. Check CFG for multiple EEprom write errors. If temperatures are correct. errors are noted: Note: a. Select Resume. (from display panel) b. Unload/Reload carrier Pausing may be caused by c. Replace spool multiple carrier read/write d.

  • Page 135: What Happens During Power Up / Boot

    What happens during Power Up / Boot Power Switch turned to ON See M - 3 Chamber lights (dim mode), display backlight and fans turn on. Material bay drive homes. See M - 5 Controller BIOS starts and loads the OS Performs Power On Self Test (POST).
  • Page 136 M. Power UP / Boot 1. Chamber won't heat up: 1. Verify top and side panels and insulation are installed. 2. Verify chamber fans are operating. 3. Check J3 heater connector/pins on the PDB. 4. Relay failed on PDB, replace PDB. 5.
  • Page 137 3. No fans, lights, text and no 1. Verify circuit breaker is in the ON position LCD back light (no nothing) 2. Verify AC power is present at outlet, i.e. plug a known good item into outlet. 3. Check if the thermal snap switches are open. If snap switches are open, verify chamber fans are operating correctly.
  • Page 138 5. System won't boot, no 1. If system homes: Check LCD cable, if OK display after 5 minutes. replace LCD 2. Immediately after power-up, the LCD Fans, lights and LCD backlight backlight should turn on, then the display are operating pixels should all turn dark briefly before NOTE: Replacement hard drive returning to light (blank) again.
  • Page 139 8. System displays “Copyright” 1. Cycle Power at the Circuit Breaker. screen and does not home 2. Reseat the IDE cable, Verify red line is to the within 5 minutes. right. (Halted on Copyright screen) 3. Reseat the connectors to the I/O Board. 4.
  • Page 140 1. Modeling base is used/defective - Replace modeling base routine then 2. Z offset value is incorrect (out of operating displays error message. range) Check/adjust value using HP Designjet 3D Diagnostic Software. 3. Flatness check may have failed. Use Tera Term to read the touchdown values.
  • Page 141 .78" offset values. default = 0.78, 0.00 2. Tip offset values change but 1. Tip offset is changed in HP Designjet 3D do not take. Diagnostic Software and the change is stored correctly in the hard drive (verified by viewing the CFG file).
  • Page 142 R. Z Calibration Failure 1. First layer too deep into modeling base 1. Add +.010 to Z offset value Diagnostic details: Left square (SS) Upper layers - Missing 1st layer - May be visible, but looks choked off. Etches may be visible in modeling base.
  • Page 143 3. Support tip much lower than model tip 1. Add -.010 to Z offset value Diagnostic details: Left square (SS) Upper layers - Built OK 1st layer - OK Right square (model) Upper layers - Missing or barely stuck to modeling base.
  • Page 144 6. Model filament not loaded 1. Load material Diagnostic details: Left square (SS) Upper layers - Built OK 1st layer - OK Right square (model) Upper layers - Missing or barely stuck to modeling base. 1st layer - Missing. No evidence of ABS extrusion 7.

  • Page 145: 5.0 Connector Pinouts And Signals

    5.0 Connector Pinouts and Signals Umbilical cable diagram Umbilical Cable I/O Card to Head Board and T/C Amp Board Cable # 205680-0004 I/O card Head board P505 P301 Signal P505-17 HD_ALARM_IN P301-14 P505-7 P301-6 P301-5 P505-4 HD_SUPPORT_HEATER P301-17 P505-3 120VDC-2 P301-16 P505-1 HD_MODEL_HEATER...
  • Page 146 Signal Signal Information P505-6 Signal ground Toggle Sensors P505-21 MODEL_TOGGLE_IN Toggle in model position. In position = 0 P505- 1 0 SUPPORT_TOGGLE_IN Toggle in support position. In position = X Axis Sensors P505- 1 1 XEOT_IN X EOT sensor. Sensor is NC = 5VDC. Open = 1.8VDC.

  • Page 147: Upper Harness

    Upper harness Upper Harness From I/O card to head blower fan, power on/off switch, left and right chamber lights, LCD display, door solenoid and door switch Cable # 102597-0002 I/O Card Signal Door latch P504-8 +12V-3 DOOR LATCH P11-1 P504 P504-20 RTN DOOR LATCH P11-3...

  • Page 148: Upper Harness Pinouts

    Upper harness pinouts Wire Signal Signal Information Color Door Latch P504-8 WHITE +12V-3 DOOR LATCH Latched = 8 V (does not receive full 12VDC to reduce heat). Unlatched = 0 V P504-20 BLACK RTN DOOR LATCH Latched = >1 V. Unlatched = Chamber Light Right P504-21 24V LAMP #1 RT...

  • Page 149: Lower Harness

    Lower harness Lower Harness From PDB to Z BOT, Z EOT, chamber fans, frame ID Cable # 102598-0004 Signal Z home (BOT) sensor P8-11 ZHOME_C P2-4 ZHOME_C P8-1 ZHOME_E_GND 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...
  • Page 150 Wire Signal Signal Description Color P8-6 BLACK Future enhancement. Frame ID. E-PROM signal (SN, CAL file, etc.) P8- 1 6 GREEN I2C DATA Future enhancement. Frame ID. E-PROM signal (SN, CAL file, etc.) Left Chamber Fan P8- 1 8 24V L-R FAN 24VDC P8-8 BLACK...

  • Page 151: Part Quality Troubleshooting

    Part Quality Troubleshooting Embedded support strands in model Characteristics: Strands of support material embedded in model. Problem corrected after re-orientation Example of embedded support Corrective actions: 1. Change the part orientation. Rotate part 90 degrees - see example above. 2. Build the part using the “Minimal” support option. 3.

  • Page 152: Brown Streaks (Burn Marks)

    Brown streaks (burn marks) Characteristics: Brown streaks in parts. Corrective actions: 1. Part geometry’s are such that the model tip sits idle for 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.

  • Page 153: Loss Of Extrusion (Loe)

    Loss of Extrusion (LOE) Characteristics: Material strands inside build envelope and/or partially built parts. Either the model or support material has failed to extrude from swivel head or toggle plate assembly. Can also be caused by a part falling over or a part shift.
  • Page 154 6. Filament motor is malfunctioning or is disconnected. Verify proper oper- ation and connections. Test using head maintenance. Also flex the wires while extruding to test for poor connections. 7. Broken wire in umbilical cable. Replace umbilical cable. 8. Check umbilical hose for proper alignment and connection to the head cooling fan.

  • Page 155: Model Embedded In To Support

    Model embedded in to 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. -139...

  • Page 156: Moisture In Material

    Moisture in material Characteristics: Material will appear to rough or stringy. Rough Stringy Corrective actions: 1. Material is older than one year. Replace with newer material. 2. Moisture in material. Replace using new material spool. -140...

  • Page 157: Open Seams

    1. Check the height of the brush and flicker. 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.

  • Page 158: Part Curling

    Characteristics: Top surface appears rough. Model and support will separate or support and substrate will separate. Corrective actions: 1. The part is too dense, try using the “Sparse Fill” option in HP Designjet Software Solution. 2. Modeling base has been re-used or is defective. Replace with unused modeling base.

  • Page 159: Part Fell Over

    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.

  • Page 160: Part Shifting

    Part shifting Characteristics: Model shifts in X or Y axis, this may cause unexpected contact errors with X or Y sensors. Corrective actions: 1. The modeling base is defective or is not latched tightly. Replace modeling base and latch properly. 2.
  • Page 161 E. Replace the XY motors or XY table as needed. 3. Check Z stage: 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.

  • Page 162: Rough Surface Quality

    Corrective actions: 1. STL wall thickness is too thin. Verify proper wall 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.

  • Page 163: Rough Quality All Over

    Characteristics: The part sides, top and bottom are very rough. Corrective actions: 1. Moisture 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.

  • Page 164: Model Strands On Parts

    Model strands on parts Characteristics: Model material strands appear outside the normal model build. Corrective actions: 1. Check for material build up on tips, brush and flicker. Remove excess material. 2. Verify brush/flicker height. Adjust if required. 3. Run Z and Offset Calibrations. 4.

  • Page 165: Witness Marks

    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. -149...

  • Page 166: Wavy Surface

    Normal Corrective actions: 1. Run Z and Offset calibrations. 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.

  • Page 167: Wavy Parts

    Wavy parts Characteristics: Parts will shift in X and Y, giving the 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.

  • Page 168: Under Fill

    Characteristics: Open seam between start and stop of toolpaths. 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.

  • Page 169: Material Sagging On Curved Parts

    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.

  • Page 170: Fused Layers

    Fused layers Characteristics: Layers appear to be fused together. Corrective actions: 1. Check Z stage: A. Check connections 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.

  • Page 171: Z Layers Inconsistent

    Z layers inconsistent Characteristics: 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).
  • Page 172 -156...

  • Page 173: Removal And Installation

    Removal and Installation Maintenance Preparation ............page 159 Pre-Maintenance Procedures........page 160 Exterior Components ...............page 161 Top Panel..............page 161 Side Panels ...............page 162 Display Panel ............page 165 Front Panel ...............page 166 Door Solenoid ............page 168 Door Sensor .............page 169 Electronics Bay Components ............page 171 Lower Electronics Bay Cover ........page 171 Electronics Bay Cooling Fan ........page 177 Controller Board ............page 179...
  • Page 174 TC Amp board ............page 239 Umbilical Hose ............page 241 Material Tubes ............page 246 Umbilical Cable ............page 247 XY Table Components ............page 249 Y Home Sensor ............page 249 Y EOT (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...

  • Page 175: Maintenance Preparation

    Maintenance Preparation Read these warnings before performing service on printer! WARNING: Make sure the power is disconnected when performing any of the disassembly or assembly instructions in this chapter. Failure to do so can cause severe personal injury or damage to the electronics. WARNING: Servicing instructions outlined in this chapter are intended for use by qualified personnel only.

  • Page 176: Tools Needed For Repair Not Order-Able As A Service Part

    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 Software Solution CD 12. Firmware CD Pre-Maintenance Procedures 1. Unload model and support material.

  • Page 177: Exterior Components

    Exterior Components Top Panel Required Tools • ⁄ ” nut driver or standard screwdriver. Hardware • 10-32 x ⁄ ” slotted screws (x3) Removing the top panel 1. Using a ⁄ ” nut driver or standard screwdriver, remove the 3 mounting screws.

  • Page 178: Installing The Top Panel

    Figure 64: Top panel removal Slide top panel toward the back of the printer and lift up to remove. Installing the top panel 1. Slide the top panel towards the front and in to place, then push down. 2. Using a ⁄...
  • Page 179 Figure 65: Left side panel mounting screw locations Remove the 3 left side panel mounting screws. 3. Slide panel towards the back of the printer and pull outward to remove. Figure 66. Figure 66: Removing the left side panel Slide top panel toward the back of the printer and pull outward to remove the left side panel.

  • Page 180: Removing The Right Side Panel

    Removing the right side panel: 1. Using a ⁄ ” nut driver or standard screwdriver, remove the 3 mounting screws. See Figure 67. Figure 67: Right side panel mounting screw locations Remove the 3 right side panel mounting screws. 2. Slide towards the back of the printer and pull outward to remove. See Figure 68.

  • Page 181: Display Panel

    Display Panel Required Tools • Standard screwdriver. Removing the display panel 1. Open the chamber door. 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.

  • Page 182: Installing The Display Panel

    Figure 71: Disconnecting the J1 connector 5. Remove the display panel. Installing the display panel 1. Connect the J1 Connector. 2. Gently push the display panel into place. 3. Close the display panel access hatch. 4. Close the chamber door. Front Panel Required Tools •...
  • Page 183 Figure 72: Front panel mounting screw locations Remove the 2 mounting screws from behind the display panel 4. Using a ⁄ ” nut driver or standard screwdriver, remove the 6 mounting screws from the front panel. See Figure 73. Figure 73: Front panel mounting screw locations Remove the 6 mounting screws for the front panel...

  • Page 184: Installing The Front Panel

    Installing the front panel 1. Align the front panel with the mounting holes. 2. Using a ⁄ ” nut driver or standard screwdriver, reinstall the 6 mounting screws. 3. Using a ⁄ ” nut driver or standard screwdriver, reinstall the 2 mounting screws behind the display panel.

  • Page 185: Installing The Door Solenoid

    Figure 75: Removing the door solenoid Installing the door solenoid 1. Push the solenoid pin out and slide door solenoid into place on the mounting plate. 2. Reconnect the DRSOL cable. 3. Reinstall the front panel. See “Installing the front panel” on page 168 4.

  • Page 186: Installing The Door Sensor

    Installing the door sensor 1. Gently 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”...

  • Page 187: Electronics Bay Components

    Electronics Bay Components The main circuit boards and power supplies for the printer are located in the electronics bay. Note: When reinstalling components in the Electronics Bay area note that cable J401 is unused. (Not connected) Lower Electronics Bay Cover Required Tools •...

  • Page 188: Closing The Electronics Bay

    Figure 79: Electronics bay cover mounting screw locations Remove the 3 mounting screws 5. Gently pull the electronics bay cover down. See Figure 80. Figure 80: Electronics bay with cover lowered Closing the electronics bay 1. Gently push the electronics bay cover back in to the closed position. 2.

  • Page 189: Upper Electronics Bay Cover

    Upper Electronics Bay Cover Required Tools • ⁄ ” nut driver or standard screwdriver. Hardware • 10-32x ⁄ ” slotted screws (x4) Removing the upper electronics bay cover 1. Remove the top panel. See “Removing the top panel” on page 161 2.

  • Page 190: Installing The Upper Electronics Bay Cover

    Figure 82: Upper electronics bay cover bottom mounting screw locations Remove the bottom left and right mounting screws 5. Lift the cover up and off of the top mounting screws. Installing the upper electronics bay cover 1. Slide the cover down on to the top left and right side mounting screws. 2.

  • Page 191: Removing The Electronics Bay

    Removing the Electronics Bay Required Tools • ⁄ ” nut driver or standard screwdriver. Hardware • 10-32 x ⁄ ” slotted screws (x8) Removing the electronics bay 1. Remove the top panel. See “Removing the top panel” on page 161 2.

  • Page 192: Installing The Electronics Bay

    Figure 84: Electronics Bay mounting screw locations Remove the 4 left side Remove the 4 right side mounting screws mounting screws 8. Slide the electronics bay out 3 inches (76mm) and disconnect the cables from the rear of the power distribution board. See Figure 85.

  • Page 193: Electronics Bay Cooling Fan

    Electronics Bay Cooling Fan Required Tools • ⁄ ” nut driver or standard screwdriver. • ⁄ ” allen wrench. Hardware ½ • 6-32 x 1 ” flat head cap screws (x4) Removing the electronics bay cooling fan 1. Remove the top panel. See “Removing the top panel”...

  • Page 194: Installing The Electronics Bay Cooling Fan

    Figure 87: Electronics bay cooling fan mounting screw locations Remove the 4 mounting screws 7. Remove the cooling fan. Installing the electronics bay cooling fan 1. Align the cooling fan with the 4 mounting holes. 2. Using a ⁄ ” allen wrench, reinstall the 4 mounting screws. 3.

  • Page 195: Controller Board

    Controller Board Required Tools • ⁄ ” nut driver or standard screwdriver. • Phillips screwdriver Hardware • 6-32 x ⁄ ” Phillips pan head screws (x6) Removing the controller board 1. Open the electronics bay. See “Opening the electronics bay” on page 171 2.
  • Page 196 Figure 89: Remove the 2 screws that hold the Diagnostics DB-9 cable in place Remove the DB-9 connector 5. Using a Phillips screwdriver, remove the 6 controller board mounting screws. See Figure 90. Figure 90: Controller board mounting screw locations Remove the (6) mounting screws 6.

  • Page 197: Installing The Controller Board

    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 3D Software Solution to the Upgrade (.UPG) file on the printer firmware CD.

  • Page 198: Single Board Computer (Sbc)

    Single Board Computer (SBC) Required Tools • ⁄ ” nut driver or standard screwdriver. • Phillips screwdriver Hardware • 6-32 x ⁄ ” Phillips pan head screws (x4) Removing the single board computer 1. Open the electronics bay. See “Opening the electronics bay” on page 171 2.
  • Page 199 6. Disconnect the RJ-45 network cable. See Figure 93. Figure 93: RJ-45 network cable location Disconnect the RJ45 connector 7. Using a Phillips screwdriver, remove the 4 mounting screws. See Figure Figure 94: SBC mounting screw locations Remove the 4 mounting screws 8.

  • Page 200: Reinstalling The Single Board Computer

    Figure 95: SBC display cable location Disconnect the Display cable Reinstalling the single board computer 1. Reconnect the display cable. 2. Using a standard screwdriver, tighten the display cable mounting screws. 3. Align the SBC with the mounting holes. 4. Using a Phillips screwdriver, reinstall the 4 mounting screws. 5.

  • Page 201: Removing The I/O Card

    Removing the I/O card 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. Open the electronics bay. See “Opening the electronics bay” on page 171 4.

  • Page 202: Installing The I/O Card

    Figure 98: I/O card mounting screw locations Remove the 3 mounting screws 8. Gently pull the I/O card out from the power distribution board sockets. Installing the I/O card 1. Gently slide the I/O card in to the power distribution board sockets. 2.

  • Page 203: Power Distribution Board (Pdb)

    Power Distribution Board (PDB) Required Tools • ⁄ ” nut driver or standard screwdriver. • Phillips screwdriver Hardware • 6-32 x ⁄ ” Phillips pan head screws (x12) • 10-32 x ⁄ ” slotted screws (x8) Removing the power distribution board 1.
  • Page 204 Figure 100: Electronics bay mounting screw locations Remove the 4 left side Remove the 4 right side mounting screws mounting screws 7. Disconnect the 4 cables from the back side of the power distribution board. See Figure 101. Figure 101: Power distribution board rear cable locations Disconnect the 4 cables on the back of the PDB 8.
  • Page 205 Figure 102: Power distribution board front cable locations Disconnect the 4 cables Disconnect the 3 ribbon Disconnect cables the 3 ribbon cables 10. Using a Phillips screwdriver, remove the 12 mounting screws. See Figure 103. Figure 103: Power distribution board mounting screw locations 1 1.

  • Page 206: Installing The Power Distribution Board

    Installing the power distribution board 1. Align the power distribution board with the mounting holes. 2. Using a Phillips screwdriver, reinstall the 12 mounting screws. 3. Reconnect the 10 cables to the front of the power distribution board. 4. Carefully slide the electronics bay out 3 inches (76mm) and reconnect the 4 cables to the back of the PDB.

  • Page 207: Hard Drive

    Hard Drive Required Tools • ⁄ ” nut driver or standard screwdriver. • Phillips screwdriver Hardware • 6-32 x ⁄ ” Phillips pan head screws (x8) Removing the hard drive 1. Open the electronics bay. See “Opening the electronics bay” on page 171 2.
  • Page 208 Figure 105: SATA cable location Disconnect the SATA cable 5. Using a Phillips screwdriver, remove the 4 mounting screws. See Figure 106. Figure 106: Hard drive mounting screw locations Remove the mounting screws Remove the mounting screws 6. Slide the hard drive up and out of the electronics bay. 7.

  • Page 209: Installing The Hard Drive

    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 firmware CD into the workstation CD drive.

  • Page 210: Line Filter

    Line Filter Required Tools • ⁄ ” nut driver or standard screwdriver. • Phillips screwdriver Hardware • 6-32 x ⁄ ” Phillips pan head screws (x3) Removing the line filter 1. Open the electronics bay. See “Opening the electronics bay” on page 171 2.

  • Page 211: Installing The Line Filter

    Figure 109: L2-1 and N2-1 Spade connector locations Disconnect the N2- 1 spade connector Disconnect the L2- 1 spade connector 5. Using a Phillips screwdriver, remove the 3 mounting screws. See Figure 1 10. Figure 1 10: Line filter mounting screw locations Remove the 3 mounting screws 6.

  • Page 212: Circuit Breaker

    Circuit Breaker Required Tools • ⁄ ” nut driver or standard screwdriver. • Phillips screwdriver Removing the circuit breaker 1. Open the electronics bay. See “Opening the electronics bay” on page 171 2. Touch the metal plate of the electronics bay cover to discharge any static electricity.

  • Page 213: Installing The Circuit Breaker

    5. Squeeze the tabs on the circuit breaker and push through the electronics bay panel. See Figure 1 13. Figure 1 13: Removing the circuit breaker Press tabs and push the circuit breaker through the panel Installing the circuit breaker 1.

  • Page 214: Removing The Ac Input

    Removing the AC Input 1. Open the electronics bay. See “Opening the electronics bay” on page 171 2. Touch the metal plate of the electronics bay cover to discharge any static electricity. 3. Remove the LF-G (green) spade connector. See Figure 1 14.

  • Page 215: Power Switch

    Power Switch Required Tools • ⁄ ” nut driver or standard screwdriver. Hardware • 10-32 x ⁄ ” slotted screws (x2) Removing the Power Switch 1. Remove the top panel. See “Removing the top panel” on page 161 2. Remove the left side panel. See “Removing the side panels”...

  • Page 216: Installing The Power Switch

    Figure 1 17: Power switch connector locations 8. Press the Power Switch tabs in and push it out of the housing. See Figure 1 18. Figure 1 18: Removing the power switch Press tabs to Press tabs to release release Installing the power switch 1.

  • Page 217: 24Vdc Power Supply

    24VDC Power Supply Required Tools • ⁄ ” nut driver or standard screwdriver. • Phillips screwdriver Hardware • 10-32 x ⁄ ” slotted screws (x3) • 6-32 x ⁄ ” Phillips pan head screws (x2) Removing the 24VDC Power Supply 1.
  • Page 218 7. Disconnect the J1 connector on the 24VDC power supply. See Figure 120. Figure 120: J1 cable location Disconnect J1 8. Disconnect J3 1 through 4 connectors using a Phillips screwdriver. Note the position of the wires for reinstallation. See Figure 121.
  • Page 219 Figure 122: Closing the rear panel of the electronics bay Remove the 2 mounting screws 10. Open the rear panel of the electronics bay and remove the 2 board mounting screws from the top of the panel using a Phillips screwdriver. Figure 123.

  • Page 220: Installing The 24Vdc Power Supply

    Installing the 24VDC power supply 1. Align the 24VDC power supply with the top of the rear panel of the electronics bay and the tab to the right of the mounting location. See Figure 124. Figure 124: Align the 24VDC power supply 2.

  • Page 221: 5/12Vdc Power Supply

    5/12VDC Power Supply Required Tools • ⁄ ” nut driver or standard screwdriver. • Phillips screwdriver Hardware • 10-32 x ⁄ ” slotted screws (x3) • 6-32 x ⁄ ” Phillips pan head screws (x3) Removing the 5/12VDC power supply 1.
  • Page 222 Figure 126: J2 spade connector location 8. Disconnect 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.

  • Page 223: Installing The 5/12Vdc Power Supply

    10. Using a Phillips screwdriver, remove the 3 mounting screws. See Figure 129. Figure 129: 5/12 VDC supply mounting screw locations 1 1. Remove the 5/12VDC power supply. Installing the 5/12VDC power supply 1. Align the 5/12VDC power supply and press down into place. 2.

  • Page 224: 120Vdc Power Supply

    120VDC Power Supply Required Tools • ⁄ ” nut driver or standard screwdriver. • Phillips screwdriver Hardware • 10-32 x ⁄ ” slotted screws (x3) • 6-32 x ⁄ ” Phillips pan head screws (x3) Removing the 120VDC power supply 1.

  • Page 225: Installing The 120 Vdc Power Supply

    Figure 131: J601 connector location Disconnect J601 8. Using a Phillips screwdriver, remove the 3 mounting screws. See Figure 132. Figure 132: 120 VDC mounting screw locations 9. Remove the 120VDC power supply. Installing the 120 VDC power supply 1. Align the 120VDC power supply with the mounting holes. 2.

  • Page 226: Head Components

    Head Components Head Cooling Fan Required Tools • ⁄ ” nut driver or standard screwdriver. • ⁄ ” allen wrench. Hardware • 6-32 x 1 ⁄ ” flat head cap screws (x2) Removing the head cooling fan 1. Remove the top panel. See “Removing the top panel”...

  • Page 227: Installing The Head Cooling Fan

    Figure 134: Head cooling fan mounting screw locations Remove the 2 mounting screws 6. Remove the head cooling fan. Installing the Head Cooling fan 1. Align the head cooling fan with the 2 mounting holes. 2. Using a ⁄ ” allen wrench, reinstall the 2 mounting screws. 3.

  • Page 228: Toggle Head Assembly

    Toggle Head Assembly Required Tools • ⁄ ” nut driver or standard screwdriver. • Cutters Hardware • Wire tie (x1) • 10-32 x ⁄ ” slotted screws (x7) • 10-32 x ⁄ ” slotted screws (x4) Removing the toggle head assembly 1.
  • Page 229 Figure 136: Head cover tab locations Press tab in to Press tab in to release head release head cover cover 5. Remove the air plenum by pressing in the upper and lower tabs and pulling outward. See Figure 137. Figure 137: Air plenum tab locations Press in tab to Press in tab to release air...
  • Page 230 Figure 138: Material tubes and retaining rings Press down on Lift the material the retaining tubes out of rings the rings 7. Disconnect the thermocouples from the TC Amp board and remove the wires from the wire retainer. See Figure 139. Figure 140.
  • Page 231 Figure 141: Heater power cable locations Disconnect the Disconnect model side the support heater cable side heater cable 9. Disconnect the toggle sensor cable from the toggle sensor. Figure 142: Toggle sensor location Disconnect the toggle sensor cable 10. Disconnect the toggle sensor cable from the head board. Figure 143: Toggle sensor cable location Disconnect the toggle sensor...
  • Page 232 Figure 144: Wire tie location Cut and remove the wire tie from the head motor 12. Disconnect the 3 cables from the rear of the head board by pressing the tabs in and pulling outward. See Figure 145. Figure 145: Rear head board cable locations Disconnect the 3 cables 13.

  • Page 233: Installing The Toggle Head Assembly

    Figure 146: Toggle head mounting screw locations Remove the Remove the toggle head toggle head mounting mounting screws screws 14. Slide the toggle head assembly out of the translator. Installing the toggle head assembly 1. Remove the tag from the new toggle head assembly and set aside for later use.
  • Page 234 12. Install tips into the heater blocks. 13. Install tip shields onto the tips. 14. Reinstall the air plenum. 15. Reinstall the head cover. 16. Reinstall the right side access cover. 17. Reinstall the side panels. See “Installing the side panels” on page 164 18.
  • Page 235 Press the Save and reboot button. B. For printer firmware version 9.0 or older: i. The printer will reboot and return to idle. Load the HP Designjet 3D Diagnostics Software. ii. Click on the + button to add the printer.

  • Page 236: Substrate Sensor

    Substrate Sensor Required Tools • ⁄ ” nut driver or standard screwdriver. • ⁄ ” allen wrench. Hardware • Wire tie (x1) • 10-32 x ⁄ ” slotted screws (x7) • 4-40 x ⁄ ” slotted screws and # 4 split lock washer (x4) Removing the substrate sensor 1.
  • Page 237 Figure 150: Substrate sensor connector location Disconnect the substrate sensor 5. Using a cutters, cut and remove the wire tie around the head motor. See Figure 151. Figure 151: Wire tie location Cut and remove the wire tie from the head motor 6.

  • Page 238: Installing The Substrate Sensor

    Installing the substrate sensor 1. Align the substrate sensor with the mounting holes. 2. Using a ⁄ ” allen wrench, reinstall the 4 substrate sensor mounting screws. 3. Reconnect the substrate sensor wire to the head board. 4. Reinstall the wire tie around the head motor and wires. See Figure 153.

  • Page 239: Z Foam Level Assembly

    Z Foam Level Assembly Required Tools • ⁄ ” allen wrench Hardware 4-40 x 1 ⁄ • ” slotted screws and # 4 split lock washer (x4) Removing the Z Foam Level Assembly: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position.

  • Page 240: Installing The Z Foam Level Assembly

    Figure 155: Z foam level assembly mounting screw locations 4 mounting screws 8. Remove the Z foam level assembly and discard. Installing the Z Foam Level Assembly: 1. Remove the Z foam level bar from the assembly by pushing the actuator into the housing and pulling the bar to the right.

  • Page 241: Toggle Sensor

    Toggle Sensor Required Tools • ⁄ ” nut driver or standard screwdriver. • ⁄ ” allen wrench. Hardware • 4-40 x ⁄ ” slotted screws (x2) Removing the toggle sensor 1. Remove the top panel. See “Removing the top panel” on page 161 2.

  • Page 242: Installing The Toggle Sensor

    Figure 157: Toggle sensor wire connector location Gently disconnect the toggle sensor cable 5. Using a standard screwdriver, remove the 2 toggle sensor mounting screws. See Figure 158. Figure 158: Toggle sensor mounting screw locations Remove the 2 mounting screws 6.

  • Page 243: Toggle Bar

    Toggle Bar Required tools: • ⁄ ” nut driver or standard screwdriver • ⁄ ” allen wrench Hardware • 6-32 x ⁄ ” slotted screws (x2) • .380” ID Closed and grounded spring (x1) • .194” ID Closed and grounded spring (x1) •...

  • Page 244: Removing The Toggle Bar

    Removing the toggle bar: 1. Unload model and support material. 2. Power the printer down. 3. Open chamber door and remove the head cover. See (Figure 159) Figure 159: Head cover tab locations Press tab in to Press tab in to release head release head cover...
  • Page 245 Figure 161: Removing the tips 6. Using a ⁄ ” allen wrench, loosen the 2 heat shield screws. See (Figure 162) Figure 162: Heat shield mounting screw locations Heat shield mounting screws 7. Remove the heat shield. 8. Using a ⁄...
  • Page 246 Figure 163: Upper spring location Upper spring screw 9. Using a ⁄ ” allen wrench, remove the lower spring screw. Remove the screw, spring and washer. See (Figure 164) Figure 164: Lower spring location Lower spring screw 10. Pull the toggle assembly away from the translator until the toggle assem- bly is at the end of the post.
  • Page 247 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 -231...

  • Page 248: Installing The Toggle Bar

    Installing the toggle bar: 1. Align the toggle bar with the translator and reinstall the washer over the bottom mounting post. See (Figure 167) Figure 167: Toggle bar alignment Reinstall washer Align toggle bar 2. Push the toggle assembly back into position. 3.

  • Page 249: Head Board

    Head Board Required tools • ⁄ ” nut driver or standard screwdriver • ⁄ ” nut driver Hardware • 10-32 x ⁄ ” slotted screws (x7) • 6-32 x ⁄ ” slotted screws (x6) Removing the head board 1. Remove the top panel. See “Removing the top panel”...
  • Page 250 Figure 169: Head cover tab locations Press tab in to Press tab in to release head release head cover cover 5. Remove the air plenum by pressing in the upper and lower tabs and pulling outward. See Figure 170. Figure 170: Air plenum tab locations Press in tab to Press in tab to release air...
  • Page 251 Figure 171: Material tube and retaining ring locations Press down on Lift the the retaining material tubes rings out of the rings 7. Remove the thermocouple wires from the wire retaining clip on the head board. See Figure 172. Figure 172: Retaining clip location Remove the thermocouple wires from the retaining clip...
  • Page 252 Figure 173: Umbilical cable location Disconnect the umbilical cable 9. Disconnect the model and support heater cables by pressing in on the tabs and pulling outward. See Figure 174. Figure 174: Model and support heater cable locations Disconnect the Disconnect the model side heater support side cable...
  • Page 253 Figure 176: Disconnect the toggle sensor cable from the toggle sensor Gently disconnect the toggle sensor cable 12. Using a ⁄ ” nut driver or standard screwdriver, remove the toggle sensor cable retaining clips. See Figure 177. Figure 177: Toggle sensor cable retaining clip locations Remove the 2 toggle sensor cable retaining clips 13.

  • Page 254: Installing The Head Board

    Figure 179: Rear head board cable locations Disconnect the 3 cables 15. Using a ⁄ ” nut driver or standard screwdriver, remove the 4 head board mounting screws. See Figure 180. Figure 180: Remove the head board mounting screws Remove the head board mounting screws Installing the head board 1.

  • Page 255: Tc Amp Board

    TC Amp board Required Tools • ⁄ ” nut driver or standard screwdriver • ⁄ ” nut driver Hardware • 10-32 x ⁄ ” slotted screws (x7) • 6-32 x ⁄ ” slotted screws (x3) Removing the TC Amp board 1.
  • Page 256 Figure 182: Disconnecting the umbilical cable Disconnect the umbilical cable 5. Disconnect the model and support thermocouple wires by pulling out- ward. See Figure 183. Figure 183: Thermocouple wire locations Disconnect the support thermocouple Disconnect the model thermocouple 6. Using a ⁄...

  • Page 257: Installing The Tc Amp Board

    Installing the TC Amp board 1. Align the TC Amp board with the mounting holes. 2. Using a ⁄ ” nut driver or standard screwdriver, reinstall the 3 mounting screws. 3. Reconnect the model and support thermocouple wires. 4. Reconnect the umbilical cable. 5.
  • Page 258 Figure 185: Right side access cover mounting screw locations Remove the 7 mounting screws. 5. Using a ⁄ ” nut driver or standard screwdriver, loosen the umbilical hose clamp. See Figure 186. 6. Disconnect the umbilical hose from the head cooling fan and remove the hose clamp.
  • Page 259 Figure 187: Head cover tab locations Press in tab to Press in tab to release head release head cover cover 8. Remove the air plenum by pressing in on the tabs and pulling outward. Figure 188. Figure 188: Air plenum tab locations Press in tab to release Press in tab to release air plenum...
  • Page 260 Figure 189: Material tube and retaining ring locations Press down on Lift the material the retaining tubes out of the rings rings 10. Cut the wire tie from around the umbilical hose. See Figure 190. Figure 190: Umbilical hose wire tie location Cut and remove the wire tie 1 1.

  • Page 261: Installing The Umbilical Hose

    Installing the umbilical hose 1. Feed the umbilical hose through the energy chain. 2. Align the energy chain with the mounting holes. 3. Using a ⁄ ” allen wrench, reinstall the energy chain mounting screws. 4. Reinstall a wire tie around the umbilical hose. See Figure 192.

  • Page 262: Material Tubes

    Material Tubes Required Tools • ⁄ ” nut driver or standard screwdriver • ⁄ ” nut driver • ⁄ ” allen wrench • Cutters Removing the material tubes 1. Remove the top panel. See “Removing the top panel” on page 161 2.

  • Page 263: Umbilical Cable

    Umbilical Cable Required Tools • ⁄ ” nut driver or standard screwdriver • Cutters • ⁄ ” nut driver • ⁄ ” allen wrench Removing the umbilical cable 1. Remove the top panel. See “Removing the top panel” on page 161 2.

  • Page 264: Installing The Umbilical Cable

    Figure 194: Head board connector location Disconnect the umbilical cable 7. Disconnect the umbilical cable from the TC Amp board by pressing in on the tab and pulling outward. See Figure 195. Figure 195: TC Amp connector location Disconnect the umbilical cable 8.

  • Page 265: Xy Table Components

    XY Table Components Y Home Sensor Required Tools • ⁄ ” nut driver or standard screwdriver. Hardware • 6-32 x ⁄ ” slotted screw (x1) Removing the Y home sensor 1. Remove the top panel. See “Removing the top panel” on page 161 2.

  • Page 266: Installing The Y Home Sensor

    Figure 197: Y home sensor mounting screw location Remove the mounting screw 4. Remove the Y home sensor. Installing the Y Home Sensor 1. Align the Y Home Sensor with the mounting hole. 2. Using a ⁄ ” nut driver or standard screwdriver, reinstall the mounting screw.

  • Page 267: Installing The Y Eot Sensor

    Figure 198: Y EOT sensor cable location Disconnect the Y EOT cable 3. Using a ⁄ ” nut driver or standard screwdriver, remove the mounting screw. See Figure 199. Figure 199: Y EOT sensor mounting screw location Remove the mounting screw 4.

  • Page 268: Motor

    X Motor Required Tools • ⁄ ” nut driver or standard screwdriver. • ⁄ ” box wrench. • ⁄ ” allen wrench. • ⁄ ” allen wrench. • Cutters. Hardware • Wire tie • 10-32 x ⁄ ” slotted screws (x16) •...
  • Page 269 Figure 200: Left side access panel mounting screw locations Remove the 7 mounting screws. 4. Using a ⁄ ” nut driver or standard screwdriver, remove the 7 right side access panel mounting screws and remove the right side access panel. Figure 201.
  • Page 270 Figure 202: X belt tension adjustment bolt location Loosen X belt adjustment bolt 7. Using a cutters, remove the X motor cable connector wire tie. See Figure 203. Figure 203: X motor wire tie locations Cut and remove wire tie 8.
  • Page 271 Figure 204: X motor cable connector location Disconnect X motor cable 9. Using a ⁄ ” nut driver or standard screwdriver, remove the 2 X energy chain mounting bracket mounting screws. See Figure 205. Figure 205: X motor energy chain mounting bracket mounting screw locations Remove the 2 mounting screws...

  • Page 272: Installing The X Motor

    Figure 206: X motor mounting bracket mounting screw locations Remove the 4 mounting screws 1 1. Using a ⁄ ” allen wrench, remove the 4 X motor mounting screws from the mounting bracket. See Figure 207. Figure 207: X motor mounting screw locations Remove the 4 mounting screws 12.
  • Page 273 6. Align the X motor energy chain mounting bracket with the mounting holes. 7. Using a ⁄ ” nut driver or standard screwdriver, reinstall the 2 X motor energy chain mounting screws. 8. Reconnect the X motor cable. 9. Reinstall a wire tie around the X motor cable connector. See Figure 208.
  • Page 274 Figure 209: Tension gauge zero setting Adjustment screw Zero gauge block 15. 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 210.) Figure 210: X belt tension location...
  • Page 275 Figure 21 1: Gauge reading at correct X belt tension (Shading indicates acceptable range) 17. If the tension is out of the range specified above, adjust the belt tension by turning the X belt tensioning nut on the X-Drive Idler/Tension Adjust gear.

  • Page 276: Y Motor

    Y Motor Required Tools • ⁄ ” nut driver or standard screwdriver. • ⁄ ” allen wrench. Hardware • 10-32 x ⁄ ” slotted screws (x1 1) • 8-32 x ⁄ ” socket head cap screws (x4) Removing the Y motor 1.
  • Page 277 Figure 214: Y motor cable location Disconnect the Y motor cable 6. Using a ⁄ ” nut driver or standard screwdriver, remove the 4 Y motor mounting bracket mounting screws. See Figure 215. Figure 215: Y motor mounting bracket mounting screw locations Remove the 4 mounting screws 7.

  • Page 278: Installing The Y Motor

    Figure 216: Y motor mounting screw locations Remove the 4 mounting screws 8. Remove the Y motor. Installing the Y motor 1. Align the Y motor with the Y motor mounting bracket, making sure the Y motor cable faces the back of the printer. 2.

  • Page 279: Y Motor Belt

    Y Motor Belt Required Tools • ⁄ ” nut driver or standard screwdriver. • Dial indicator and belt tension gauge assembly Hardware • 10-32 x ⁄ ” slotted screws (x30) • 3- 1 6 x 1” fender washer Removing the Y Motor Belt 1.
  • Page 280 Figure 217: Left side access panel mounting screw locations Remove the 7 mounting screws. 5. Disconnect the material bay cable from the printer. 6. Remove the Front Panel. See “Removing the front panel” on page 166 7. Remove the Electronics Bay. See “Removing the Electronics Bay”...
  • Page 281 Figure 219: Left side Y belt retaining clip mounting screw locations Remove the outer mounting screws Loosen, but do not remove the inner mounting screws 12. Using a ⁄ ” box wrench, remove the outer Y belt retaining clip mount- ing screws from the right side.
  • Page 282 Figure 221: Y drive belt tension adjustment Y-Drive Belt Tension Adjusting 16. Disconnect the head cooling fan. See Figure 222. Figure 222: Disconnect head cooling fan J258 Disconnect J258 17. Using a ⁄ ” nut driver or standard screwdriver, remove the head cool- ing fan mounting bracket screws.
  • Page 283 Figure 223: Head cooling fan mounting bracket screw locations 18. Let head cooling fan hang off to side. 19. Using a ⁄ ” 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.
  • Page 284 Figure 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. -268...
  • Page 285 Figure 227: Lower Y drive rod mounting screw locations Lower Y drive rod mounting screw locations 24. Using a ⁄ ” nut driver or standard screwdriver, remove the 2 Y drive rod mounting screws. See Figure 228. Figure 228: Y drive rod mounting screws Right side mounting screw Left side mounting screw 25.
  • Page 286 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 -270...

  • Page 287: Installing The Y Motor Belt

    Installing the Y Motor Belt 1. Slide the Y motor belt over the Y drive rod. 2. Align Y drive rod with the 6 mounting holes. 3. Using a ⁄ ” nut driver or standard screwdriver, reinstall the 6 Y drive rod mounting screws.

  • Page 288: Y Drive Rod

    Y Drive Rod Required Tools • ⁄ ” nut driver or standard screwdriver. • Dial indicator and belt tension gauge assembly Hardware • 10-32 x ⁄ ” slotted screws (x30) • 3- 1 6 x 1” fender washer Removing the Y Drive Rod 1.
  • Page 289 Figure 231: Left side access panel mounting screw locations Remove the 7 mounting screws. 5. Disconnect the material bay cable from the printer. 6. Remove the Front Panel. See “Removing the front panel” on page 166 7. Remove the Electronics Bay. See “Removing the Electronics Bay”...
  • Page 290 Figure 233: Left side Y belt retaining clip mounting screw locations Remove the outer mounting screws Loosen, but do not remove the inner mounting screws 12. Using a ⁄ ” box wrench, remove the outer Y belt retaining clip mount- ing screws from the right side.
  • Page 291 Figure 235: Y drive belt tension adjustment Y-Drive Belt Tension Adjusting 16. Disconnect the head cooling fan. See Figure 236. Figure 236: Disconnect head cooling fan J258 Disconnect J258 17. Using a ⁄ ” nut driver or standard screwdriver, remove the head cool- ing fan mounting bracket screws.
  • Page 292 Figure 237: Head cooling fan mounting bracket screw locations 18. Let head cooling fan hang off to side. 19. Using a ⁄ ” 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.
  • Page 293 Figure 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. -277...
  • Page 294 Figure 241: Lower Y drive rod mounting screw locations Lower Y drive rod mounting screw locations 24. Using a ⁄ ” nut driver or standard screwdriver, remove the 2 Y drive rod mounting screws. See Figure 242. Figure 242: Y drive rod mounting screws Right side mounting screw Left side mounting screw 25.
  • Page 295 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 -279...
  • Page 296 Installing the Y Drive Rod 1. Slide the Y drive rod through the Y belts and into position. 2. Align Y drive rod with the 6 mounting holes. 3. Using a ⁄ ” nut driver or standard screwdriver, reinstall the 6 Y drive rod mounting screws.

  • Page 297: Xy Table

    XY Table Required Tools • ⁄ ” nut driver or standard screwdriver. • ⁄ ” box wrench. • ⁄ ” box wrench. • ⁄ ” allen wrench. • ⁄ ” allen wrench. • ⁄ ” allen wrench. • Cutters. • Z Guide rod stand off (x2) •...

  • Page 298: Removing The Xy Table

    Hardware • Wire tie • 10-32 x ⁄ ” slotted screws (x14) • 10-32 x ⁄ ” slotted screws (x4) • 10-32 x ⁄ ” socket head cap screws (x4) • 8-32 x ⁄ ” socket head cap screws (x4) •...
  • Page 299 Figure 245: Left side access panel mounting screw locations Remove the 7 mounting screws. 5. Using a ⁄ ” nut driver or standard screwdriver, remove the right side access panel mounting screws and remove the right side access panel. Figure 246. Figure 246: Right side access panel mounting screw locations Remove the 7 mounting screws.
  • Page 300 Figure 247: Umbilical hose wire tie location Cut and remove the wire tie 10. Using a ⁄ ” allen wrench, remove the 2 energy chain mounting screws. See Figure 248. Figure 248: Energy chain mounting screw locations Remove the 2 mounting screws 1 1.
  • Page 301 Figure 249: X belt tension adjustment bolt location Loosen X belt adjustment bolt 14. Using a cutters, remove the X motor cable connector wire tie. See Figure 250. Figure 250: X motor wire tie locations Cut and remove wire tie 15.
  • Page 302 Figure 251: X motor cable connector location Disconnect X motor cable 16. Using a ⁄ ” nut driver or standard screwdriver, remove the 2 X energy chain mounting bracket mounting screws and set bracket to the side. See Figure 252. Figure 252: X motor energy chain mounting bracket mounting screw locations Remove the 2...
  • Page 303 Figure 253: Left side Y belt retaining clip mounting screw locations Remove the outer mounting screws Loosen, but do not remove the inner mounting screws 20. Using a ⁄ ” box wrench, remove the outer Y belt retaining clip mount- ing screws from the right side.
  • Page 304 Figure 255: Right side X guide rod mounting screw locations Remove the 2 right side X guide rod mounting screws 25. Using a ⁄ ” allen wrench, remove the right side front Y guide rod mounting screw. See Figure 256. Figure 256: Right side front Y guide rod mounting screw location Remove the right front Y guide rod mounting...
  • Page 305 Figure 257: Right side rear Y guide rod mounting screw location Remove the right rear Y guide rod mounting screw 27. Disconnect the Y Home sensor cable by pressing in on the tab and pull- ing outward. See Figure 258. Figure 258: Y EOT sensor wire connector location Disconnect the Y Home cable...
  • Page 306 Figure 259: Left side front Y guide rod mounting screw location Remove the left front Y guide rod mounting screw 29. Using a ⁄ ” allen wrench, remove the left side rear Y guide rod mount- ing screw. See Figure 260. Figure 260: Left side rear Y guide rod mounting screw location Remove the left rear Y guide rod mounting...

  • Page 307: Installing The Xy Table

    Installing the XY table 1. Insert the zero gauge block into the gauge. See Figure 261. 2. 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.
  • Page 308 6. The gauge should read between 0.425 and 0.435 mils. See Figure 263. Figure 263: Gauge readings Adjustment Limit Service Limit 7. If the tension is not within specification, locate the Y belt tension adjust- ment nut on the front of the system. See Figure 262.
  • Page 309 12. Push the left side Y guide rod in towards the back of the printer. 13. Rotate the left side Y guide rod towards the left side of the printer and raise the guide rod to the top of the frame. 14.
  • Page 310 30. Using a ⁄ ” box wrench, tighten the right side Y belt clamp mounting screws. 31. Using a ⁄ ” box wrench, tighten the left side Y belt clamp mounting screws. 32. Using a ⁄ ” allen wrench, securely fasten the left rear Y guide rod mounting screw.
  • Page 311 Figure 267: XY Table alignment bracket mounting locations Place an alignment Place an alignment bracket at the front of the bracket at the back of the printer printer 44. Using a ⁄ ” nut driver or standard screwdriver, loosen but do not remove the left side X guide rod mounting screws.
  • Page 312 50. Raise the Z stage up near the XY table and hold in place 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.
  • Page 313 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 Color 3D, see Figure 273.
  • Page 314 Figure 272: HP Designjet 3D measurement points and worksheet -298...
  • Page 315 Figure 273: HP Designjet Color 3D measurement points and worksheet -299...
  • Page 316 58. Move the dial indicator to the front left of the Z stage and zero the dial indicator. 59. Using the XY guide rod leveling fixture, adjust the rod up or down until the dial indicator reads the value the calculator has given. See Figure 274.
  • Page 317 Figure 275: Tension gauge zero setting Adjustment screw Zero gauge block 75. 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. See Figure 276.
  • Page 318 Figure 277: Gauge reading at correct X belt tension (Shading indicates acceptable range) 77. If the tension is out of the range specified above, adjust the belt tension by turning the X belt tensioning nut on the X-Drive Idler/Tension Adjust gear.
  • Page 319 “Z Calibration” on page 338 92. Perform XY Offset calibration. See “XY Tip Calibration” on page 340 93. Perform Part Based calibration. See “Performing part based calibration for HP Designjet 3D with the HP Designjet 3D Diagnostic Software” on page 352. -303...

  • Page 320: Z Stage Components

    Z Stage Components Z Home Sensor Required Tools • ⁄ ” nut driver or standard screwdriver. Hardware • 6-32 x ⁄ ” slotted screw (x1) Removing the Z home sensor 1. Open the chamber door. 2. Lower the Z stage all of the way down. 3.

  • Page 321: Installing The Z Home Sensor

    Figure 281: Z home sensor mounting screw location Remove mounting screw 5. Remove the Z home sensor. Installing the Z home sensor 1. Align the Z home sensor with the mounting hole. 2. Reinstall the mounting screw with a 1/4” nut driver or standard screw- driver.

  • Page 322: Installing The Z Eot Sensor

    Figure 282: Z EOT sensor cable location Disconnect the Z EOT cable 4. Using a ⁄ ” nut driver or standard screwdriver, remove the mounting screw. See Figure 283. Figure 283: Remove the mounting screw Remove the mounting screw 5. Remove the Z EOT Sensor. Installing the Z EOT sensor 1.

  • Page 323: Chamber Fans

    Chamber Fans Required Tools • ⁄ ” nut driver or standard screwdriver. • ⁄ ” box wrench Hardware • 10-32 x ⁄ ” slotted screws (x8) • 8-32 x ⁄ ” slotted screws (x4) Removing the right side chamber fan 1.

  • Page 324: Installing The Right Side Chamber Fan

    Remove the 2 mounting screws Installing the right side chamber fan 1. Align chamber fan with mounting holes. 2. Using a ⁄ ” box wrench, reinstall the 2 chamber fan mounting screws. 3. Align the right side heater panel with the mounting holes. 4.

  • Page 325: Installing The Left Side Chamber Fan

    Figure 286: Left side heater panel mounting screw locations Remove the 4 mounting screws 4. Using a ⁄ ” box wrench, remove the 2 chamber fan mounting screws. Figure 287. Figure 287: Left side chamber fan mounting screw locations Remove the 2 mounting screws Installing the left side chamber fan 1.

  • Page 326: Chamber Heaters

    Chamber Heaters Required Tools • ⁄ ” nut driver or standard screwdriver. • ⁄ ” nut driver. Hardware • 10-32 x ⁄ ” slotted screws (x8) • 10-32 x ⁄ ” slotted screws (x4) • 10-32 x ⁄ ” nut (x4) Removing the right side heater 1.
  • Page 327 Figure 288: Right side heater panel mounting screw locations Remove the 4 mounting screws 4. Remove the black power wire from the right mounting post with a ⁄ ” nut driver. See Figure 289. 5. Remove the white power wire from the left mounting post with a ⁄...

  • Page 328: Installing The Right Side Heater

    Figure 290: Right side heater mounting screw locations Remove the mounting screws 7. Remove the heater. Installing the right side heater 1. Align the heater with the mounting posts. 2. Insert the insulating washers and reinstall the mounting screws using a ⁄...
  • Page 329 Figure 291: Left side heater panel mounting screw locations Remove the 4 mounting screws 4. Using a ⁄ ” nut driver, remove the white power wire from the right mounting post. See Figure 292. 5. Using a ⁄ ” nut driver, remove the black power wire from the left mount- ing post.

  • Page 330: Installing The Left Side Heater

    Figure 293: Left side heater mounting screw locations Remove the mounting screws 7. Remove the heater. Installing the left side heater 1. Align the heater with the mounting posts. 2. Insert the insulating washers and reinstall the mounting screws using a ⁄...

  • Page 331: Thermal Fuses

    Thermal Fuses Required Tools • ⁄ ” nut driver or standard screwdriver. Hardware • 10-32 x ⁄ ” slotted screws (x8) • 4-40 x ⁄ ” slotted screws (x4) Removing the right side thermal fuse 1. Remove the top panel. See “Removing the top panel”...

  • Page 332: Installing The Right Side Thermal Fuse

    Figure 295: RTH1 and RTH2 spade connector locations Disconnect Disconnect RTH1 RTH2 5. Using a standard screwdriver, remove the 2 mounting screws. See Figure 296. Figure 296: Right side thermal fuse mounting screw locations Remove the mounting screws 6. Remove the thermal fuse. Installing the right side thermal fuse 1.

  • Page 333: Removing The Left Side Thermal Fuse

    Removing the left side thermal fuse 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 ⁄ ” nut driver or standard screwdriver, remove the 4 mounting screws from the left side heater panel and remove the heater panel.

  • Page 334: Installing The Left Side Thermal Fuse

    Figure 299: Left side thermal fuse mounting screw locations Remove the mounting screws 6. Remove the thermal fuse. Installing the left side thermal fuse 1. Align the thermal fuse with the mounting holes. 2. Using a standard screwdriver, reinstall the 2 mounting screws. 3.

  • Page 335: Chamber Thermocouple

    Chamber Thermocouple Required Tools • ⁄ ” nut driver. • standard screwdriver. Removing the chamber thermocouple 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.
  • Page 336 Figure 301: Bending the thermocouple 4. Reinstall the electronics bay. See “Installing 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”...

  • Page 337: Z Motor

    Z Motor Required Tools • ⁄ ” nut driver or standard screwdriver. • ⁄ ” allen wrench. • ⁄ ” allen wrench. • Cutters Hardware • Wire ties (x2) • 10-32 x ⁄ ” slotted screws (x4) • 4-40 x ⁄...
  • Page 338 Figure 302: Removing the Z stage panel 6. Remove the 4 Z motor energy chain mounting screws with a ⁄ ” allen wrench. See Figure 303. 7. Cut the tie wraps holding from around Z stage energy chain. See Figure 303.
  • Page 339 Figure 304: Loosen Z stage leadscrew mounting bracket set screws Loosen set screws on both sides of the mounting bracket. 9. Turn the leadscrew counter clockwise until it is free of the motor. See Fig- ure 305. Figure 305: Remove the leadscrew 10.

  • Page 340: Installing The Z Motor

    Installing the Z motor 1. Place the Z motor in its mounting location and loosely fasten the mounting screws with a ⁄ ” allen wrench. 2. Insert the leadscrew and turn clockwise until the leadscrew clears the bottom of the motor. 3.

  • Page 341: Z Stage

    Z Stage The HP Designjet 3D printer has a Z stage pan that is 8 x 6 inches. The HP Designjet Color 3D printer has a Z stage pan that is 8 x 8 inches. The physical replacement is the same for both printers. When its time to calibrate they will have different procedures.

  • Page 342: Removing The Z Stage

    • Z Guide rod spacer (x2) • Head bracket, dial indicator and belt tension gauge assembly • Z guide rod alignment fixture Hardware • 10-32 x ⁄ ” slotted screws (x4) Removing the Z stage 1. Remove the top panel. See “Removing the top panel”...

  • Page 343: Installing The Z Stage

    6. Using a ⁄ ” socket driver or ⁄ ” box wrench, remove the 2 lower Z stage guide rod mounting screws. See Figure 308. Figure 308: Lower Z stage guide rod mounting screw locations Remove the 2 mounting screws 7.
  • Page 344 4. Using a ⁄ ” allen wrench, Reinstall the 4 Z motor energy chain mount- ing screws. 5. Move Z stage to the middle of travel. 6. Place one Z stage guide rod alignment fixture at the bottom of the Z stage.
  • Page 345 Figure 31 1: Z stage leadscrew mounting bracket locations Z Stage leadscrew mounting brackets 15. Raise the Z stage up all the way and insert the Z stage leadscrew align- ment fixture at the bottom of the guide rods. See Figure 312.
  • Page 346 19. Lower the Z stage to the bottom. 20. Insert the Z stage leadscrew alignment fixture at the top of the guide rods. See Figure 313. 21. Once the alignment fixture is in properly, turn the locking screws ⁄ turn counter clockwise to lock in place.
  • Page 347 314and figure 315. These marks will be used to reference the same locations when leveling the table. Figure 314: HP Designjet 3D (8in x 6in) Z stage table location points BL (Back Left) BR (Back Right) FL (Front Left) FR (Front Right)
  • Page 348 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 8x6 worksheet for HP Designjet 3D, see Figure 316. Use the 8x8 worksheet for HP Designjet Color 3D, see Figure 317.
  • Page 349 Figure 316: HP Designjet 3D measurement points and worksheet -333...
  • Page 350 Figure 317: HP Designjet Color 3D measurement points and worksheet -334...
  • Page 351 39. Move the dial indicator to the front left of the Z stage and zero the dial indicator. 40. Using the XY guide rod leveling fixture, adjust the rod up or down until the dial indicator reads the value the calculator has given. See Figure 274.
  • Page 352 -336...

  • Page 353: Service Calibrations & Adjustments

    Part Based Calibration ............... page 343 When to Perform Part Based calibration ........page 343 Performing part based calibration for HP Designjet 3D from the Service Cal- ibration menu (Firmware version 9.1 or newer) ......page 343 Performing part based calibration for HP Designjet 3D with the HP Designjet 3D Diagnostic Software............

  • Page 354: Offset Calibrations

    Offset Calibrations Adjusting Z Calibration and XY Tip Offset Z calibration is needed to adjust the slight differences in tip heights. XY Tip Offset is required to correct for the slight differences in tip alignment. Failure to perform these calibrations will result in poor part quality and possible LOE’s.

  • Page 355: Z Tip To Tip (Zt2T)

    Figure 319: Service Calibration button sequence Button 0 Button 1 Button 2 Button 3 3. Press the Edit Configuration button. 4. Press the Next... button. 5. Press the Next... button. 6. Press the ZT2B (Z tip to base) button. 7. Enter the calibration value by pressing the Increment, Decrement and Next Digit buttons.

  • Page 356: Xy Tip Calibration

    4. Press the Next... button. 5. Press the Next... button. 6. Press the ZT2T (Z tip to tip) button. 7. Enter the calibration value by pressing the Increment, Decrement and Next Digit buttons. NOTE: The value for ZT2T must be between -0.0500” and 0.0500”.

  • Page 357: Entering Xy Tip Calibration Values Manually (Firmware Version 9.1 Or Newer)

    Figure 320: Example XY Tip Calibration Part. This example requires an adjustment of X = + 2 mils, Y = - 4 mils NOTE: Unusual circumstances may require that the XY Tip Calibration values be entered manually. To change these values, “Entering XY Tip Calibration values manually (Firmware version 9.1 or newer)”...
  • Page 358 Figure 321: Service Calibration button sequence Button 0 Button 1 Button 2 Button 3 3. Press the Edit Configuration button. 4. Press the Next... button. 5. Press the Next... button. 6. Press the XTIP (X tip offset) button. 7. Enter the calibration value by pressing the Increment, Decrement and Next Digit buttons.

  • Page 359: Part Based Calibration

    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...
  • Page 360 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 the filled circle, this indicates the front of the substrate, see Figure Figure 323: Locating the Filled Circle (B) 9.
  • Page 361 Figure 325: Measuring distance from outside edges of A and B 1 1. Next measure and record the distance from the outside edges of circle B and C, see Figure 326 Ensure that the caliper is not seated on the small bump of circle C.
  • Page 362 Figure 328: Measuring distances from outside edges of F and G 15. Measure and record the diameter of circle F along the center line between E and G. See Figure 329 Figure 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.
  • Page 363 Figure 330: Measuring distances from outside edges of C and G 18. Measure and record the distance from the outside edges of circles A and E. Ensure the caliper is not seated on the small bump of circles A or E.
  • Page 364 Figure 332: Measuring distances from outside edges of C and D 20. Measure and 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.
  • Page 365 Figure 334: Measuring diameter of circle D 22. Add the lengths derived from steps 20 and 21 (C-D and D-E) and then subtract the width of circle D derived from 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.
  • Page 366 Figure 336: Measuring distances from outside edges of D and G 25. Measure and record the diameter of circle D along the center line between A and G. See Figure 337 Figure 337: Measuring diameter of circle D 26. Add the lengths derived from steps 24 and 25 (A-D and D-G) and then subtract the width of circle D derived from step 26.
  • Page 367 31. Press the GRight button. Enter the value recorded from step by press- ing the Increment, Decrement and Next Digit buttons. NOTE: The value for GRight must be between 5.250” and 5.750”. 32. When finished, press Done... 33. Press the GFront button. Enter the value recorded from step by press- ing the Increment, Decrement and Next Digit buttons.

  • Page 368: Performing Part Based Calibration For Hp Designjet 3D With The Hp Designjet 3D Diagnostic Software

    Performing part based calibration for HP Designjet 3D with the HP Designjet 3D Diagnostic Software 1. Open HP Designjet 3D Diagnostic Software and select the current modeler from the pull down menu. 2. Open Gantry Calibration Dialog box in HP Designjet 3D Diagnostic Software 3.
  • Page 369 Figure 339: Measuring diameter of B 1 1. Next measure and record the distance from the outside edges of circle A and B, see Figure 340 Ensure that the caliper is not seated on the small bump of circle A. Figure 340: Measuring distance from outside edges of A and B 12.
  • Page 370 Figure 342: Measuring distances from outside edges of E and F 15. Measure and record the distance from the outside edges of circles F and G. Ensure the caliper is not seated on the small bump of circle G. See Figure 343 Figure 343: Measuring distances from outside edges of F and G 16.
  • Page 371 Figure 345: Measuring distances from outside edges of C and G 19. Measure and record the distance from the outside edges of circles A and E. Ensure the caliper is not seated on the small bump of circles A or E.
  • Page 372 Figure 347: Measuring distances from outside edges of C and D 21. Measure and 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.
  • Page 373 Figure 349: Measuring diameter of circle D 23. Add the lengths derived from steps 20 and 21 (C-D and D-E) and then subtract the width of circle D derived from step 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.
  • Page 374 D derived from step 26. Record this 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.

  • Page 375: Part Measurement Equations

    Part Measurement Equations Use the equation table below to record part measurements. Refer to these equations when entering values in HP Designjet 3D Diagnostic Software. Front: _______ + ______ - ____ = ________ (A + B) + (B + C) - B...

  • Page 376: Performing Part Based Calibration For Hp Designjet Color 3D From The Service Calibration Menu (Firmware Version 9.1 Or Newer)

    Performing part based calibration for HP Designjet Color 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 the display panel: 3,2,3,3,1.
  • Page 377 Figure 355: Locating the Filled Circle (B) 9. Using a digital caliper, measure and record the diameter of circle B along the center line between A and C. See Figure 356 NOTE: Reference letters are not actually “printed” on the part. If needed, use the Part Measurement Equations sheet to record the values.
  • Page 378 Figure 357: Measuring distance from outside edges of A and B 1 1. Next measure and record the distance from the outside edges of circle B and C, see Figure 358 Ensure that the caliper is not seated on the small bump of circle C.
  • Page 379 14. Measure and record the 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.
  • Page 380 Figure 361: Measuring diameter of circle F 16. Add the lengths derived from steps 14 and 15 (C-F and F-I) and then sub- 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.
  • Page 381 Figure 363: Measuring distances from outside edges of D and G 19. Measure and record the diameter of circle D along the center line between A and G. See Figure 383 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.
  • Page 382 22. Measure and record the distance from the outside edge of circle H to the outside edge of circle I. See Figure 385 Figure 366: Measuring distances from outside edges of H and I 23. Measure and record the diameter of circle H along the center line between G and I.
  • Page 383 Figure 368: Measuring distances from outside edges of C and E 26. Measure 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.
  • Page 384 Figure 370: Measuring diameter of circle E 28. Add the lengths derived from steps 26 and 27 (C-E and E-G) and then subtract the width of circle 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.
  • Page 385 Figure 372: Measuring distances from outside edges of E and I 31. Measure and record the diameter of circle E along the center line between A and I. See Figure 392 Figure 373: Measuring diameter of circle E 32. Add the lengths derived from steps 30 and 31 (A-E and E-I) and then subtract the width of circle E derived from step 32.
  • Page 386 37. Press the GRight button. Enter the value recorded from step by press- ing the Increment, Decrement and Next Digit buttons. NOTE: The value for GRight must be between 5.250” and 5.750”. 38. When finished, press Done... 39. Press the GFront button. Enter the value recorded from step by press- ing the Increment, Decrement and Next Digit buttons.

  • Page 387: Performing Part Based Calibration For Hp Designjet Color 3D With The Hp Designjet Diagnostics Software

    Performing part based calibration for HP Designjet Color 3D with the HP Designjet Diagnostics Software 1. Open HP Designjet 3D Diagnostic Software and select the current modeler from the pull down menu. 2. Open Gantry Calibration Dialog box in HP Designjet 3D Diagnostic Software 3.
  • Page 388 Figure 375: Measuring diameter of B 1 1. Next measure and record the distance from the outside edges of circle A and B, see Figure 376 Figure 376: Measuring distance from outside edges of A and B 12. Next measure and 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...
  • Page 389 Figure 378: Measuring distances from outside edges of 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.
  • Page 390 Figure 380: Measuring diameter of circle F 17. Add the lengths derived from steps 14 and 15 (C-F and F-I) and then sub- 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.
  • Page 391 Figure 382: Measuring distances from outside edges of D and G 20. Measure and record the diameter of circle D along the center line between A and G. See Figure 383 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.
  • Page 392 23. Measure and record the distance from the outside edge of circle H to the outside edge of circle I. See Figure 385 Figure 385: Measuring distances from outside edges of H and I 24. Measure and record the diameter of circle H along the center line between G and I.
  • Page 393 Figure 387: Measuring distances from outside edges of C and E 27. Measure 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.
  • Page 394 Figure 389: Measuring diameter of circle E 29. Add the lengths derived from steps 26 and 27 (C-E and E-G) and then subtract the width of circle 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.
  • Page 395 E derived from step 32. Record this 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.

  • Page 396: Part Measurement Equations

    Part Measurement Equations Use the equation table below to record part measurements. Refer to these equations when entering values in HP Designjet 3D Diagnostic Software. Front: _______ + ______ - ____ = ________ (A + B) + (B + C) - B...

  • Page 397: Tensioning The X & Y Drive Belts

    Tensioning the X & Y Drive Belts 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 temperature). Zero the Dial Indicator 1.

  • Page 398: Checking/Adjusting The X-Drive Belt Tension

    Checking/Adjusting the X-Drive Belt Tension 1. Remove the top and side panels. 2. If required, allow system to cool to room temperature (approximately 20 minutes). 3. Move the Head Assembly to the full right travel position within the build envelope (as viewed from the front of the printer). 4.
  • Page 399 Figure 396: Gauge reading at correct X belt tension (Shading indicates acceptable range) 6. If the tension is out of the range specified above, adjust the belt tension by turning the X belt tensioning nut on the X-Drive Idler/Tension Adjust gear.

  • Page 400: Checking/Adjusting The Y-Drive Belt Tension

    Checking/Adjusting the Y-Drive Belt Tension 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. 1. Remove the top, side and side access panels. 2.
  • Page 401 Figure 399: Gauge readings Adjustment Limit Service Limit 6. If the tension is not within specification, remove the front panel to gain access to the tensioning nuts. 7. Next loosen, but do not remove, the 4 Y-Drive Belt clamp screws. Check that the belt is clear of the clamp before adjusting the tension.

  • Page 402: Get/Send Calibration Files

    Get/Send Calibration Files The .cal file contains the calibration values for the system. If the hard drive is replaced the .cal file will be automatically downloaded from the frame ID chip. Situations where the printer will not calibrate before a build, even if manual calibration has been performed by the technician, the factory .cal file may need to be obtained from Stratasys, Inc.
  • Page 403 Measure and record the difference (e.g. the dial indi- cator reads +0.008 in). 1 1. Enter the values that are written down into the XY level worksheet. Use the 8x6 worksheet for HP Designjet 3D, see Figure 402. Use the 8x8 worksheet for HP Designjet Color 3D, see Figure 403.
  • Page 404 Figure 402: HP Designjet 3D measurement points and worksheet -388...
  • Page 405 Figure 403: HP Designjet Color 3D measurement points and worksheet -389...

  • Page 406: Adjusting The Xy Table Level

    Adjusting the XY Table Level 1. Loosen the left front (LF), right front (RF) and back right (BR) guide rod mounting screws. NOTE: The back left (BL) corner does not have an adjustment gap and will not require adjustment. 2. Move the indicator to the back left (BL) corner mark and verify gauge reading is still zero 3.
  • Page 407 15. Using the table leveling adjustment tool move the rod up until the dial indicator reading matches the value from the calculator. (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.

  • Page 408: Head Alignment Procedure

    Head Alignment Procedure This procedure is used verify and correct head alignments when misalignment is suspected. 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. Figure 405: Special Head Alignment Tools Shim set Shim set...
  • Page 409 5. Make sure that the Drive Wheel Alignment Rod is straight. Roll the Rod along a flat surface to check for bends. Straighten as necessary. 6. Insert the Drive Wheel Alignment Rod from the bottom of the right side (model) heater block (before using, check the rod to make sure that it is straight).
  • Page 410 Figure 408: Viewing the drive wheel alignment B. The Alignment Pin should not deflect forward or backward as the Drive Wheel is brought into contact with the Pin. C. The Alignment Pin should be centered within the groove of the Drive Wheel. •...

  • Page 411: Idler Wheel Check/Adjustment

    Figure 410: Wheel alignment check 2 of 2 5. Move the Toggle Bar to the right. 6. Loosen the Heater Block Clamp screws and the Heater Block Mount screws. 7. Remove the Alignment Rod. 8. Install the right side Pivot Block. a.
  • Page 412 If the tension is not correct remove the Idler Wheel Tension Adjust screw (5/64” Allen), apply LocTite 222 to the screw threads, and install the screw. G. Adjust the screw to obtain a light drag on .003 inch feeler gauge when it is positioned between the Drive Wheel and the Idler Wheel.

  • Page 413: Liquefier Alignment

    If the tension is not correct remove the Idler Wheel Tension Adjust screw (5/64” Allen), apply LocTite 222 to the screw threads, and install the screw. G. Adjust the screw to obtain a light drag on .003 inch feeler gauge when it is positioned between the Drive Wheel and the Idler Wheel.

  • Page 414: Verify Liquefier Alignment

    Position the Liquefier Alignment Rod so that the stepped portion is flush with the top of the Heater Block. G. Tighten the Heater Block Clamp screws. CAUTION: Use care when moving the Toggle Bar. Forcing the bar, or applying too much pressure, will damage the Liquefier Alignment Rod and cause a misalignment of the Liquefier Tubes with the filament path.
  • Page 415 Figure 413: Identifying tips B. Insert the new tip into the heater block. C. Use needle nose pliers to grasp the stainless steel shield of the tip. D. Pull the tip shield toward you, then lift up to install the tip. E.
  • Page 416 B. Make sure that the Liquefier Alignment Rod is straight. Roll the Rod along a flat surface to check for bends. Straighten as necessary. C. Insert the Liquefier Alignment Rod - small end first - from the TOP of the right side Toggle Block, past the Drive Wheel, to just above the Liquefier inlet.

  • Page 417: Complete The Re-Assembly Of The Toggle Head Assembly

    Figure 416: Liquefier alignment check (2 of 2) Unacceptable liquefier alignment Pinch point is the same as the centerline of the alignment rod. Complete the Re-Assembly of the Toggle Head Assembly 1. Connect the Filament Tubes to the top of the Toggle Head Assembly - make sure the model tube is on the right;...

  • Page 418: Tip Wipe Assembly

    Tip wipe assembly If the XY Table or Z stage has been replaced or leveled, the tip wipe assembly will need to be adjusted to ensure proper functionality. Required Tools • Standard screwdriver • 7/64” allen wrench • Tip wipe height block Adjusting tip wipe assembly height: 1.
  • Page 419 4. Move the toggle bar to the model side, then move the toggle assembly over the tip wipe height block. See Figure 419 Figure 419: Toggle assembly location 5. Using a 7/64” allen wrench, loosen but do not remove the tip wipe assembly bracket screws.
  • Page 420 Figure 421: Tip wipe assembly bracket adjustment 7. Using a 7/64” allen wrench, tighten 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.

  • Page 421: Appendix

    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 Designjet 3D Diagnostic Software Help....... page 424 Tera Term................page 431 -405...

  • Page 422: Front Door Area Components

    Front door area components Figure 422: Front door area component locations Item Part Number Description CQ656-67130 LCD Display CQ656-671 13 Panel, Left Side Not Shown CQ656-671 17 Insulation Foam, Left Panel CQ656-671 1 1 Panel, Front Not Shown CQ656-671 19 Insulation Foam, Front Panel CQ656-671 15 Panel, Door...

  • Page 423: Electronics Bay Components

    Electronics bay components Figure 423: Electronics bay component locations Item Part Number Description CQ656-67177 I/O Card CQ656-67176 Power Distribution Board (PDB) CQ656-67178 Controller Board CQ656-67179 Single Board Computer (SBC) CQ656-67184 Differential Line Filter CQ656-67185 AC Input CQ656-67141 Circuit Breaker CQ656-67186 Electronics Bay Cooling Fan CQ656-67180 Hard Drive with Software...
  • Page 424 Figure 424: Electronics bay component locations Item Part Number Description CQ656-67181 120 VDC Auxiliary Power Supply CQ656-67182 24 VDC Power Supply CQ656-67183 5/12 VDC Power Supply -408...

  • Page 425: Head Area Components

    Head area components Figure 425: Head area components Item Part Number Description CQ656-67159 Toggle Head Cover CQ656-67158 Toggle Head Manifold Not Shown CQ656-67195 Tip Shroud Not Shown CQ656-67196 T16 Model Liquefier Not Shown CQ656-67197 T16 Support Liquefier -409...
  • Page 426 Figure 426: Head area components Item Part Number Description CQ656-67149 Toggle Head Assembly CQ656-67148 Filament tube, Support CQ656-67147 Filament tube, Model -410...
  • Page 427 Figure 427: Head area component locations Item Part Number Description CQ656-67150 Head Board CQ656-67153 Toggle Bar CQ656-67151 TC Amp Board -411...
  • Page 428 Figure 428: Head area component locations Item Part Number Description CQ656-67154 Toggle Sensor Cable CQ656-67152 Toggle Sensor CQ656-67155 Substrate Sensor CQ656-67156 Substrate Sensor Arm -412...

  • Page 429: Xy Table Area Components

    XY Table area components Figure 429: XY Table component locations Item Part Number Description CQ656-67157 Umbilical Hose CQ656-67193 Umbilical Cable CQ656-67147 Model Material Tube CQ656-67131 Y Motor CQ656-67132 X Motor CQ656-67137 Y Motor Belt CQ656-67148 Support Material Tube -413...
  • Page 430 Figure 430: XY Table component locations Item Part Number Description CQ656-67134 XY Table Not Shown CQ656-67135 X Drive Belt Not Shown CQ656-67136 Y Drive Belt Figure 431: XY Table component locations Item Part Number Description CQ656-67122 Y Home sensor CQ656-67122 Y EOT (End of Travel) Sensor -414...

  • Page 431: Z Stage Area Components

    Z Stage area components Figure 432: Z Stage component locations Item Part Number Description CQ656-67122 Z Home Sensor CQ656-67194 Chamber Thermocouple, K-type 36 inch CQ656-67122 Z EOT (End of Travel) Sensor CQ656-67142 Chamber Fan CQ656-67138 Z Stage 8x6 CQ656-67139 Z Stage 8x8 CQ656-67133 Z motor, leadscrew and energy chain CQ656-671 10...

  • Page 432: Chamber Heater Area Components

    Chamber heater area components Figure 433: Chamber heater area components Item Part Number Description CQ656-67143 Heater, Finned Strip CQ656-67146 Thermostat, 121 DEG C Disc -416...

  • Page 433: Cables

    Cables Part Number Description CQ656-67161 Cable, 120 Volt Auxiliary Power CQ656-67162 Cable, UPS to PDB CQ656-67163 Cable, RS232 Diagnostic CQ656-67164 Cable, Ribbon, SBC to PDB CQ656-67165 Cable, AC to PDB and Power Supplies CQ656-67213 Cable, +24VDC to PDB and Fan CQ656-67166 Cable, +5/12 VDC Power CQ656-67167...

  • Page 434: Material Bay Components

    Material Bay Components Figure 434: Material Bay components Item Part number Description Qty. CQ656-67103 Door, Support Side CQ656-67102 Door, Model Side CQ656-67104 Skins, Left or Right Side CQ656-67101 Material Bay Assembly CQ656-67109 Material Bay Cable CQ656-67107 Model Material Tube, dual bay CQ656-67105 Model Material Tube, single bay CQ656-67108 Support Material Tube, dual bay CQ656-67106 Support Material Tube, single bay...

  • Page 435: Tools

    Tools Part Number Description CQ656-67202 Special Tools Kit CQ656-67203 Head Alignment Tool Kit CQ656-67205 Spring Removal Tool CQ656-67206 Belt Tension Gauge CQ656-67207 Head Bracket CQ656-67208 Brush/Flicker Spacer Consumables Part Number Description CQ656-67214 P430L Ivory, Single Spool, 40cu in CQ656-67215 P430L Red, Single Spool, 40cu in CQ656-67216 P430L Green, Single Spool, 40cu in CQ656-67217...

  • Page 436: Hard Drive Installation Checklist

    If the system will be operating in a Dynamic environment, the UPGRADE can be loaded from the PC. Use the Manage 3D Printers button in HP Designjet Software Solution to connect to the printer -Choose “Add from Network...” Set Net- •...

  • Page 437: Toggle Head Assembly Installation Checklist

    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.

  • Page 438: Xy Table Assembly Installation Checklist

    XY Table Assembly Installation Check- list If you have any questions before or during installation, do not hesitate to call your Customer Support provider. Replace the XY table Assembly. Verify that all electrical leads are connected correctly Perform the XY Leveling 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...

  • Page 439: Controller Board Checklist

    Controller Board Checklist Use this checklist when replacing the controller board. Due to possible software version conflicts, additional steps must be taken after installing a controller board - the complete (X, Y, Z) homing process must be run before building a part. Unload material.

  • Page 440: Hp Designjet 3D Diagnostic Software Help

    Connect Select a Modeler From the Current Modeler drop down list select a modeler to connect to with HP Designjet 3D Diagnostic Software. To add modelers to the list, use the plus button at the bottom of the window. -424...

  • Page 441: Modeler States

    If present, the previous internal state to which the current state will return when complete. Modeler Setup In order to use HP Designjet 3D Diagnostic Software on a network modeler, you must first create a modeler definition. You can create modeler definitions by clicking the button in the main window.

  • Page 442: Position And Temperatures

    Position and Temperatures Current Position The current X, Y and Z position in micro steps. X and Y = 16000 micro-steps per inch. Z = 128000 micro-steps per inch. Current / Total The current build layer and the total number of layers in the model Layers Current Curve...

  • Page 443: Material

    Material Model Latched The model material cartridge latch state Model in Head The state of the modeling material in the printer. True = material moved out of cartridge False = material not moved out of cartridge. Support Latched The support material cartridge latch state. Support in Head The state of the support material in the printer.

  • Page 444: Gantry

    Gantry The gantry controls the adjustment for the XY gantry. These values are set in the factory and do not need to be adjusted unless the XY gantry is adjusted or replaced where part based calibration is required. See “Part Based Calibration”...

  • Page 445: Outputs

    Outputs The outputs dialog contains toggle buttons to control solenoids and motors that can not be directly controlled on the Control Panel Display. NOTE: It is suggested, that due to the time required to display switch state changes, that you use the LEDs on the PDB to verify switch operations. Model Latch The check box shows the state of the model (top) cartridge latch.

  • Page 446: Send Calibration

    If the system is not available over the network, when HP Designjet 3D Diagnostic Software first loads, HP Designjet 3D Diagnostic Software will only try to connect one time. This allows you to interact with HP Designjet 3D Diagnostic Software when it is not connected to a printer. The Connect button allows you to request additional connection attempts.

  • Page 447: Tera Term

    Tera Term Using Tera Term When using these commands, there is a high risk of damage to the machine because the printer does not recognize the location of any other components in the machine that may be in the way. This means if you use the command to move the Z-Stage, you will have to make sure that the Head is moved out of the way.
  • Page 448 Figure 435: New Connection Window 5. Select 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.
  • Page 449 Figure 437: Setup Serial Port 9. From the Baud Rate: pull-down menu select 38400, see Figure 438 10. From the Flow Control: pull-down menu select hardware, see Figure 1 1. The rest of the settings should default to the correct values. Click OK, see Figure 438 Figure 438: Serial Port Setup 12.

  • Page 450: Tera Term Commands

    Tera Term Commands Tera Term is an easy way to check and troubleshoot the hardware of a machine. Here are a couple of helpful commands which can be used to operate the machine through Tera Term. All values, which are displayed in Tera Term, are in inches.
  • Page 451 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. 3.
  • Page 452 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 between the sub- strate and the Z BOT sensor.
  • Page 453 5. gp = get POST. Displays power on self test results Use this for checking: • If the controller 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;...
  • Page 454 6. rt = repeat This command will tell the machine to repeat the previous command. The command line takes a repeat count, and flags whether or not to ignore errors. It also flags wether or not to show the command line of the command to be run.
  • Page 455 7. le = load exception log This command prints the contents of the exception log located in non-volatile memory. This exception log contains a record of the most recent exceptions that occurred within the controller. The exceptions are printed in chronological order.
  • Page 456 8. tm = monitors temperatures This command displays temperature information for the model Liquefier, support liquefier, and chamber heater. Use this command if you experience temperature problems with the head. Check if the model and support temperature reach the set point and if the temperature is stable once it reaches the set point temperature.
  • Page 457 The MZ command moves the Z-Stage relative to the current position. A positive value moves the Z-Stage down. A negative value moves the Z-Stage Example: mz 4.0 This command will move the Z-Stage 4 inch down. 10. mx = move x This command moves the head in the X axis.
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