Objet Alaris30 Service Manual

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Page 1: Table Of Contents
Pump Tubing ........................ 27 Wiper Assembly Servicing ..................32 Roller Assembly Servicing..................38 Roller Replacement...................... 49 Head Driver Card Cooling Fan Filters..............67 Print Head Replacement ..................... 69 X Encoder Replacement ....................78 Print Block Replacement..................... 88 Main Power Supply Replacement ................96 UV Power Supply Replacement................102 Copyright © by Objet Geometries Ltd. all rights reserved. Objet Confidential and Proprietary Information DOC-04204 Rev. A...
Page 2: Yearly Maintenance Tasks
Alaris30 Service Guide 1 Yearly Maintenance Tasks Refer to the Alaris30 Preventive Maintenance Kit (DOC‐04005) for the preventive maintenance task list for the Alaris30 printers. DOC-04204 Rev. A Confidential and Proprietary Information...
Page 3: Z-Axis Cover Cleaning
Alaris30 Service Guide 2 Z-axis Cover Cleaning The z‐axis cover collects residue that falls inside the printer. Periodically, empty the cover to prevent buildup of foreign matter. The z‐axis cover is behind the blower. 2.1 Tools • Allen key set 2.2 Procedure Remove the rear panel of the printer. Remove the filter from the blower. Figure 1 Filter on Blower DOC-04204 Rev. A Confidential and Proprietary Information...
Page 4 Alaris30 Service Guide Open the pump panel (next to the blower). Screw Figure 2 Pump Panel—Closed Remove the two screws, which secure the guard to the blower and remove the guard. Top screws Side screws Connector Wing nuts Guard screws Base screws Figure 3 Blower Remove the rubber cover from each of the base screws. DOC-04204 Rev. A Confidential and Proprietary Information...
Page 5 Alaris30 Service Guide Remove the following screws, which secure the blower to the frame: • Base screws • Top screws • Side screws (two screws for each side). Loosen the wing nuts (one on each side). Disconnect the connector. Lift the blower by the wing nuts and remove the blower from the printer. Loosen the 4 thumb screws that fasten the z‐axis cover to the printer and remove the cover. Figure 4 Z-axis Cover—Screws Circled Figure 5 Remove Z-axis Cover Discard (according to local regulations) any waste residue in the cover and wipe it clean with a paper towel. Replace the z‐axis cover and refasten the thumb screws. Reattach the blower. DOC-04204 Rev. A Confidential and Proprietary Information...
Page 6 Alaris30 Service Guide Insert the carbon filter into the blower Close the pumps panel. Reattach the back panel. DOC-04204 Rev. A Confidential and Proprietary Information...
Page 7: Leaks And Spills
Alaris30 Service Guide 3 Leaks and Spills As part of yearly maintenance, the service engineer checks for support or model material leaks. In particular, leaked printing material often collects in the reservoir underneath the blower. Warning: Be sure to read and understand “” on page 1. 3.1 Tools • Paper towels • Cleaning solution (isopropyl alcohol) 3.2 Procedure Remove the printer covers and the blower. Inspect for leaked printing material inside the printer. Be sure to look in the following locations: • Under the pumps panel • Under and around the check valves • Near the wiper motor (located underneath the build tray) and near the printer computer • Under the materials drawer •...
Page 8 Alaris30 Service Guide If you detect a leak, do the following: Leak Cleaning • Locate the source of the leak and repair it. • For smaller leaks, soak up any leaked printing material using paper towels. • For larger spills, follow the instructions in the Material Safety Data Sheet (MSDS) and any local regulations. Clean any residue using a paper towel wetted with cleaning solution (isopropyl alcohol). If people are in contact with the area (as compared to areas with electronics), rinse with soap and water, and then dry. Dispose of the waste in accordance with local regulations. DOC-04204 Rev. A Confidential and Proprietary Information...
Page 9: Model Cooling Fan Inspection
Alaris30 Service Guide 4 Model Cooling Fan Inspection Inspection procedure to verify that the model cooling fans are operational. The UV lamp and head driver cooling fans do not require inspection, since they contain speed sensors and their status is routinely checked by the printer. 4.1 Procedure Make sure the printer is powered ON. In the Alaris30 software, select Maintenance > Actuators and Sensors. The Actuators & Sensors Control window opens.
Page 10 Alaris30 Service Guide Visually inspect the model cooling fans and verify the following: • The blades are turning rapidly • The fans are moving air and not clogged with dust. Figure 8 Model Cooling Fans DOC-04204 Rev. A Confidential and Proprietary Information...
Page 11: Head Driver Interface Card Connector Cleaning
Alaris30 Service Guide 5 Head Driver Interface Card Connector Cleaning Proper cleaning of the connectors ensures good contact. 5.1 Tools • Contact cleaner or isopropyl alcohol • Non‐shedding cleaning swab or cloth 5.2 Procedure Turn off the printer. Loosen the two thumb screws that secure the upper cover of the head driver compartment to the print block and lift off the cover. Figure 9 Upper Cover Thumb Screws Support head Model head interface card interface card Figure 10 Print Head Interface Cards DOC-04204 Rev.
Page 12 Alaris30 Service Guide Lift the support head interface card off its socket. (It may be necessary to lift the card using a rocking movement.) Lift the model head interface card off its socket. Apply contact cleaner or isopropyl alcohol to a non‐shedding cleaning swab or cloth, and use it to clean the metal contacts in the two sockets. Similarly clean the metal contacts of the interface cards. Allow the contacts to air dry. Reconnect the interface cards. Place the upper cover back in its position on the print block and tighten its thumb screws DOC-04204 Rev. A Confidential and Proprietary Information...
Page 13: Electrical Cable Inspection
Alaris30 Service Guide 6 Electrical Cable Inspection The electrical cables inside the printer may become dirty, move or work themselves loose from their connectors. As well, solvents in the printing material can attack and damage electrical insulation. Therefore, the service engineer must visually inspect the cleanliness, routing, and integrity of the cables. 6.1 Procedure Inspect the cleanliness of the electrical cables inside the printer. If a cable is dirty, clean it with isopropyl alcohol and air dry. Inspect the routing of the electrical cables inside the printer. If a cable has moved out of place, reposition it so that it will not be pinched by or impede mechanical parts. If necessary, use cable ties or another means to fasten it in position. Inspect the integrity of the electrical cables inside the printer, and their insulation. If a cable is damaged, replace it. DOC-04204 Rev. A Confidential and Proprietary Information...
Page 14: Needle Inspection & Replacement
Alaris30 Service Guide 7 Needle Inspection & Replacement To prevent leaks from the model and support material cartridges, regularly inspect the needle tips and ensure that they are straight. Replace needles with bent tips. When you replace a needle, inspect the needle dome and, if it is worn or torn, replace it too. 7.1 Tools • Protective gloves • Cleaning solution • Needle Replacement Kit (KIT‐04009‐S) The Needle Replacement kit contains: • 2 needle domes (RBR‐04016) • 2 needles (MCP‐04127) • Teflon® roll (MSC‐00094) • A needle dome placement jig (JIG‐04062) • ¼ inch drive metric deep socket (D=10 mm L= 49 mm), (TOL‐00119) 7.2 Procedure Remove the material cartridges and examine the needle tips. Replace needles with bent tips (see Figure 11). Figure 11 Magnification of a Bent Needle Tip (Example) DOC-04204 Rev.
Page 15 Alaris30 Service Guide Remove (using a plier) the needle dome from the base of the needle. Caution: The needle tips are very sharp and can cause injury. Model 1 Support 1 Needle and dome Support 2 Model 2 Figure 12 Cartridge Drawer Using the socket, remove the needle. Figure 13 Removing Needle with Socket DOC-04204 Rev. A...
Page 16 Alaris30 Service Guide Figure 14 Socket and Needle Remove the old thread‐seal tape from the needle. Wrap new Teflon tape twice around the threaded shaft of the new needle. Figure 15 Wrapping Thread-Seal Tape Put on protective gloves and clean the area in the drawer surrounding the needle. Caution: The needle tips are very sharp and can cause injury. Using the socket, install the new needle. Examine the needle and make sure it is straight and firmly attached to the cartridge drawer. Tighten as required. DOC-04204 Rev. A Confidential and Proprietary Information...
Page 17 Alaris30 Service Guide Using the placement jig, attach a dome to the base of the needle. Figure 16 Placing a Needle Dome in the Jig Figure 17 Placing a Dome on a Needle DOC-04204 Rev. A Confidential and Proprietary Information...
Page 18 Alaris30 Service Guide In the Alaris30 software, select Maintenance > Calibration. The Calibrate Load Cells Calibration window opens. Figure 18 Calibration Window Select the Weight Sensors tab. Figure 19 Calibration Window—Weight Sensors Tab Select Model 1 from the Cartridge list. Remove the Model 1 cartridge from the cartridge drawer. Click Empty. In the Full Weight (gr.) text box, enter the known weight of the test load in grams. Test load is a known weight ± 15 g. The test load should weigh about 2 kg. DOC-04204 Rev. A Confidential and Proprietary Information...
Page 19 Alaris30 Service Guide Place the test load into the Model 1 compartment. Figure 20 Model 1 Compartment Click Full and then click Save. Repeat this procedure for the Model 2, Support 1 and Support 2 load cells. Reinstall the material cartridges. DOC-04204 Rev. A Confidential and Proprietary Information...
Page 20 Alaris30 Service Guide 8 UV Lamp When the intensity of a UV light drops below a usable level, replace the UV lamp. 8.1 Procedure In the Alaris30 software, select Maintenance > Motors Control. The Motors Control window opens. Figure 21 Motors Control Window DOC-04204 Rev. A Confidential and Proprietary Information...
Page 21 Alaris30 Service Guide Select the Z tab. Figure 22 Motors Control Window—Z Tab If the Z‐axis is disabled, select the Enable check box. Click Home. Click Go Z Down. Click Close. Shutdown the Alaris30 software. Shutdown the Alaris30 computer. Turn off the printer. Open the cover of the printer. Warning: Make sure that the UV lamp is not hot. DOC-04204 Rev. A Confidential and Proprietary Information...
Page 22 Alaris30 Service Guide Disconnect the power connection to the UV lamp. Figure 23 Disconnect Power Cable to UV Lamp Do not disconnect the power connection to the cooling fans. Loosen the screws securing the UV lamp cover and remove the cover. Figure 24 Loosen UV Lamp Cover Screws DOC-04204 Rev. A Confidential and Proprietary Information...
Page 23 Alaris30 Service Guide Loosen the two screws that secure the lamp housing. Figure 25 UV Lamp Housing Screws Remove the lamp housing by raising and tilting it slightly while pulling it out of the printing assembly. Discard the old reflector and lamp (according to local regulations). Ensure that the black strip is present along the head side of the new UV lamp/reflector unit and the internal surface of the unit is clean. Insert the new UV lamp/reflector unit into the housing and tighten the two screws to secure it. Put the lamp cover back on and tighten the securing screws. Reconnect the power connection to the UV lamp. Turn on the printer. Start the Alaris30 software. Check that the tray is clear. Close the cover of the Alaris30 printer. DOC-04204 Rev. A Confidential and Proprietary Information...
Page 24 Alaris30 Service Guide Press F5 (Go to Tray Upper Position). The following Confirmation box opens. Figure 26 Confirm Dialog Box—Go to Tray Upper Position Click Yes. Continue with the UV Lamp calibration procedure on page 26. DOC-04204 Rev. A Confidential and Proprietary Information...
Page 25: Support And Model Material Filters
Alaris30 Service Guide 9 Support and Model Material Filters Material filters gradually become clogged and must be periodically replaced to prevent blockage. 9.1 Tools • Screwdrivers • Protective gloves and glasses • Disposable container or absorbent paper • Material filters 9.2 Procedure Remove the rear panel of the printer. Loosen the screw fastening the pumps panel to the printer, and open the pumps panel. Screw Figure 27 Pumps Panel Put on protective gloves. Put on protective glasses. This is prevent any possibility of printing material splashing into the eyes. Place a container (or piece of absorbent paper) underneath the material filters to catch any printing material that spills while the tubing is open. For each of the material filters, do the following: DOC-04204 Rev. A...
Page 26 Alaris30 Service Guide Unscrew the tubing from both sides of the old filter. Identify the tube connected to the INLET side of the filter. This tube is to be connected to the INLET side of the new filter. Figure 28 Material Filter—Inlet Side Discard the old filter (according to local regulations). Tightly screw the tube fittings onto the filter. Be sure that the INLET tube is connected to the INLET side of the filter. Print a test model and check the material filter area for any leaks. If there are leaks, tighten the tube fittings on the filter connectors until they seal. Clean up any spilled model and support material with a paper towel and discard (according to local regulations). DOC-04204 Rev. A Confidential and Proprietary Information...
Page 27: Pump Tubing
Alaris30 Service Guide 10 Pump Tubing The model and support material pumps use a “peristaltic” action to pump the printing material to the printing head—the pump action squeezes the a length of tubing within the pump progressively and this action pumps the printing material. The squeezing action crushes and gradually deforms the pump tubing, which must therefore be periodically replaced. To replace the tubes in the model and support pumps, it is necessary to remove the waste pump from the pump panel. The pump tube replacement procedure consists of the following main steps: • Removing the waste pump from the pump panel. • Replacing the model pump tube • Replacing the support pump tube. • Replacing the waste pump tube. • Reattaching the waste pump to the pump panel. 10.1 Tools • Norprene® 3/16ʹʹ ID 5/16ʹʹ OD tubing (PNM‐01006‐S) • Cutting pliers • 6 cable ties • Allen key set • Protective gloves and glasses • Cleaning cloths 10.2 Procedure Cut three 18 cm (7.1 in) lengths of the Norprene tubing for use as ...
Page 28 Alaris30 Service Guide Loosen the screw fastening the pumps panel to the printer, and open the pump panel. Model pump Support pump Waste pump Figure 29 The Pump Panel Put on protective gloves. Using a M3 Allen key, remove the screws that fasten the waste pump to the pump panel. Securing screws Figure 30 Pump Screws DOC-04204 Rev. A Confidential and Proprietary Information...
Page 29 Alaris30 Service Guide Open (turn) the clip that locks the tube cover to the waste pump. Locking clip Figure 31 Waste Pump Locking Clip Remove the plastic tube cover from the pump. Tube cover Figure 32 Removing the Tube Cover Remove the waste pump from the pump panel. DOC-04204 Rev. A Confidential and Proprietary Information...
Page 30 Alaris30 Service Guide Open (turn) the clip that locks the tube cover to the model pump. Replacing the Model and Support Pump Tubes L-fitting locking clip Figure 33 Model Pump Locking Clip Remove the plastic tube cover from the model pump. Remove the two cable ties securing the model pump tube to the L‐ fittings. Disconnect the ends of the tube from the two L‐fittings and discard the old tube (according to local regulations). Attach a new tube to the tube cover. Figure 34 New Tube Attached to a Tube Cover Reattach the tube cover with the new tube to the model pump. DOC-04204 Rev. A Confidential and Proprietary Information...
Page 31 Alaris30 Service Guide Close the clip that locks the tube cover to the model pump. Attach the ends of new tube to the two L‐fittings and secure each end with a cable tie. Make sure you connect the pressure and suction tubes correctly. The tube from the valves connects to the suction inlet and the tube from the cartridge drawer connects to the pressure outlet. Clean up any spills and leaks from the tubes. Repeat this procedure from Step 10 for the support pump tube.
Page 32: Wiper Assembly Servicing
Alaris30 Service Guide 11 Wiper Assembly Servicing A rubber wiper blade removes excess material from the print heads after the purge sequence. This is done automatically before each print job, and performed manually during maintenance tasks. The following maintenance tasks are required: • Inspect the wiper blade, if the wiper is damaged or worn, replace it. • After replacing the wiper blade, seal the front end of the wiper waste collector (bath) and area surrounding the wiper blade with paste. 11.1 Tools • Isopropanol (IPA—isopropyl alcohol) or ethanol (ethyl alcohol) • Disposable protective gloves • An Objet‐supplied cleaning cloth or equivalent • A spare wiper blade • Molykote® DX Paste • A M2.5 Allen key 11.2 Procedure In the Alaris30 software, select Options > Wizards > Wiper Cleaning. Cleaning the Wiper The Clean Wiper Wizard window opens. Figure 35 Clean Wiper Wizard Window DOC-04204 Rev.
Page 33 Alaris30 Service Guide Close the printer cover and click Next in the wizard screen. Figure 36 Clean Wiper Wizard—Check Boxes Check that the tray in the Alaris30 printer is clean and then close the printer cover. Select both the check boxes on the Clean Wiper Wizard screen and click Next. When the Is Wiper Clean window opens, open the cover. Figure 37 Is Wiper Clean Window Put on the cleaning glove. DOC-04204 Rev. A Confidential and Proprietary Information...
Page 34 Alaris30 Service Guide With the M2.5 Allen key, loosen (but do not remove) the screw Replace the Wiper Blade securing the wiper blade. Wiper blade and holder Securing screw Figure 38 Wiper Blade & Wiper Waste Collector Remove the wiper blade unit. Push the washers on the wiper blade’s securing screw and washer Apply Paste to the Wiper away from the wiper waste collector (bath) so they do not get covered with paste. Using a flat‐headed screwdriver, apply paste onto the entire area where the wiper blade unit sits on the wiper waste collector, including the front corners of the wiper waste collector as shown in Figure 39 and Figure 40. Figure 39 Wiper Waste Collector with Paste—Front View DOC-04204 Rev.
Page 35 Alaris30 Service Guide Figure 40 Wiper Waste Collector with Paste—Side View Inspect the wiper blade. If the wiper blade is scratched, torn or worn, or if you cannot clean it completely, replace it. To ensure that model quality does not decrease over time, you should replace the wiper at least once a month, even if you do not notice any wear.
Page 36 Alaris30 Service Guide Using a generous amount of cleaning fluid and the cleaning cloth, remove any material and excess paste remaining on the wiper blade and the wiper waste collector. Figure 41 Clean Wiper Waste Collector In the wizard window (“Is wiper clean?”) (see Figure 37), select the confirmation check box and click Next. A Clean Wiper Wizard window opens. Figure 42 Clean Wiper Wizard—Finishing Up Make sure that you have removed all tools and cleaning materials from the printer, and close the cover. DOC-04204 Rev. A Confidential and Proprietary Information...
Page 37 Alaris30 Service Guide Select both the check boxes on the Clean Wiper Wizard window and click Next. Figure 43 Wiper Cleaning—Final Screen Click Done to close the wizard. Select Options > Execute Purge Sequence. Check that the wiper operates properly. DOC-04204 Rev. A Confidential and Proprietary Information...
Page 38: Roller Assembly Servicing
Alaris30 Service Guide 12 Roller Assembly Servicing The roller assembly must be serviced every year or if damage is suspected. The following steps are required: • “Remove Roller Waste Collector Assembly” on page 39 • “Remove Old Roller Knife” on page 42 • “Install New Knife on Clamp” on page 44 • “Check Roller Surface” on page 45 • “Smoothing the Roller Surface” on page 46 • “Clean Roller Surface” on page 46 • “Clean Roller Waste Collector” on page 46 • “Closing the Roller Waste Collector Assembly” on page 47 • “Reinstall the Roller Waste Collector Assembly” on page 48 For the procedure on replacing the roller, see page 49. 12.1 Tools • Roller Knife •...
Page 39 Alaris30 Service Guide 12.2 Procedure In the Alaris30 software, select Options > Wizards > Heads Cleaning. Remove Roller Waste The Clean Heads Wizard window opens. Collector Assembly Figure 44 Clean Heads Window Close the printer cover and click Next. The next wizard window opens. Figure 45 Clean Heads Window Select the two check boxes to confirm that the tray is empty and the cover is closed Click Next. The build tray moves down and the print block moves over the center of the build tray. When the following window opens, open the cover. DOC-04204 Rev. A Confidential and Proprietary Information...
Page 40 Alaris30 Service Guide Figure 46 Are the Heads Clean Window Warning: The print head orifice plate (bottom surface) and the UV lamp may be hot. Do not touch them with your bare hands, and proceed with caution. Disconnect the UV lamp power and ventilation connections from the printing assembly. UV-lamp...
Page 41 Alaris30 Service Guide Loosen the two side screws securing the UV lamp assembly, and remove the UV lamp assembly. This permits access to the roller waste collector assembly. Figure 48 UV Lamp Assembly Securing Screws Put on protective gloves. Pull the print block all the way to the front, exposing the roller waste collector locking pin. Figure 49 Roller Waste Collector Locking Pin Lift the locking pin’s hook and turn it counter‐clockwise, to raise the drain‐tube bracket from the roller waste collector. DOC-04204 Rev. A Confidential and Proprietary Information...
Page 42 Alaris30 Service Guide Figure 50 Raised Drain-Tube Bracket Place your hand under the roller waste collector to support it, and use a M3 Allen key to loosen the screws Insert the tip of a screwdriver into the end of the roller waste Remove Old Roller Knife collector assembly between the knife clamp and the knife and carefully pry apart (separate) the knife clamp from the roller waste collector. Figure 51 Removing the Roller Knife DOC-04204 Rev. A Confidential and Proprietary Information...
Page 43 Alaris30 Service Guide Figure 52 Prying Apart the Clamp from the Roller Waste Collector The roller knife is sandwiched between the knife clamp and the roller waste collector. Strong magnets fasten the knife between the clamp and the roller waste collector.
Page 44 Alaris30 Service Guide Align a new roller knife with the knife clamp. The large and small Install New Knife on holes in the knife must match the large and small pins of the clamp. Clamp Lay the new knife onto the clamp and make sure the knife is installed flat and oriented correctly. It may be necessary to carefully stretch the knife flat. Caution: Be careful not to damage the roller knife; it is delicate. Figure 54 New Roller Knife on Clamp Figure 55 Roller Knife Installed Correctly Ensure that the knife is installed parallel to the edge of the clamp as shown in Figure 55.
Page 45 Alaris30 Service Guide In the Alaris30 software, select Maintenance > General Devices Check Roller Surface Control. The General Devices window opens. Figure 56 General Devices Window In the Roller area, click Turn On. DOC-04204 Rev. A Confidential and Proprietary Information...
Page 46 Alaris30 Service Guide Place your fingertips against the underside of the roller and, by moving your fingertips along the length of the roller, feel the roller surface for bumps. If the roller surface is smooth then continue with Step 20. Figure 57 Checking the Roller Surface If the roller surface is rough, wipe the roller with a cleaning wipe Smoothing the Roller Surface sprayed with WD40. Replacing the roller is very complicated. Only a severely damaged roller should be replaced. An example of severe roller damage is deep scratches that cause lines or drips on the printed model.
Page 47 Alaris30 Service Guide Wet a paper towel with cleaning solution (isopropyl alcohol) and wipe the inside of the roller waste collector until the it is clean. Figure 58 Roller Waste Collector Cleaning Discard the paper towel (according to local regulations). Align the large and small knife clamp pins with the similar holes in Closing the Roller Waste the roller waste collector. Collector Assembly Figure 59 Align Roller Knife Clamp with the Roller Waste Collector Insert the pins into the holes and press the clamp against the roller waste collector assembly. Inspect the roller knife to see whether there are ripples in the knife. DOC-04204 Rev. A Confidential and Proprietary Information...
Page 48 Alaris30 Service Guide Carefully insert the roller waste collector assembly. Reinstall the Roller Waste Secure the assembly evenly, by alternating between the screws as Collector you tighten them. Assembly Turn the locking pin clockwise to lower the drain‐tube bracket onto the roller waste collector, and secure the locking pin’s hook in its socket. Push the print block to the center of the Y‐axis (over the middle of the build tray). In the Heads Cleaning wizard screen, click Cancel to exit the wizard and return the build tray to its former position. In the Roller area of the General Devices window, click Turn On. Check that the roller works well without any retries. Turn off the roller. Replace the UV lamp assembly and secure it. Connect the UV lamp power and ventilation connections to the printing assembly (see Figure 47). DOC-04204 Rev. A Confidential and Proprietary Information...
Page 49: Roller Replacement
Alaris30 Service Guide 13 Roller Replacement Replacing the roller is very complicated. Only a severely damaged roller should be replaced. An example of severe roller damage is deep scratches that cause lines or drips on the printed model. If you suspect the roller is damaged, first make sure that the roller knife is installed straight. 13.1 Tools • Allen key set • 5.5 × 125 mm socket screwdriver • Lift jig • 2 pivot jigs 13.2 Procedure In the Alaris30 software, select Maintenance > Motors Control. The Motors Control window opens. Figure 60 Motors Control Window DOC-04204 Rev. A Confidential and Proprietary Information...
Page 50 Alaris30 Service Guide Select the Z tab. Figure 61 Motors Control Window—Z Tab If the z‐axis is disabled, select the Enable check box. Click Home. Click Go Z Down. Turn off the printer. Remove all the printer covers: • Top • Front • Back • Left • Right. DOC-04204 Rev. A Confidential and Proprietary Information...
Page 51 Alaris30 Service Guide Disconnect the UV lamp power and ventilation connections from the Remove UV Lamp printing assembly. Assembly UV lamp connector Fan connector Figure 62 UV Lamp Assembly Connection Warning: Be careful when handling the UV lamp assembly. It may be hot! Loosen the two securing screws at the ends of the UV lamp assembly. Figure 63 UV Lamp Assembly Securing Screws Lift the UV lamp assembly off of the printing assembly.
Page 52 Alaris30 Service Guide Open the pump panel (next to the blower). Open Pump Panel Screw Figure 64 Pump Panel—Closed Remove the carbon filter. Remove Blower Remove the two screws, which secure the guard to the blower and remove the guard. Top screws Side screws Connector Wing nuts Guard screws Base screws Figure 65 Blower DOC-04204 Rev. A Confidential and Proprietary Information...
Page 53 Alaris30 Service Guide Remove the rubber cover from each of the base screws. Remove the following screws, which secure the blower to the frame: • Base screws • Top screws • Side screws (two screws for each side). Loosen the wing nuts (one on each side). Disconnect the connector. Lift the blower by the wing nuts and remove the blower from the printer. Detach the blue sensor holder bracket. Remove the two bottom Remove Encoder screws first. The bracket is secured with 4 screws: two at the top and two at the bottom. Figure 66 Sensor Holder Bracket—Top Two Screws Visible Hold the encoder and use a M3 Allen key to remove the screw at ...
Page 54 Alaris30 Service Guide Loosen the X‐axis belt locking screws. Loosen X-axis Belt Locking screws Tension screw Figure 67 X-belt Pulley Loosen (a lot) the tension on the X‐axis belt. Pull the print block all the way to the front, exposing the roller waste Remove Roller Waste collector locking pin. Collector Figure 68 Roller Waste Collector Locking Pin DOC-04204 Rev. A Confidential and Proprietary Information...
Page 55 Alaris30 Service Guide Pull the bottom of the locking pin, and turn it counter‐clockwise, to raise the drain‐tube bracket from the roller waste collector. Drain-tube bracket Roller waste collector screws Figure 69 Raising the Drain-Tube Support the roller waste collector with your hand under it, and use a M3 Allen key to loosen the 2 screws. Pull out the roller waste collector, taking care not to touch or damage the roller knife. Loosen the locking nuts and then use a M1.5 Allen key to loosen the Loosen Print Block Set set screws of the printing assembly. Screws Use a 5.5 × 125 mm socket screwdriver to loosen the rear locking nuts There are 2 set screws at the front side of the printer and 4 set screws at the rear.
Page 56 Alaris30 Service Guide Figure 70 Front Print Block Set Screws and Locking Nuts Figure 71 Back Print Block Set Screws and Locking Nuts DOC-04204 Rev. A Confidential and Proprietary Information...
Page 57 Alaris30 Service Guide Figure 72 Set Screws Visible through Access Holes Use a M4 Allen key to remove the 6 screws holding the Y‐axis Remove Y-axis Screws carriage to the X‐axis rails (see Figure 73 and Figure 74). Figure 73 Front Y-axis Screws The front Y-axis screws are required later in this procedure to secure the Y-axis carriage to the lift jig (Step 40).
Page 58 Alaris30 Service Guide Use a M2.5 Allen key to remove the 3 screws that secure the cable Disconnect Cable Bridge bridge to the bracket. Figure 75 Left Side Cable Bridge Screws Figure 76 Right Side Cable Bridge Screw Disconnect all the ribbon cable connectors from the underside of the cable bridge. DOC-04204 Rev. A Confidential and Proprietary Information...
Page 59 Alaris30 Service Guide Remove the 2 screws that secure the bracket to the rear of the Y‐axis Disconnect Bracket carriage. Figure 77 Bracket Screws Use a M2.5 Allen key and remove the rear cable clamp. Lower Roller Motor Rear Cable Clamp Figure 78 Rear Cable Clamp DOC-04204 Rev. A Confidential and Proprietary Information...
Page 60 Alaris30 Service Guide Use a M2.5 Allen key and loosen the 4 screws that hold the roller motor. Figure 79 Roller Motor Screws (2 Visible) Slide the motor downward. (This removes the tension from the roller motor pulley belt.) Lift the rear Y‐axis carriage, slide the left‐side (determined when Insert Pivot Jigs standing at the back of the printer) linear‐slide carrier out from under the carriage and insert the pivot jig under the carriage. (Lower the carriage onto the jig.) Linear-slide Carrier Figure 80 Lift the Rear Y-axis Carriage DOC-04204 Rev. A Confidential and Proprietary Information...
Page 61 Alaris30 Service Guide Pivot Jig Figure 81 Pivot Jig Inserted Note the orientation of the pivot jig under the carriage. Repeat Step 36 for the right side of the carriage. Carefully insert the lift jig into the space in front of the front X‐axis rail. Figure 82 Lift Jig Inserted Next to Front X-axis Rail DOC-04204 Rev. A Confidential and Proprietary Information...
Page 62 Alaris30 Service Guide Lift the front of the Y‐axis carriage and gently slide the lift jig across until the Y‐axis carriage can be lowered onto the lift jig. Make sure that the X-axis belt is not stretched. If necessary, loosen the X-axis belt more. Figure 83 Lift Jig Under Y-axis Carriage Use the front Y‐axis screws (from Step 29) to secure the Y‐axis carriage to the lift jig. DOC-04204 Rev. A Confidential and Proprietary Information...
Page 63 Alaris30 Service Guide Remove the 2 brackets supporting the roller (2 hex screws for each Remove Roller Brackets bracket). Figure 84 Front Roller Bracket Figure 85 Rear Roller Bracket Lower the roller from the front first and then pull the roller out of Remove Roller the roller motor pulley belt. If necessary, carefully use a screwdriver to assist in lowering the roller and in separating the roller from the roller motor pulley belt.
Page 64 Alaris30 Service Guide Clean the area that contained the roller. Install Roller Install the new roller: first one end in the roller motor pulley belt, and then the other end of the roller to the front of the Y‐axis carriage. Pull the roller toward the front of the printer and push the roller up. Hold the roller and secure the roller in place with its 2 brackets. Remove the front Y‐axis screw securing the Y‐axis carriage to the lift Remove Lift jig. Lift the front of the Y‐axis carriage and gently slide the lift jig away from the carriage. Lower the front of the Y‐axis carriage onto the front X‐axis rail carrier. Remove the lift jig from the printer. Lift the rear of the Y‐axis carriage, remove each pivot jig and move Remove Pivot Jigs the linear‐slide carriers back under the Y‐axis carriage. Lower the Y‐axis carriage onto the carriers. Re‐establish the tension in the roller motor pulley belt by raising the Raise Roller Motor roller motor while keeping it horizontal. Tighten evenly the 4 screws that secure the roller motor. Secure the bracket to the rear of the Y‐axis carriage (2 screws). Reconnect Bracket Connect all the ribbon cables to the underside of the cable bridge. Reconnect Cable Bridge Reattach the cable bridge to the bracket (3 screws). Attach the Y‐axis carriage to the front and rear linear‐slide carriers ...
Page 65 Alaris30 Service Guide Bypass the printer’s interlock. In the Alaris30 software, select Maintenance > Motors Control. The Motors Control window opens. Select the Z tab. If the z‐axis is disabled, select the Enable check box. Click Home. Move the Y‐axis carriage close to the print tray and check that the roller is parallel to the tray. If in this step or in Step 75 the roller is not parallel to the tray, start again from Step 28 until Step 41 and check that the roller is flat in its holding area.
Page 66 Alaris30 Service Guide In the Roller section, click Turn On. Check that the roller rotates smoothly. Click Turn Off and close the General Devices window. Click Go Z Down (in the Motors Control window). Turn off the printer and remove the interlock bypass. Reattach the roller waste collector. Attach Roller Waste Reattach the UV Lamp. Collector, UV Lamp and Check and adjust the X‐axis belt tension. Encoder Reattach the encoder assembly. Assembly Reattach the blue sensor holder bracket. Secure the 2 top screws first. Check and adjust the Z‐Start position. Checks and Calibrations Check the encoder calibration. Reattach the Blower. Close the pumps panel. Check the transparency test. Reattach the covers of the printer. DOC-04204 Rev. A Confidential and Proprietary Information...
Page 67: Head Driver Card Cooling Fan Filters
Alaris30 Service Guide 14 Head Driver Card Cooling Fan Filters 14.1 Tools • Allen key set • Screwdriver 14.2 Procedure Turn the printer power switch OFF. Using a Allen key, loosen and remove the 2 thumb screws that secure the print block cover to the print block. Remove the print block cover. For both fans do the following: Loosen the 4 screws that fasten the filter and the filter grille to the fan. Figure 87 Filter Grilles Remove the filter grille. Figure 88 Removing the Filter Grille DOC-04204 Rev. A Confidential and Proprietary Information...
Page 68 Alaris30 Service Guide Remove and discard the used filter pad. Insert a new filter pad. Re‐install the filter grille and secure the grille with 4 screws. DOC-04204 Rev. A Confidential and Proprietary Information...
Page 69: Print Head Replacement
Alaris30 Service Guide 15 Print Head Replacement Print heads are expensive and should only be replaced after contacting Objet for assistance. Print heads with clogged nozzles should be unblocked by cleaning and purging the affected head. 15.1 Tools • Protective gloves 15.2 Procedure In the Alaris30 software, select Options > Shutdown Wizard. The Empty Print Block Shutdown Wizard window opens. Figure 89 Preparing for Shutdown Window DOC-04204 Rev. A Confidential and Proprietary Information...
Page 70 Alaris30 Service Guide Select the option “Run wizard manually” and click Next. The next wizard window opens. Figure 90 Door Status Window Close the printer cover and select the check box to confirm. Click Next. The next wizard window opens. Figure 91 Tray Status Window DOC-04204 Rev. A Confidential and Proprietary Information...
Page 71 Alaris30 Service Guide Indicate whether or not the tray is empty and click Next. The shutdown procedure begins. Figure 92 Shutdown Sequence Window The shutdown procedure may take up to 10 minutes while the following tasks are performed. When the shutdown procedure is complete, the final wizard window opens. Figure 93 Computer Shutdown Confirmation Window Select No and click Next. DOC-04204 Rev. A Confidential and Proprietary Information...
Page 72 Alaris30 Service Guide In the Alaris30 software, select Maintenance > Motors Control. The Prepare for Print Head Motors Control window opens. Replacement Figure 94 Motors Control Window (If required, select the T tab.) Ensure that the T motor is enabled and click Home. Select the Z tab. Make sure that the Z motor is enabled and click Home. Click Go Z Down. Select the Y tab and clear the Enable check box. Select the X tab and clear the Enable check box. Put on protective gloves. Move the print block to the middle of the build tray manually. Warning: Ensure that you only touch cool areas of the printing assembly. Avoid burning yourself.
Page 73 Alaris30 Service Guide Loosen the two thumb screws that secure the upper cover of the head driver compartment to the print block and lift off the cover. Figure 95 Upper Cover Thumb Screws Model head Support head interface card interface card Support head cable Model head cable Support head Model head Figure 96 Print Heads DOC-04204 Rev. A Confidential and Proprietary Information...
Page 74 Alaris30 Service Guide Lift the support head interface card off its socket. (It may be Remove Support Print necessary to lift the card using a rocking movement.) Head The support head cable lies over and in front of the model head cable. Removing the support head is therefore required even if you are replacing only the model head. Support Head...
Page 75 Alaris30 Service Guide Figure 99 Print Head Released from Print Block Check that the print head’s two rubber O‐rings remained together with the print head. O-rings Figure 100 Print Head If both O‐rings did not remain with the print head, use a mirror to inspect the bottom of the print block. If an O‐ring is stuck to the print block, remove it from the print block. O-ring Figure 101 Underside of Print Block If the support head is not being replaced, cover the (now‐removed) support head with a cleaning cloth to protect it from UV light. Set the support head aside for later reinstallation. DOC-04204 Rev. A Confidential and Proprietary Information...
Page 76 Alaris30 Service Guide If only the support head is to be replaced, continue with Step 36. Lift the model head interface card off its socket. (It may be necessary Remove Model Print Head to lift the card using a rocking movement.) Figure 102 Model Head Interface Card Loosen the two (inner) thumb screws that fasten the model head to the print block. Figure 103 Model Head Thumb Screws Caution: In the next step, support the print head to prevent the print head falling once it is released from the print block.
Page 77 Alaris30 Service Guide Inspect the replacement head and make sure that the O‐ring seals Install Model Print Head are in place (see Figure 100 on page 75). Lift the replacement head and press it firmly upwards into its location in the print block, until it clicks into place. Ensure that the model head is in the (inner) model head position. Fasten the print head to the print block by tightening the two (inner) thumb screws. Route the interface cable over the side of the print block. and press the print head interface card into its socket (the left socket) on the top of the print block. Inspect the original/replacement head and make sure that the O‐ring Install Support Print Head seals are in place (see Figure 100 on page 75). Lift the print head and press it firmly upwards into its location in the print block, until it clicks into place. Ensure that the support head is in the (outer) support head position. Fasten the print head to the print block by tightening the two (outer) thumb screws. Route the interface cable over the side of the print block and press the print head interface card into its socket (the right socket) on the top of the print block. Place the upper cover back in its position on the print block and Install Cover tighten its thumb screws (see Figure 95 on page 73). 15.3 Testing and Aligning the Heads Turn on the printer power.
Page 78: Encoder Replacement
Alaris30 Service Guide 16 X Encoder Replacement 16.1 Tools • M4 Allen key • 1 mm (orange) spacers (two required) 16.2 Procedure Turn off the printer. If required to improve access to the back of the printer, disconnect the following cables from the printer: • power • monitor • USB • communication Remove the side (left and right) and rear printer panels. Remove the carbon filter from the blower. Remove Blower Figure 104 Carbon Filter on Blower DOC-04204 Rev. A Confidential and Proprietary Information...
Page 79 Alaris30 Service Guide Open the pump panel (next to the blower). Screw Figure 105 Pump Panel—Closed Remove the two screws, which secure the guard to the blower and remove the guard Top screws Side screws Connector Wing nuts Guard screws Base screws Figure 106 Blower Remove the rubber cover from each of the base screws. DOC-04204 Rev. A Confidential and Proprietary Information...
Page 80 Alaris30 Service Guide Remove the following screws, which secure the blower to the frame: • Base screws • Top screws • Side screws (two screws for each side). Loosen the wing nuts (one on each side). Disconnect the connector. Lift the blower by the wing nuts and remove the blower from the printer. Move the print‐print block all the way over to the right. Remove Encoder Remove the two screws securing the encoder sensor to the sensor holder bracket and separate the encoder sensor from the bracket. Figure 107 Encoder Sensor Screws DOC-04204 Rev. A Confidential and Proprietary Information...
Page 81 Alaris30 Service Guide Disconnect the sensor’s cable connectors. Move the disconnected cables away from the sensor holder bracket. Figure 108 Sensor Cable Connectors Hold the encoder and use a M3 Allen key to remove the screw at each end of the encoder. To unscrew the screw at the ends of the encoder, insert the M3 Allen key through the access holes in the frame of the printer. Figure 109 Right and Left Access Holes DOC-04204 Rev.
Page 82 Alaris30 Service Guide Figure 110 Left Encoder Screw Move the print block all the way to the right. Carefully remove the encoder through the “right” side (determined when standing at the back of the printer) of the printer. Figure 111 Remove Encoder DOC-04204 Rev. A Confidential and Proprietary Information...
Page 83 Alaris30 Service Guide Remove the bracket attached to the sensor on the encoder (2 screws). Figure 112 Sensor Bracket Screws Attach the bracket to the sensor on the new encoder. Tighten the screws. Slide the encoder back into the printer through the right side and align the encoder‐reader screw holes. Make sure the sensor bracket is on the bottom of the encoder when you slide it into the printer. Reattach (with 2 screws) the encoder to the printer. Install New Encoder Reattach the sensor to the sensor holder bracket (2 screws). (Don’t tighten the screws.) Move the print block all the way to the right side of the printer. Insert the 1 mm spacers between the sensor holder bracket and the ...
Page 84 Alaris30 Service Guide Figure 114 Orange Spacers between Encoder and Bracket. Adjust the position of the screws of the sensor and the sensor holder bracket so that the orange spacer should just fit between the bracket and the encoder. Remove the spacers. Move the print block all the way to the left side of the printer. Insert the 1 mm spacers between the sensor holder bracket and the encoder. The orange spacer should just fit between the bracket and the encoder. Adjust the position of the screws of the sensor and the sensor holder bracket so that the orange spacer should just fit between the bracket and the encoder. If disconnected, connect the power, monitor, USB and communication cables. Turn the printer on. Locate Encoder Zero Start the Alaris30 software. Position DOC-04204 Rev. A Confidential and Proprietary Information...
Page 85 Alaris30 Service Guide Select Maintenance > Motors Control. The Motors Control window opens. Figure 115 Motors Control Window Select the X tab. Select Enable. Click Home. DOC-04204 Rev. A Confidential and Proprietary Information...
Page 86 Alaris30 Service Guide Select Maintenance > Parameters Manager. The Parameters Settings window opens. Figure 116 Parameters Settings Window Select Motors from the parameter list. Figure 117 Motors Parameters Write down the value in the XEncoderHomeInStep parameter. Click Close (on the Parameters Settings screen). DOC-04204 Rev. A Confidential and Proprietary Information...
Page 87 Alaris30 Service Guide Type the value from Step 40 in the Move field. Select Absolute value. Click Move. When the print block has stopped moving, clear Absolute value. Type small positive or negative values in the Move field and click Move until the encoder’s zero position (0000/FFFF) is reached. Once the encoder’s zero position is reached, write down the value of the Position field. Select Maintenance > Parameters Manager. The Parameters Settings window opens. Type the value from Step 47 into the XEncoderHomeInStep parameter. Click Close (on the Parameters Settings screen). Type 17000 (steps) in the Move field. (Make sure Absolute value is Verify Encoder Zero Position not selected.) Click Move. Write down the value displayed in the Read Encoder field. Type the number ‐17000 in the Move field. Click Move. Make sure that the Read Encoder field returns to zero (0000/FFFF). The permitted deviation is up to two steps (0002 or FFFD). Repeat Steps 51–56 five times. Make sure the encoder returns to the zero position each time. If the deviation is larger than two steps, do the following: • Clear Enable (on the X tab of the Motors Control window) • Adjust the position of the screws of the sensor holder bracket (see steps 23–30). Reinstall the Blower. Completion Steps Reinstall the carbon filter in the blower.
Page 88: Print Block Replacement
Alaris30 Service Guide 17 Print Block Replacement Print blocks are expensive and should only be replaced after contacting an Objet Regional Technical Specialist (RTS) for assistance. One of the following may indicate the print block must be replaced. • Leaks from the print block. • The vacuum levels in the print block are unstable. • Malfunction of the material level thermistors. • The print block heaters do not heat the print block to the required temperature. 17.1 Tools • Protective gloves • Allen keys (M2.5, M4) • Cleaning cloths • Micrometer (for block rotation test) • Loupe/measuring microscope 17.2 Procedure In the Alaris30 software, select Options > Shutdown Wizard. The Empty the Print Block Shutdown Wizard window opens. Figure 118 Preparing for Shutdown Window DOC-04204 Rev.
Page 89 Alaris30 Service Guide Select the option “Run wizard manually” and click Next. The next wizard window opens. Figure 119 Door Status Window Close the printer cover and select the check box to confirm. Click Next. The next wizard window opens. Figure 120 Tray Status Window DOC-04204 Rev. A Confidential and Proprietary Information...
Page 90 Alaris30 Service Guide Select the “Tray is full” option to lower the build tray. Figure 121 Shutdown Sequence Window The shutdown procedure may take up to 10 minutes. When the shutdown procedure is complete, the final wizard window opens. Figure 122 Computer Shutdown Confirmation Window Before shutting down the computer verify that the tray has been lowered. • If so, select Yes, click Next and continue with Step 14. • If not, select No, click Next and continue with Step 7. DOC-04204 Rev. A Confidential and Proprietary Information...
Page 91 Alaris30 Service Guide In the Alaris30 software, select Maintenance > Motors Control. The Motors Control window opens. Figure 123 Motors Control Window (If required, select the T tab.) Ensure that the T motor is enabled and click Home. Select the Z tab. Make sure that the Z motor is enabled and click Home. Click Go Z Down. Select the Y tab and clear the Enable check box. Select the X tab and clear the Enable check box. Put on protective gloves. Move the print block to the middle of the build tray manually. Warning: Ensure that you only touch cool areas of the printing assembly. Avoid burning yourself. Close the printer application. Shut down the printer computer. DOC-04204 Rev. A Confidential and Proprietary Information...
Page 92 Alaris30 Service Guide Remove the print heads manually from the print block. (For the procedure on removing the print heads, refer to “Print Head Replacement” on page 69.) Disconnect the model, support and vacuum tubes from the print block. Model tube Vacuum tube Support tube Figure 124 Tubes Connected to the Print Block When you disconnect the tubes from the print block, excess material may leak from the tubes. DOC-04204 Rev. A...
Page 93 Alaris30 Service Guide Disconnect the 3 connectors to the Spartan board. 3 Connectors to Spartan Figure 125 Print Block Connectors to the Spartan Board Remove the three screws (2 at the front and 1 at the rear of the print block) that secure the print block to the printing assembly. Front securing screw Rear securing screw Figure 126 Print Block Securing Screws DOC-04204 Rev. A Confidential and Proprietary Information...
Page 94 Alaris30 Service Guide Pull the print block towards the front of the printer to release the pins from the securing bracket, and remove it from the printer. Pins Figure 127 Print Block Attached to the Securing Bracket Remove the block rotation bracket (two screws) from the old print block and attach it the new print block. Block rotation bracket screws Figure 128 Print Block with Block Rotation Bracket Attached Reattach the new print block. Make sure you insert the pins at the rear of the print block into their the holes on the securing bracket. Reattach the print block to the printing assembly with 3 screws (2 at the front and 1 at the rear of the print block). DOC-04204 Rev. A Confidential and Proprietary Information...
Page 95 Alaris30 Service Guide Connect all the connectors to the Spartan board. Connect the material and vacuum tubes. Install the print heads. Turn on the printer and start the printer computer. Press F4 (Execute Purge Sequence). Run the Head Filling Calibration wizard. Perform a Transparency test. Print the service_engineer_ATP.stl file. (Partner Zone> Customer Support > Technical resources > Alaris30 Lobby > Main Service Documents) Perform a Weight test. DOC-04204 Rev. A Confidential and Proprietary Information...
Page 96: Main Power Supply Replacement
Alaris30 Service Guide 18 Main Power Supply Replacement 18.1 Tools • Allen keys (M2.5, M3) • Screwdriver • Small screwdriver • Pliers • 7 mm open‐end wrench 18.2 Procedure Close the printer application. Disconnect Printer Shut down the printer computer. Turn off the printer and disconnect the power cord from the wall outlet. Remove the front and rear printer panels. Remove the excess fluid collector from the printer. (Dispose of the waste according to local regulations.) DOC-04204 Rev. A Confidential and Proprietary Information...
Page 97 Alaris30 Service Guide Disconnect the following from the rear of power supply unit: Removing the Power Supply • DC power cable (at the end of CBL‐04034) Unit • UV power cable (at the end of CBL‐04034) • UV lamp power connector (at the end of CBL‐04005) • ground (earth) wire UV power Power cable cable Ground wire UV lamp Power connector Figure 129 Power Supply Unit (rear view) Using an M3 Allen key, remove the two rear screws that secure the power supply to the printer. Figure 130 Power Supply Rear Screws DOC-04204 Rev.
Page 98 Alaris30 Service Guide Remove the four front securing screws. printer computer connector UV lamp Hard disk sensor connector connector Ground wire Front securing screws Figure 131 Power Supply Unit (Front View) Disconnect the following at the front of the power supply unit (see Figure 131): • ground wire • UV lamp sensor connector (at the end of CBL‐04120) Lift off the power supply cover. Disconnect the power cable from the hard disk (CBL‐04305) shown in Figure 131. Disconnect the DC power cable from the printer computer board (CBL‐04305) shown in Figure 131. DOC-04204 Rev. A...
Page 99 Alaris30 Service Guide Disconnect JT27 and JT28 connectors on the Lotus board. JT27 cable tie JT28 Figure 132 JT27 and JT28 Connectors Cut the cable tie around CBL‐04120, CBL‐04306 and CBL‐04305. Remove the power supply unit from the printer and place it on a flat surface. Using an M3 Allen key, remove the four screws that secure the main Replacing the Main Power power supply (PWR‐04004) to its housing. Supply UV power supply Main power supply (PWR-04004) Figure 133 Power Supply Housing Remove the main power supply from the housing. Place the new (wired) power supply in the housing. DOC-04204 Rev. A...
Page 100 Alaris30 Service Guide Make sure you route the power supply cables through the side opening on the metal housing. Secure the power supply to the metal housing with the four screws (Figure 133). Replace the power supply housing in the printer. Make sure you Reinstalling the Power route the hard disk and printer computer power cables under the Supply Unit power supply unit. Caution: To avoid damage the ribbon cables on the floor of the printer, place the power supply unit carefully in the printer. Figure 134 Cables Routed Under the Power Supply Reconnect the following at the front of the printer:...
Page 101 Alaris30 Service Guide Make sure the cables at the front of the power supply are routed around the solenoid as shown in Figure 135, so they do not touch the power supply cover. Figure 135 Correct Wire Routing Around Solenoid. Replace the cover and secure with two screws to the printer (see Figure 131). Connect the ground wire. Connect the UV lamp sensor connector at the end of CBL‐04120 (see Figure 131). Reconnect the following at the rear power supply unit: • power cables • UV lamp power connector • ground wire Carefully place the excess fluid collector on the power supply cover. Reattach the panels of the printer. Connect the printer to the electric line. Switch on the printer. DOC-04204 Rev. A Confidential and Proprietary Information...
Page 102: Uv Power Supply Replacement
Alaris30 Service Guide 19 UV Power Supply Replacement 19.1 Tools • Allen keys (M2.5, M3) • Screwdriver • Small screwdriver • Pliers • 7 mm open‐end wrench 19.2 Procedure Close the printer application. Disconnect Printer Shut down the printer computer. Turn off the printer and disconnect the power cord from the wall outlet. Remove the front and rear printer panels. Remove the excess fluid collector from the printer. (Dispose of the waste according to local regulations.) DOC-04204 Rev. A Confidential and Proprietary Information...
Page 103 Alaris30 Service Guide Disconnect the following from the rear of power supply unit: Removing the Power Supply • DC power cable (at the end of CBL‐04034) Unit • UV power cable (at the end of CBL‐04034) • UV lamp power connector (at the end of CBL‐04005) • ground (earth) wire UV power Power cable cable Ground wire UV lamp Power connector Figure 136 Power Supply Unit (rear view) Using an M3 Allen key, remove the two rear screws that secure the power supply to the printer. Figure 137 Power Supply Rear Screws DOC-04204 Rev.
Page 104 Alaris30 Service Guide Remove the four front securing screws. printer computer connector Hard disk UV lamp connector sensor connector Ground wire Front securing screws Figure 138 Power Supply Unit (Front View) Disconnect the following at the front of the power supply unit (see Figure 131): • ground wire • UV lamp sensor connector (at the end of CBL‐04120) Lift off the power supply cover. Disconnect the power cable from the hard disk (CBL‐04305) shown in Figure 131. Disconnect the power cable from the printer computer board (CBL‐ 04305) shown in Figure 131. DOC-04204 Rev. A...
Page 105 Alaris30 Service Guide Disconnect JT27 and JT28 connectors on the Lotus board. JT27 cable tie JT28 Figure 139 JT27 and JT28 Connectors Cut the cable tie around CBL‐04120, CBL‐04306 and CBL‐04305. Remove the power supply unit from the printer and place it on a flat surface. Detach the UV lamp connector shown in Figure 140 from the metal Replacing the UV Power housing. Supply UV lamp power connector Figure 140 Power Supply Housing (Rear View) DOC-04204 Rev. A Confidential and Proprietary Information...
Page 106 Alaris30 Service Guide Disconnect the Live (black) and Neutral (white) wires from the terminals on back of the UV power socket. Figure 141 Wires Connected to the UV Power Socket Disconnect the following from the UV power supply interface board (BRD‐04032): • J2 • J3 • J4 • 2 ground (earth) wires 2 ground wires Figure 142 Power Supply Unit (Front View) DOC-04204 Rev. A Confidential and Proprietary Information...
Page 107 Alaris30 Service Guide Remove the four screws that secure the UV power supply to the housing. Figure 143 UV Power Supply Securing Screws Remove the UV power supply. Place the new (wired) UV power supply in the housing and secure with four screws. Figure 144 Replacing the UV Power Supply DOC-04204 Rev. A Confidential and Proprietary Information...
Page 108 Alaris30 Service Guide Reconnect the following at the front of the power supply (see Figure 142): • J2, J3 and J4 • two ground wires Reconnect the following at the rear of the power supply (see Figure 136 and Figure 137): • Live wire (Black) • Neutral wire (white) • UV lamp power connector Replace the power supply unit in the printer. Make sure you route Reinstalling the Power the hard disk and printer computer power cables under the power Supply Unit supply unit. Caution: To avoid damage the ribbon cables on the floor of the printer, place the power supply unit carefully in the printer.
Page 109 Alaris30 Service Guide Reconnect the following at the front of the printer: • Hard disk power connector • Printer computer power connector • JT27 (Lotus board) • JT28 (Lotus board) Secure the power supply unit to the printer with four screws (see Figure 130 and Figure 131). Make sure the cables at the front of the power supply are routed around the solenoid as shown in Figure 135, so they do not touch the power supply cover. Figure 146 Correct Wire Routing Around Solenoid. Replace the cover and secure with two screws to the printer (see Figure 131). Connect the ground wire. Connect the UV lamp sensor connector at the end of CBL‐04120 (see Figure 131). DOC-04204 Rev. A Confidential and Proprietary Information...
Page 110 Alaris30 Service Guide Reconnect the following at the rear power supply unit: • Power cables • UV lamp power connector • Ground wire Carefully place the excess fluid collector on the power supply cover. Reattach the panels of the printer. Connect the printer to the electric line. Switch on the printer. DOC-04204 Rev. A Confidential and Proprietary Information...

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