HP Jet Fusion 5200 Series User Manual
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HP Jet Fusion 5200 Series User Manual

HP Jet Fusion 5200 Series User Manual

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HP Jet Fusion 5200 Series
3D Printing Solution
Product Documentation
User Guide
SUMMARY
How to use your product.

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Summary of Contents for HP Jet Fusion 5200 Series

  • Page 1 HP Jet Fusion 5200 Series 3D Printing Solution Product Documentation User Guide SUMMARY How to use your product.
  • Page 2 The use of any trademark is for The only warranties for HP products and identification and reference purposes only services are set forth in the express and does not imply any association between...

  • Page 3: Table Of Contents

    Table of contents 1 Welcome to your MJF system........................................1 Documentation..............................................1 Product usage requirements ........................................ 1 MJF technology.............................................. 2 Usage recommendations........................................3 2 Safety precautions ............................................4 Introduction............................................... 4 General safety guidelines........................................4 Final parts/builds ............................................5 Explosion hazard ............................................6 Electric shock hazard ..........................................
  • Page 4 Beacon ..............................................28 Change system options......................................29 Set the administrator password..................................30 Software................................................30 HP SmartStream 3D Command Center ................................. 31 HP SmartStream 3D Build Manager................................. 35 4 Power on and off...............................................36 Turn the printer on and off........................................36 Turn on the printer for the first time ..................................36 Turn the printer on and off......................................37...
  • Page 5 Delay printing..............................................71 Select a job to be printed ........................................72 Add job while printing..........................................73 Cancel a job ..............................................74 Check status on the front panel ......................................75 Check status remotely..........................................76 Possible errors while printing......................................76 Print modes ..............................................76 9 Unpack the build..............................................77 General advice and precautions.....................................77 If the forklift does not fit.........................................77 Sheet-metal installation process ..................................78 Calibration process ........................................81...
  • Page 6 12 Troubleshooting ............................................325 General advice............................................325 Entering the Diagnostics menu (service boot-mode)........................... 325 Diagnostic tests and utilities....................................325 Entering the Diagnostics menu (service boot-mode) ........................326 Diagnostic menu look........................................327 Printhead health troubleshooting....................................328 Align the printheads ........................................328 Printhead Health Gauge front-panel messages...........................334 Nozzle status ..........................................335 Print the printhead status plot ....................................337 How to interpret the printhead status plot..............................337...
  • Page 7 0087-0002-0059 Recoating unit system - Roller spreader motor and encoder servo shutdown......371 1020-0009-0180 Material Management - Feeder Vane module (rear) not enough material.........373 1020-0009-0280 Material Management - Feeder Vane module (front) not enough material ......373 1020-0010-0159 Material management - Vane feeder (rear) stalled..................375 1020-0010-0259 Material management - FMaterial management - Vane feeder (front) stalled......375 1030-0021-1001 Build Unit heating - BU heating control PCA 3 fan fault ................377 System errors in full ..........................................378...

  • Page 8: Welcome To Your Mjf System

    The conditions are as follows: ● The customer agrees to use only HP Branded Consumables and HP Certified Materials in the 3D HP printer product, and understands that use of any consumables other than HP consumables may cause serious product functionality and/or safety issues, including, but not limited to those outlined in the user guide.

  • Page 9: Mjf Technology

    3D printing processes. HP Multi Jet Fusion technology starts by laying down a thin layer of material in the working area. Next, the carriage containing an HP Thermal Inkjet array passes from left to right, printing chemical agents across the full working area.

  • Page 10: Usage Recommendations

    HP Multi Jet Fusion technology to produce parts that cannot be made by other methods. For example, taking advantage of HP’s in-depth knowledge of color science, HP Multi Jet Fusion printers could selectively print a different color at each voxel with agents containing cyan, magenta, yellow, or black (CMYK) colorants.

  • Page 11: Safety Precautions

    Safety precautions How to use your product safely. Introduction Before using the equipment, read the following safety precautions and operating instructions to make sure you can use it safely. You are expected to have the appropriate technical training and experience necessary to be aware of hazards to which you may be exposed in performing a task, and to take appropriate measures to minimize the risks to yourself and to others.

  • Page 12: Final Parts/Builds

    Use HP-certified and HP-branded material and agents only. Do not use unauthorized third-party material or agents. Use HP-certified external tanks only. The use of third-party external tanks can cause safety risks, material leakages, and malfunctions in the processing station; and may affect your system warranty.

  • Page 13: Explosion Hazard

    Explosion hazard Take precautions to avoid the risk of explosion. WARNING! Dust clouds can form explosive mixtures with air. Take precautionary measures against static charges, and keep away from sources of ignition (hot surfaces, hot flames or gases, mechanical sparks, electrical equipment, electromagnetic waves, exothermic reactions including self-combustion of solids).
  • Page 14 Use HP-certified and HP-branded material and agents only. Do not use unauthorized third-party material or third-party agents. ● HP recommends the use of HP accessories for unpacking 3D parts and refilling the build chamber. If other methods are used, read the following notes: –...

  • Page 15: Electric Shock Hazard

    ○ Non-conductive material ○ Material non-reactive with other material or HP agents (refer to agents MSDS), stable. Additionally, for the 5210 Pro processing station only: ● Use a bulk discharging system and drum rotator suitable for combustible dust and compatible with the material that you intend to use.

  • Page 16: Heat Hazard

    Take the following precautions: ● Do not attempt to dismantle the internal circuit enclosures, top heating, fusing lamps, build unit, processing station, or e-cabinet except during hardware maintenance tasks. In that case, follow the instructions strictly. ● Do not remove or open any other closed system covers or plugs. ●...

  • Page 17: Mechanical Hazard

    Do not attempt to modify the top heating, fusing, build chamber, e-cabinet, or enclosures. ● Proper maintenance and genuine HP consumables are required to ensure that the equipment operates safely as designed. The use of non-HP consumables may present a risk of fire. ● Take special care with zones marked with warning labels.

  • Page 18: Light Radiation Hazard

    To manipulate material (load, unpack, and so on) and green parts, use protective personal equipment according to the Safety Data Sheets of your processed material. ● Use HP-branded agents only. Do not use unauthorized third-party agents. ● Take special care in any zones marked with warning labels.

  • Page 19: Extraction System

    Therefore, HP highly recommends connecting the printer to an extraction system, and this may be obligatory depending on the material processed and local regulations.

  • Page 20: Build Unit Transport Hazard

    Build unit transport hazard Special care must be taken to avoid personal injury when moving the build unit. ● Always wear personal protective equipment including boots and gloves. ● Keep the safety lid on top of the build unit at all times, except when it is inside the printer or processing station.

  • Page 21: 3D Part Unpacking

    Refer to the safety data sheet instructions of the powder or consult your environmental health and safety (EHS) specialist for advice on appropriate measures for your location and application. HP recommends the following equipment, which may be used for material handling, unpacking parts, and certain maintenance and cleaning tasks: ●...

  • Page 22: Warnings And Cautions

    Warnings and cautions Warning and caution symbols are used to ensure the proper use of the equipment and to prevent it from being damaged. Follow the instructions marked with these symbols. WARNING! Failure to follow the guidelines marked with this symbol could result in serious personal injury or death.
  • Page 23 Table 2-1 Warning labels (continued) Label Explanation Risk of burns. Let the equipment cool down before accessing internal parts. You are required to wear gloves when handling material cartridges, agents, printheads, the printhead cleaning roll, and when performing maintenance and cleaning tasks.
  • Page 24 Table 2-1 Warning labels (continued) Label Explanation Do not climb onto the external tank, which could cause the processing station to fall over. Crush hazard. Keep your hands clear of the edge of the top cover. Open and close the top cover using the handle (highlighted in blue) only.
  • Page 25 Table 2-1 Warning labels (continued) Label Explanation Protective conductor current. CAUTION: High touch current. Connect to earth before connecting to supply. For service personnel only Hazardous moving parts. Keep away from moving fan blades. For maintenance and service personnel only Risk of trapped fingers.

  • Page 26: Emergency Stop Buttons

    Table 2-1 Warning labels (continued) Label Explanation Firmly tighten all fasteners, ensuring that the assembly is well fixed together before turning on the build unit. Emergency stop buttons There is an emergency stop button on the printer and another on the processing station. If an emergency occurs, simply push the emergency stop button to stop all processes.
  • Page 27 For safety reasons, access to the print zone is not permitted while printing is in progress. Let the printer cool down before touching anything inside it. To stop the equipment completely, turn it off. See Turn the printer on and off on page 37 Turn the processing station on and off on page Chapter 2 Safety precautions...

  • Page 28: Main Components

    Main components These are the principal components of your 3D printing solution. Printer Parts of the printer. Top cover Heating lamps Thermal camera Recoating unit and recoating roller Heating-lamps filter Top-enclosure filters Print bed Printhead Fusing lamps Print carriage Fusing agent Main components...
  • Page 29 Agent door Detailing agent Printhead cleaning roll Internal cleaning-roll door Cleaning-roll collector External cleaning-roll door Build-unit door Main switch Circuit breaker Rearm button Emergency stop button Front panel Spittoon Air exhaust Print-zone filter E-cabinet filter Network and electrical connections Air exhaust system Chapter 3 Main components...

  • Page 30: Processing Station

    Processing station Parts of the processing station. Hood Mixer Reusable material collector Storage tank Emergency stop button Service switch Sieve External tank Platform control buttons Dust extractor Material loading nozzle Processing station...

  • Page 31: Build Unit

    1. E-cabinet filters Build unit Parts of the build unit. Material loading inlet Safety lid Chapter 3 Main components...

  • Page 32: Accessories

    Handle Overflow trays (4) Printing platform Feed trays (2) Vane feeders (2) Build chamber Material chamber Material chamber filter Build unit socket Accessories Accessories are not supplied with your printer, but are available for purchase separately. The following accessories are available: ●...

  • Page 33: Front Panel

    Table 3-1 Natural cooling unit specifications Characteristic Specification Weight empty 11 kg (24.3 lb) Weight full of PA12 34.5 kg (76. 1 lb) ● The RFID reader identifies individual natural cooling units and the jobs contained in them, by radio frequency, enabling job tracking for easier monitoring and analysis.
  • Page 34 It includes the following components: A Hi-Speed USB host port, intended for connecting a USB flash drive, which can provide firmware update files to the printer The front panel itself: an 8 inch, full-color, touch-sensitive screen with a graphical user interface The loudspeaker The power key The beacon...

  • Page 35: Status Center

    Table 3-2 Front panel Printer Processing station ● The all-app screen displays a list of all available apps. Table 3-3 All-app screen Printer Processing station Status center At the top of the front panel is the status center, which can be expanded by swiping down from the top.

  • Page 36: Change System Options

    Table 3-4 Beacon Graphics State Description White light The printer is ready. White moving light The printer is printing or preparing to print. The printer can print, but there is something wrong. If the problem Yellow light persists, contact your support representative. While printing, you will see a yellow instead of a white light.

  • Page 37: Set The Administrator Password

    The administrator password must be given in order to change printer settings. Software HP provides software to accompany your 3D printing solution. The software can be downloaded from the HP website: ●...

  • Page 38: Hp Smartstream 3D Command Center

    HP SmartStream 3D Command Center Each device is represented by a card that summarizes the most important information about the device. By default, the build status information is shown. Table 3-5 Cards Card Information Card information The upper part of the card shows the following information: ●...
  • Page 39 Table 3-6 Cards Builds Supplies Click the card for more detailed information about the device. Figure 3-1 The Build status tab Figure 3-2 The Builds tab Chapter 3 Main components...
  • Page 40 Figure 3-3 The Supplies tab Figure 3-4 The About tab Click Back or the breadcrumb to go back to the monitoring overview area. Types of devices Command Center can monitor all models of 3D printers, processing stations, build units, and cooling frames.
  • Page 41 – PARTS: The number of parts printed, and the total number of parts to print ● Builds: Information about the current job file that is being printed, the upcoming jobs, and the pending jobs to be printed. – UPCOMING JOB: This appears only when a new job has been submitted while the current job is printing, to be printed in the same build chamber –...

  • Page 42: Hp Smartstream 3D Build Manager

    An error about a particular component is displayed on the icon representing that component. HP SmartStream 3D Build Manager Use the powerful 3D print-preparation capabilities of HP SmartStream 3D Build Manager to help make all of your 3D printing jobs successful: Add parts to begin preparing the print job.

  • Page 43: Power On And Off

    Power on and off How to turn your printer and processing station on and off. NOTICE: Operate the equipment only within the specified ranges of operating temperature and humidity (see the site preparation guide). If the equipment or supplies are exposed to conditions outside the environmental operating range, wait at least 4 hours for everything to reach environmental operating conditions before turning on the equipment or using the supplies.

  • Page 44: Turn The Printer On And Off

    2 hours. If it will be idle for a long time and you want to turn it off, HP recommends the soft method from the front panel.

  • Page 45: Turn The Processing Station On And Off

    Turn the processing station on and off The correct procedure changes after the first time. Turn on the processing station for the first time Follow these steps carefully, the first time that you turn on the processing station. Make sure that the wheels are braked: the processing station should remain stationary while operating.

  • Page 46: Turn The Processing Station On And Off

    Turn the service switch to the on position. Perform a visual check of the station. Wait for the front panel to indicate that the station is ready. This can take several minutes. When initialization is complete, the front panel displays a Ready message. If a system error message is displayed, see System errors on page 356.
  • Page 47 Table 4-3 Circuit-breaker labels (continued) Label Description DC power E-box Build unit Fusing lamps Heating lamps Rearm Chapter 4 Power on and off...

  • Page 48: Printer And Processing Station Networking

    ● Site Preparation Guide means the site preparation guide for the Product that has been provided to the customer by HP or HP authorized personnel (either online or in paper form) in advance of the sale of the Product. ●...

  • Page 49: Configuration

    HP’s products and offerings in the future. In addition, the Customer Machine Data will help HP determine how Products are being used, which product features are used the most, and to calculate various aggregate Product usage statistics.

  • Page 50: Link Speed

    Link speed When connected and powered on, the printer auto-negotiates with your network to operate with a link speed of 10, 100, or 1000 Mbps, and to communicate using full- or half-duplex mode. However, you can manually configure the link using the printer's front panel, or through other configuration tools once network communication is established.

  • Page 51: Prepare A File For Printing

    Introduction You can create a print job using HP SmartStream Build Manager or various third-party programs. HP SmartStream 3D Build Manager supports STL and 3MF files. The software creates slices that the printer can convert to layers in order to prepare the job. This preparation process may take from 15 minutes to 2 hours depending on the complexity of the job.
  • Page 52 SolidWorks settings SolidWorks is one of the available software options. Click File > Save As. Select STL (*.stl) as the file type. Click Options. Choose the Binary option. Binary files are smaller than ASCII files for the same tessellation. Choose Custom resolution. Set the deviation tolerance to 0.05 mm.
  • Page 53 Repairing STL files Software tools and common STL file errors STL-repairing software ● Magics – Materialise ● Netfabb ● HP SmartStream 3D Build Manager Common errors in STL files ● Triangles not joined Chapter 6 Prepare a file for printing...
  • Page 54 ● Overlapping triangles ● Holes in parts ● Flipped-direction triangles Repairing STL files...
  • Page 55 ● Tiny shells Chapter 6 Prepare a file for printing...

  • Page 56: Load Material Into The Build Unit

    Ensure that the build unit is located on the processing station. Ensure that the build unit printing platform is clean. If you want to change the mix ratio, HP recommends cleaning the build unit first. See Empty the material from the build unit on page...
  • Page 57 Ensure that the material loading inlet is clean. Open the lid of the material loading inlet of the build unit. Attach the material loading nozzle. Chapter 7 Load material into the build unit...
  • Page 58 Loading time Estimated loading time (min) Material Mix ratio Full print chamber Half print chamber HP 3D HR PA12 80% R – 20% F HP 3D HR PA11 70% R – 30% F TPU Ultrasint 80% R – 20% F PA12 GB 70% R –...
  • Page 59 Detach the material loading nozzle and leave it in parking position. NOTE: If the loading nozzle is not correctly parked, there could be a material spillage while the processing station is idle. Close the material loading inlet. At the front panel, tap Eject the build unit. Chapter 7 Load material into the build unit...
  • Page 60 Extract the build unit from the processing station by pulling the handle, put the safety lid on top of the build unit, and move it to the printer. Open the printer door. Remove the lid of the build unit. Loading procedure...

  • Page 61: Change To A Different Type Of Material

    Download the material package from the HP webpage to a USB flash drive, connect it to the processing station, and then to the printer. At the processing station’s front panel, tap the Maintenance icon then Material >...

  • Page 62: Grade 1: Light Cleaning

    Grade 1: Light cleaning Light cleaning is sufficient when the materials are relatively compatible. Perform the following operations: ● See: Empty the material from the build unit on page 60 ● See: Check and clean the interior of the build unit on page 68 ●...

  • Page 63: Grade 3: Full Deep Clean

    Turn on the printer (see Turn the printer on and off on page 37). Perform diagnostics: Calibrate the cooling system. Finish checking/cleaning the spittoon. Clean the exterior of the printer on page 166. Grade 3: Full deep clean If your new material cannot tolerate any contamination at all, you should clean the processing station manually.
  • Page 64 Take the purge tool from the drawer and place it on the side of the working area. Connect the material loading nozzle to the reusable material collector with the purge tool. CAUTION: Ensure that the hoses are connected properly. The loading nozzle should be connected to the top and the material collector to the side.
  • Page 65 Tap Continue. Unlatch and open the external tank lid. Connect the external tank collector and pipe. You are recommended to wear gloves and goggles. NOTE: The pipe sucks up material in its immediate vicinity. If you leave it in one position, it will consume all the material in that area, while there is still material elsewhere in the tank.
  • Page 66 NOTE: You can insert the pipe with the vacuum switched off, if you like. Start the process from the front panel to extract the material from the external tank. Confirm that all the material has been removed from the external tank. Tap Continue.

  • Page 67: Empty The Material From The Build Unit

    Tap Continue, and follow the instructions on the front panel to complete the process. When it is complete, tap Finish. Dispose of the material from the external tank according to local laws. Clean the external tank with an explosion-protected vacuum cleaner. Connect the material cartridges that you intend to use.
  • Page 68 Remove both vane feeders. Follow the front panel instructions to vacuum the material inside the build unit. Connect the material collector to the front material lifter, and tap Start on the front panel. Repeat the same process with the rear material lifter. Repeat again with the front material lifter until there is no material left inside.
  • Page 69 Vacuum the front overflow tray. Vacuum the area below the cap of the build unit’s loading inlet. Vacuum the feed trays, making sure there is no material left. Vacuum the other overflow trays. Chapter 7 Load material into the build unit...
  • Page 70 Attach the wide nozzle to the reusable material collector. Vacuum the build unit platform. Go to the front panel and move down the platform of the build unit by 350 mm. To do this, tap the Settings icon , then Utilities > Maintenance > Lower build platform. Remove the build unit from the processing station.
  • Page 71 Manually remove the screw on top of each material lifter, and remove both material lifters. Vacuum both material lifters with a soft-brush nozzle. Clean the material lifter duct with a hand-held low-scratch tube brush. Locate the material lid and remove the two Torx 20 screws from it. Chapter 7 Load material into the build unit...
  • Page 72 Loosen the six flat screws. Empty the material from the build unit...
  • Page 73 Remove the lid. Using a soft-brush nozzle, vacuum the material inside the build unit from top to bottom. Vacuum the perimeter below the platform. Chapter 7 Load material into the build unit...
  • Page 74 Vacuum the column gasket. Vacuum the mesh point by point. You cannot slide the nozzle over the mesh, but must vacuum one point and then lift the nozzle and put it down in another point. Using a narrow nozzle, vacuum first around the mesh and then the material-lifter inlets. Empty the material from the build unit...

  • Page 75: Check And Clean The Interior Of The Build Unit

    Ensure that you have an explosion-protected vacuum cleaner with soft-brush nozzle, an absorbent all-purpose cloth, a flat screwdriver, a Torx 20 screwdriver, and deionized water (these things are not provided by HP). You are recommended to wear gloves, goggles, and mask.
  • Page 76 Loosen the six flat screws. Remove the lid. Check and clean the interior of the build unit...
  • Page 77 Check the interior of the build unit and use the explosion-protected vacuum cleaner with soft-brush nozzle, if needed, to remove the remaining material. Finish cleaning Tighten the four captive flat screws. Put back and tighten the two Torx 20 screws. Vacuum the area below the cap of the build unit’s loading inlet.

  • Page 78: Print

    Load material into the build unit on page HP SmartStream Then use the HP SmartStream 3D Build Manager to send the job to the printer. See the 3D Build Manager User Guide . Delay printing This option allows the user to program printing time.

  • Page 79: Select A Job To Be Printed

    Tap the icon with three dots on the printer’s front panel's home screen. Select the option to delay printing that appears after selecting the icon with three dots. Select date and time in order to program the job. Device will be blocked when verifying process is finished.

  • Page 80: Add Job While Printing

    At the printer’s front panel, tap the Jobs icon on the home screen. If the build unit has not been inserted, open the door and insert the build unit by pushing the handles. Select the processed job and tap Print. The printer checks that all subsystems and supplies are ready to complete the build.

  • Page 81: Cancel A Job

    NOTE: When adding a job to the queue, the button at the bottom of the page becomes Remove, allowing you to remove the job from the queue and return it to its initial location. When you add a job while printing, sacrifice layers are added between jobs; see diagram below. A job can be added only if there is enough height available for it.

  • Page 82: Check Status On The Front Panel

    IMPORTANT: When printing with TPU material, if you cancel during the annealing process, your parts may have major print-quality issues. HP does not recommend canceling. IMPORTANT: Wait until the printer tells you it is safe to remove the build unit.

  • Page 83: Check Status Remotely

    Proceed with the cooling process and unpacking if relevant. If no parts have been printed, the build unit should be cleaned and loaded before using it again. Print modes In the HP SmartStream 3D Build Manager, you can choose the balanced or the fast print mode from the print profile drop-down menu. ●...

  • Page 84: Unpack The Build

    For more information on the product and to order the Hovmand Forklift 5200, consult your local HP 3D printing specialist. – Please be aware that HP’s Limited Warranty does not cover any problems that may arise from the use of non-approved third-party lifting devices. –...

  • Page 85: Sheet-Metal Installation Process

    How to install the sheet-metal parts. Installation process, left side Remove the six screws highlighted below. Remove the metal tube. The tube is needed when transporting the processing station, so HP recommends keeping it in case of need. Chapter 9 Unpack the build...
  • Page 86 Assemble the new metal piece and one sheet-metal part with one screw in the front position. Do not tighten the screw, as you may need to add more sheet-metal parts after calibration. Installation process, right side If on the right side you see two metal tubes as shown below, continue with the rest of this procedure.
  • Page 87 Remove two screws from the tubes. Remove both tubes. Keep the one with a U shape. The other one is not needed, unless you decide to reinstall it in the future. Chapter 9 Unpack the build...

  • Page 88: Calibration Process

    Attach the new sheet metal parts and the U-shaped tube with the two screws that you just removed. Do not tighten the screws until the calibration process has finished. Calibration process Position the forklift in front of the processing station and check how it aligns with the processing-station guide on the right.
  • Page 89 Figure 9-1 To move to the left: Figure 9-2 To move to the right: Vertical adjustment (if needed) Use the sheet-metal parts to make the vertical adjustment. Chapter 9 Unpack the build...
  • Page 90 Take four sheet-metal parts from the left side and place them on top of the forklift foot. Compare the sheet-metal parts on top of the processing-station guide and the ones on top of the forklift foot, and count how many overlap. If the forklift is too high, remove sheet-metal parts from the processing-station guide until there is no overlap.

  • Page 91: Extracting The Build To The Natural Cooling Unit

    The final position of the forklift foot should be as shown below. Now you can tighten the screws attaching the U-shaped tube. Count the number of sheet-metal parts you have used on the right, make sure you have used the same number of parts on the left, and tighten the screw on the left.
  • Page 92 You cannot pull up the natural cooling unit without opening the latches. CAUTION: HP recommends leaving the build unit in the processing station while attaching the natural cooling unit. If you first remove the build unit from the processing station, it is your...
  • Page 93 Remove the slicing blade from the natural cooling unit. Make sure the front flap (slicing blade flap) remains closed. WARNING! Hazardous substances could be released during the natural cooling process. Ensure that the room is ventilated as recommended in the site preparation guide, and do not open the natural cooling cover before the recommended time.
  • Page 94 If any material spillage is detected, make sure the slicing blade is closed, and clean up the material with an explosion-protected vacuum cleaner. NOTE: HP recommends transporting the natural cooling unit in the lowest position of the forklift, to avoid it falling. After cleaning, the build unit will be ready for a new print job.

  • Page 95: Unpacking With The Natural Cooling Unit

    Unpacking with the natural cooling unit Insert the natural cooling unit into the processing station for unpacking. NOTE: The natural cooling unit is an accessory. See Accessories on page If there is a build unit in the processing station, remove it. Put the natural cooling unit inside the processing station, in place of the build unit, using a forklift.
  • Page 96 Put on heat-resistant gloves and vacuum the top surface of the build unit with an external explosion-protected vacuum cleaner. At this point you can choose to follow the natural cooling process: Move the build unit aside to cool down further. CAUTION: You are recommended to lock the wheels of the build unit while it is outside the printer.
  • Page 97 Fast cooling starts. You can tap the Cancel icon at any time to cancel fast cooling. To resume the process, ensure that the build unit is inserted, and tap Fast cooling. Table 9-1 Default fast cooling times for PA11 and PA12 material Description PA11 PA12...
  • Page 98 When cooling is complete, remove the safety lid and park it on the front of the build unit. Use the build unit app on the processing station’s front panel to check that the build is ready for unpacking. At the processing station’s front panel, tap Build unit > Unpack > Start to start the unpacking process.
  • Page 99 ● Wide nozzle, for cleaning the working area rapidly CAUTION: Do not use the wide nozzle to clean the mesh shaker (on the feed trays of the build unit), as you could damage the accessory and leave residues inside. Vacuum the external perimeter of the platform (this step is unnecessary if you have used fast cooling).
  • Page 100 Raise the platform by pressing the button. Vacuum the build to reveal the parts. Clean each part separately to avoid having big clumps of material covering the part. You don’t need to clean every surface thoroughly because: ● The material that is closest to the part or attached to it may reduce the overall quality of reused material.
  • Page 101 Continue until all parts are extracted from the build chamber. Use the physical buttons to lift the platform to reach all parts. After checking that all parts are unpacked, put them in a box and take them to the postprocessing section.
  • Page 102 Vacuum the empty printing platform and feed tray. Tap Finish on the front panel. Clean the surface of the build unit. See Clean the surface of the build unit on page 307. Vacuum the platform control buttons to prevent loose material from blocking them. Unpacking without the natural cooling unit...

  • Page 103: Part Cleaning And Postprocessing

    Once parts have been unpacked from the build in the processing station, they should be cleaned. There are different processes that can be followed, depending on your needs. In general, you will need equipment not provided by HP. The main process recommended by HP is a combination of bead blasting (first) and air blasting (second).

  • Page 104: Hardware Maintenance

    Hardware maintenance Hardware maintenance is needed from time to time, to keep your products in good working order. WARNING! Hardware maintenance may be performed by trained personnel only. During printer installation, the designated personnel receive training for safe operation and maintenance of the printer.

  • Page 105: Maintenance Resources

    In some locations the use of cleaner products is regulated. Ensure that your cleaner follows federal, state, and local regulations. Maintenance resources Supplies and tools that you may need for maintenance operations. Maintenance kits These maintenance kits are available from HP. Table 11-1 Maintenance kits Name Purpose...
  • Page 106 Purpose items inside SKUs in Initial each SKU kit for 5200A (8VJ71A) HP Jet Fusion 5200 Series 3D 8VJ74A Replace an intermediate tank on page 268 Printer Intermediate Tank HP Jet Fusion 5200/4200 8VJ67A Replace the heating-lamp filter on page 213...
  • Page 107 Purpose items inside SKUs in Initial each SKU kit for 5200A (8VJ71A) HP Jet Fusion 5200 Series 3D 1X9A5A Replace the top-enclosure left and right fan Printer Top Enclosure Right filters on page 226 Filters HP Jet Fusion 5200 Series...
  • Page 108 5200 Processing Station E-Cabinet filters. Each SKU can be ordered separately if needed. Maintenance tools recommended but not provided These common tools may be needed but are not provided by HP. ● Spiral scourer, for some cleaning operations Use a scourer that does not scratch glass;...
  • Page 109 ● Lint-free cloth or all-cotton cloth, for cleaning covers and general cleaning ● General-purpose industrial cleaner (such as Simple Green industrial cleaner), for general cleaning ● Deionized water, for general cleaning ● Explosion-protected vacuum cleaner, with nozzle accessories for general cleaning (crevice and soft brush nozzles highly recommended) Chapter 11 Hardware maintenance...
  • Page 110 NOTE: Inside and outside the equipment should be cleaned regularly with an explosion-protected vacuum cleaner to prevent dust and condensation from accumulating. Do not sweep the dust or try to remove it with a compressed-air gun. An explosion-protected vacuum cleaner certified for collection of combustible dust is required for cleaning.

  • Page 111: Preventive Maintenance

    ● Torx screwdriver Preventive maintenance The purpose of scheduled preventive maintenance is to perform regular maintenance operations as required, in order to prevent possible failures from occurring and ensure good performance throughout the life of the product. For each scheduled preventive maintenance action, there is an internal life counter in the firmware that counts a variable related to the life of the component.
  • Page 112 Table 11-5 Service preventive maintenance alerts Alert Description Printer maintenance kit #1 required Replace the scan-axis motor and front bar SRV Printer maintenance kit #2 required Replace the recoating unit carriage and sax chain assy SRV Printer maintenance kit #3 required Replace the carriage Build unit maintenance kit #1 required Replace platform nut and column gasket...
  • Page 113 NOTE: The status center displays alerts only for the build unit that is inserted at that time. Check preventive maintenance usage level on the front panel You can check the preventive maintenance usage levels, which are automatically converted to a percentage according to the life counter values, on the front panel.

  • Page 114: Consumables

    Please note: ● This is a dynamic security-enabled printer. Cartridges using a non-HP chip may not work, and those that work today may not work in the future. For more information, see the HP website http://www.hp.com/go/learnaboutsupplies. ● This printer is not designed to use continuous agent systems. To print successfully, remove any continuous agent system and install genuine HP cartridges.
  • Page 115 Low on agents: The agent is low and should be replaced soon. ● Very low on agents: The agent is very low and should be replaced soon. ● Incorrect ● Non-HP ● OK: The agent is working normally. ● Out of agents: The agents should be replaced. NOTE: The level of each agent shown on the front panel is an estimate.
  • Page 116 Press the agent door to release it, and open the door. Locate the agent to be replaced. You can see which agent needs to be replaced on the front panel; it is also indicated by a red LED beside the cartridge. Disconnect the agent connector by pressing the tabs on each side of it and pulling it away gently.
  • Page 117 (plastic retainer and packaging box) can be recycled through commonly available recycling programs. HP recommends that you wear gloves when handling supplies. Remove the new agent from its packaging, place it on a flat surface, and turn it four times (rotating it through 360 degrees) as indicated on the label, to ensure that the agent is well mixed before use.
  • Page 118 Ensure that the tabs on each side of the agent connector are open but in place, showing a successful connection. You will hear a click. Close the door. Tap Finish and Check on the front panel. Agent troubleshooting If a new agent fails to work, try these suggestions. The problem may be with the connector rather than the agent itself.
  • Page 119 At the printer’s front panel, tap the Maintenance icon , then Printheads, then tap any printhead to see its status: ● OK: The printhead is working normally. ● Check pending ● Missing: The printhead is missing. ● Error ● Warning ● Non-HP Chapter 11 Hardware maintenance...
  • Page 120 Replace a printhead Follow these steps to replace a printhead. At the printer’s front panel, tap the Maintenance icon , then Printheads > Replace. Put on chemical-resistant gloves. Open the top cover. Pull the handle to open the printhead cover. Replace a printhead...
  • Page 121 Lift off the printhead cover. Release the printhead latch. Chapter 11 Hardware maintenance...
  • Page 122 Lift the printhead latch. Place the extraction tool on the left side of the printhead. Replace a printhead...
  • Page 123 After removing the printhead, remove the extraction tool, and clean it with a lint-free cloth dampened with deionized water. Dispose of the old printhead in accordance with local regulations. Most HP printheads can be recycled through the HP supplies recycling program. For more information, see the HP website http://www.hp.com/recycle/.
  • Page 124 Put the new printhead into its correct place in the printer, and lower its handle. CAUTION: Insert the printhead slowly, without hitting any parts of the carriage. It may be damaged if you insert it too fast, or if you hit something. Lower the latch until it lies on the printhead.
  • Page 125 Close and secure the latch. Put the printhead cover back into place. Close the top cover. Tap Finish and Check. The printer checks that the new printhead has been correctly inserted, and recommends printhead alignment. See Align the printheads on page 328.
  • Page 126 Replace the printhead cleaning roll Follow these steps to replace the printhead cleaning roll. Ensure that you have a new cleaning roll ready. Put on chemical-resistant gloves. At the printer’s front panel, tap the Maintenance icon , then Printhead cleaning roll > Replace. Tap Start when ready.
  • Page 127 Detach the end of the cleaning roll from the upper roll core. Pull the black knob at the top left and move the pinch system aside. Chapter 11 Hardware maintenance...
  • Page 128 Clean the rubber blade, the roll input, and the cleaning roll platen with the end of the roll. Wind the remainder of the cleaning roll onto the lower axle. Replace the printhead cleaning roll...
  • Page 129 Remove the hub of the lower roll by pressing on the tab, then remove the lower roll. Dispose of the roll of used cleaning material according to the instructions provided with the new roll. Also consult your local authorities to determine the correct manner in which to dispose of wastes.
  • Page 130 Place the lower hub, pull the core against the hub, and push them both in until the hub snaps into place (you will hear a click). Place the upper hub onto the new roll, and slide them onto the upper axle until you hear a click. CAUTION: Make sure the cloth is aligned with the front of the core, touching the hub.
  • Page 131 Pass the leading edge of the roll over the upper rollers, and thread the cleaning material through the rollers on the left. There is a strip of polyester film on the leading edge of the cleaning material. Insert it into the hole in the takeup core, which takes hold of it.
  • Page 132 Take care to route the cleaning material correctly. Rotate the lower roll one full turn. Replace the printhead cleaning roll...
  • Page 133 Restore the pinch system by moving the black knob back into place. If you feel resistance because the cleaning roll is too tight, turn the roll slightly counter-clockwise. Close and lock the doors. The length of used printhead cleaning roll tracked by the printer is now reset to zero. NOTE: If you tamper with partly-used rolls, the usage shown in the front panel will not be accurate.
  • Page 134 Ensure that all windows, covers, and doors are closed and remain in their original positions. Turn off the printer. Remove the fusing-lamp module Table 11-7 Warning labels Risk of burns Crush hazard Risk of trapped Hazardous moving Light radiation Electric shock fingers part hazard...
  • Page 135 Pull the print carriage handle to open the cover. Remove the print carriage cover. Chapter 11 Hardware maintenance...
  • Page 136 ● The safety and functional reliability of the IR heating device are guaranteed only if you are using original accessories and spare parts from HP. ● After an emitter break, a dangerous voltage may be exposed to contact by the heating spiral.
  • Page 137 Grip the emitter only by the glass tube, and not by the pinches or ceramics. When installing IR emitters ● HP recommends that you wear protective goggles when installing or replacing emitters, to protect yourself from broken glass that you may come into contact with. ●...
  • Page 138 Remove the exterior glass. Remove the middle glass. Open the metallic clip on one side, remove the fusing lamp, then do the same on the other side. Insert the fusing lamp, making sure that it is fully inserted into the ceramic connector. Replace a fusing lamp...

  • Page 139: Processing Station

    Insert the internal glass by pulling the metallic clip. Add the frame with the bottom glass, securing it with four screws. Reassemble the fusing-lamp module Turn the assembly upside down and put it back into the print carriage. Tighten the captive screw. Plug in the black power connector.
  • Page 140 The HP Jet Fusion 5200 accepts cartridges with a capacity of 30 or 300 liters. ● The HP Jet Fusion 5210 accepts the use of the refillable HP Material Loading Tank with a capacity of 300 liters. The weight of the cartridge varies according to the material type. Special care must be taken to avoid personal injury when handling heavy cartridges.
  • Page 141 ● If it is empty, dispose of it according to local regulations. To prepare the new cartridge, tear off the square and fold it inside the handle as illustrated on the box. Remove the seal from the rear spout. IMPORTANT: The cartridge will not work unless you remove the seal.
  • Page 142 Put the new cartridge into its correct place next to the storage tank. Open the front spout. Remove the seal from the front spout. CAUTION: Once the seal has been removed, the cartridge should be used until it is empty, and not put into storage.
  • Page 143 sensitive to temperature, humidity, or other factors. Using cartridges under uncontrolled conditions can affect the functionality of the equipment or severely damage it. Connect the cartridge connector to the cartridge. 300 liter cartridge replacement Follow these steps to replace a 300 liter cartridge. At the processing station’s front panel, tap the Maintenance icon , then Material >...
  • Page 144 Remove the cardboards indicated on the packaging as 1 and 2. Remove the seal from the rear spout of slot 1. IMPORTANT: The cartridge will not work unless you remove the seal. 300 liter cartridge replacement...
  • Page 145 Open the front spout. Remove the seal from the front spout. CAUTION: Once the seal has been removed, the cartridge should be used until it is empty, and not put into storage. Cartridges are not designed for storing material after removing the seal, and storing an opened cartridge containing material can render the material unusable and cause safety hazards, such as a cloud of material if dropped.
  • Page 146 Connect the cartridge connectors to the cartridge 1 and 2. You are recommended to wear gloves and goggles. Tap Finish and check on the front panel. 300 liter cartridge: Swap the material connector When running out of material on one connector, you can swap it for a full one. Number 1 can be replaced by 3 and 2 by 4.
  • Page 147 Remove the cardboard and seal from the rear and front spouts. Connect the material cartridge connector to the new material cartridge. Tap Finish and check on the front panel. Material cartridge troubleshooting If a new cartridge fails to work, follow the troubleshooting procedure below. TIP: The problem may be with the connector rather than the cartridge itself.
  • Page 148 CAUTION: HP recommends storing only sealed cartridges. Cartridges are not designed for storing material after removing the seal, and storing an opened cartridge containing material can render the material unusable and cause safety hazards, such as a cloud of material if dropped. Depending on the material, it can be sensitive to temperature, humidity, or other factors.
  • Page 149 If you use a drum rotator, take care that it does not rub against the base or the cover of the material loading tank while rotating. Connect the material loading tank connector to the lid. NOTE: HP recommends using tanks in the same order in which they were filled from the bulk material supply. Chapter 11 Hardware maintenance...
  • Page 150 Connect the static earthing clamps from one material loading tank lid to the other. NOTE: If you are using only one material loading tank, connect it to the external tank lid. Fill the material loading tanks from the bulk material supply The recommended method is to create your own infrastructure to transfer the material according to the requirements of the material.
  • Page 151 Connect the tube from the external equipment and close it with the clamp. IMPORTANT: Do not forget the rubber. Use a multimeter to measure the continuity between the processing station structure and the external equipment structure. The measurement should be less than 100 Ω. IMPORTANT: The processing station and the external equipment should both be disconnected from the mains supply before the measurement.
  • Page 152 Material may be stored temporarily in the build unit. CAUTION: HP recommends not storing material in the build unit for more than one or two weeks. Storage and external tanks When unpacking, all reused material is stored in the storage tank until it is full, but there are some cases in which it will be stored directly in the external tank even if the storage tank is not full.
  • Page 153 CAUTION: Use HP-certified external tanks only. The use of third-party external tanks can cause safety risks, material leakages, and malfunctions in the processing station; and may affect your system warranty.

  • Page 154: How To Recycle Supplies

    ISO 11469 to encourage recycling. HP provides many free and convenient ways to recycle your used HP cartridges and other supplies. For information about these HP programs, see the HP website http://www.hp.com/recycle/.
  • Page 155 Table 11-8 Summary of maintenance operations Frequency Maintenance operation After every job Clean the print zone, carriage, and housing structure on page 151 Clean the front bar (after every job/daily) on page 157 Clean the spittoon on page 158 Clean the bottom of the carriage and of the fusing lamps on page 161 Clean the thermal camera glass on page 163 Clean the service-station caps on page 177 Cooling plate maintenance on page 272...
  • Page 156 Table 11-8 Summary of maintenance operations (continued) Frequency Maintenance operation When required Replace the print-zone filter on page 224 Replace the heating-lamp filter on page 213 Replace the e-cabinet filter on page 215 Replace the power-box fan filters on page 218 Replace the top-enclosure left and right fan filters on page 226 Replace a primer on page 229 Replace a service-station cap module on page 234...
  • Page 157 Figure 11-1 After-each-job maintenance operations (25–30 min) Figure 11-2 Weekly maintenance operations (60 min) Chapter 11 Hardware maintenance...

  • Page 158: Maintenance Operations

    Figure 11-3 Every 2-weeks maintenance operations (60 min) Figure 11-4 Every 6-months maintenance operations (60 min) Maintenance operations Each maintenance operation in detail. Clean the print zone, carriage, and housing structure Cleaning inside the printer. Maintenance operations...
  • Page 159 Prepare for cleaning Ensure that you have an explosion-protected vacuum cleaner, an absorbent all-purpose cloth, and deionized water (these things are not provided by HP). If the build unit is in the printer, remove it. Ensure that the printer is not printing.
  • Page 160 Clean the printer Vacuum all the top-cover surfaces including the heating-lamp quartz-glass zone and the left and right filters. NOTE: If the internal metallic part is dirty, clean it with a lint-free cloth dampened with water. Clean the dust from the print zone using an explosion-protected vacuum cleaner with a soft brush nozzle.
  • Page 161 Vacuum the whole recoating unit. Additionally, you can use a lint-free cloth dampened with general- purpose industrial cleaner to clean the surfaces. Make sure that the carriage is dry before printing. Vacuum the left area of the printing zone: the spittoon, cooling plates, and blowers. Chapter 11 Hardware maintenance...
  • Page 162 Vacuum the metallic sheets on both sides of the printing platform, then clean them with a lint-free cloth dampened with deionized water. Vacuum the housing structure for the build unit and its internal parts. Clean the printer...
  • Page 163 Make sure there is no material left on the build-unit seal. Clean it with an explosion-protected vacuum cleaner, then wipe it with a cloth dampened with deionized water. If any material is still left, remove it with a scraper. Besides vacuuming, you must clean the rear areas indicated below with a lint-free cloth dampened with general-purpose industrial cleaner Chapter 11 Hardware maintenance...
  • Page 164 Clean the front bar (after every job/daily) Cleaning inside the printer. Prepare for cleaning Ensure that you have an absorbent all-purpose cloth (not provided by HP). Ensure that the printer is not printing. Turn off the printer. Clean the front bar (after every job/daily)
  • Page 165 If a job has just been printed, wait about 20 minutes for the printer to cool down. You are recommended to wear gloves. Clean the front bar Open the top cover. Clean the front bar using a lint-free cloth dampened with deionized water. Move the carriage manually in order to clean the part of the bar underneath the carriage.
  • Page 166 Prepare for cleaning Ensure that you have a plastic scraper, lint-free cloth, deionized water, and a general-purpose industrial cleaner, such as Simple Green industrial cleaner (these things are not provided by HP). Ensure that the printer is not printing. Turn off the printer.
  • Page 167 Clean the spittoon Remove the screw, then remove the spittoon from the printer. Wet the surface covered with ink and wait 5 minutes. Scrape the spittoon with a plastic scraper. Clean the spittoon with a lint-free cloth dampened with deionized water. NOTE: About once a month, turn off the printer, and clean the spittoon area with a lint-free cloth dampened with a general-purpose industrial cleaner, such as Simple Green industrial cleaner.
  • Page 168 Figure 11-7 Safety warnings Prepare for cleaning Ensure that you have a lint-free cloth and deionized water (these things are not provided by HP). Ensure that the printer is not printing. Turn off the printer. If a job has just been printed, wait about 20 minutes for the printer to cool down.
  • Page 169 Open the build-unit door and remove the build unit from the printer, if it is present. Open the top cover. Move the print carriage manually over the build unit space. CAUTION: When moving the print carriage manually, do it slowly, and be careful not to crash it into any other component or the sides of the printer.
  • Page 170 Cleaning inside the printer. Prepare for cleaning Ensure that you have an explosion-protected vacuum cleaner, a supply of soft cloths, a mild, non-abrasive detergent, a general-purpose industrial cleaning liquid, and deionized water (these things are not provided by HP). Finish cleaning...
  • Page 171 If the build unit is in the printer, remove it. Ensure that the printer is not printing. Turn off the printer. If a job has just been printed, wait about 20 minutes for the printer to cool down. You are recommended to wear gloves and goggles. Open the top cover.
  • Page 172 by the detergent manufacturer). Then rinse the glass with another cloth dampened with deionized water, and wipe it with a dry cloth. If necessary, clean the glass with a sponge scourer. Continue cleaning the glass with the cloth and sponge scourer until it is completely clean. Wait until the glass is dry to start printing.
  • Page 173 Cleaning the outside of the printer. Prepare for cleaning Ensure that you have an explosion-protected vacuum cleaner, an absorbent all-purpose cloth, and deionized water (these things are not provided by HP). Ensure that the printer is not printing. Turn off the printer.
  • Page 174 Afterwards, you can wipe it with a dry cloth. Still wearing gloves and goggles, clean condensation from the external surfaces behind the air- collection hoods. Clean the recoating roller and recoating plates Cleaning inside the printer. Figure 11-8 Safety warnings Prepare for cleaning Ensure that the printer is not printing.
  • Page 175 Ensure that all windows, covers, and doors are closed and remain in their original positions. Open the top cover. Remove the build unit from the printer, if it is present. Move the recoating unit manually to the front, slowly and carefully. Clean the recoating roller and recoating plates Locate the recoating unit and use a flat screwdriver to remove four T15 screws.
  • Page 176 Remove the front lid. Remove four T10 screws (two on each side). Clean the recoating roller and recoating plates...
  • Page 177 Remove the roller by pulling it towards you, and place it gently on a table or flat surface. Use a lint-free cloth dampened with a general-purpose industrial cleaner, such as Simple Green industrial cleaner, to clean all along the recoating roller. Remove any remaining soap foam with a dry cloth.
  • Page 178 Clean the dust from the inside of the recoating unit, using an explosion-protected vacuum cleaner with a crevice nozzle. Place special attention to the right-hand side, where the gears are located. Finish cleaning Put back both recoating plates. Carefully reinsert the recoating roller by placing it and pushing it to the end. NOTE: The gears should be on the right when placing the roller.
  • Page 179 Align the plates with the line as shown below. Secure the recoating roller with the top four screws. TIP: Hold the plate up while tightening the top screws. Put back the front lid of the recoating unit, but do not insert the screws yet. Attach the lid with the four T15 screws.
  • Page 180 Close the top cover. Ensure that all windows, covers, and doors are closed and remain in their original positions. Clean the scan-axis wipers Cleaning inside the printer. Prepare for cleaning Ensure that you have an explosion-protected vacuum cleaner and a screwdriver. Ensure that the printer is not printing.
  • Page 181 Clean the scan-axis wipers Open the top cover to access the scan-axis wipers. Locate the scan-axis wipers, one on each side. Remove two screws from each wiper, and remove the wipers. CAUTION: Material can fall when you remove the wipers. Chapter 11 Hardware maintenance...
  • Page 182 HP support representative to proceed with the replacement of the part. Inspect the scan-axis wiper status. If there is clustered powder that cannot be removed with vacuum, and the felt is damaged, it must be replaced.
  • Page 183 Ensure that the printer is not printing. Turn off the printer. If a job has just been printed, wait about 20 minutes for the printer to cool down. You are recommended to wear gloves and goggles. Open the top cover. Clean the inside of the carriage Pull the print carriage handle to open the cover.
  • Page 184 Clean the service-station caps with a cloth and industrial cleaner. Prepare for cleaning Ensure that you have a lint-free cloth and a general-purpose industrial cleaner, such as Simple Green industrial cleaner (these things are not provided by HP). Finish cleaning...
  • Page 185 Ensure that the printer is not printing. Turn off the printer. If a job has just been printed, wait about 20 minutes for the printer to cool down. You are recommended to wear gloves. Open the top cover. Move the print carriage manually to the left to access the capping station. CAUTION: When moving the print carriage manually, do it slowly, and be careful not to crash it into any other component or the sides of the printer.
  • Page 186 Safety warnings Prepare for cleaning Ensure that you have a lint-free cloth, vacuum cleaner, and deionized water (these items are not provided by HP). Ensure that the printer is not printing. Turn off the printer. If a job has just been printed, wait about 20 minutes for the printer to cool down.
  • Page 187 You are required to wear gloves and goggles. Open the top cover. Clean the recoater reflector Vacuum the metallic sheets on both sides of the printing platform. Clean the metallic sheets with a lint-free cloth dampened with deionized water. Vacuuming alone is insufficient.
  • Page 188 Clean the top-enclosure left and right fan filters Open the top cover. Locate the fan filters on the printer top cover at right and left. Unscrew the captive screws. Clean the top-enclosure left and right fan filters...
  • Page 189 At the front panel, tap the Maintenance icon , then Filters > Replace Remove the filter cover. Remove each filter assembly, and take it somewhere with a non-explosive atmosphere. Position the filter horizontally over a hard surface, with the airflow direction arrow pointing upwards. Then knock the filter gently against the hard surface until no material drops out of it.
  • Page 190 Inspect the folds of the filter, following the direction of the fold to try to detect holes, which may be small and hard to see. Inspect both sides of the filter media following this checklist: Inspect along the folds of the media, following the direction of the fold with your eyes to detect if there are holes.
  • Page 191 Inspect also the edges of the filter, next to the frame, where holes are more common and harder to see. If you find any holes in the filter, replace the filter with a new one. See Replace the top-enclosure left and right fan filters on page 226.
  • Page 192 Clean the front bearing with a lint-free cloth dampened with deionized water. Move the carriage over the cloth. CAUTION: When moving the print carriage manually, do it slowly, and be careful not to crash it into any other component or the sides of the printer. Clean the front bearing...
  • Page 193 Move the cloth back and forth below the carriage (parallel to the front bar) to ensure that the bearing’s surface is being cleaned. Repeat this movement in different positions to ensure that the whole bearing surface is cleaned. Clean the front bar (weekly procedure) These are the removal and installation procedures.
  • Page 194 Place the carriage in the Trolley area. Move the carriage to the left side and use a foam, carton or soft material to slightly lift the carriage as illustrated in the following image. CAUTION: Ensure that the foam stays within the area marked in the previous step and not below the fusing lamps.
  • Page 195 Remove the 7 screws shown in the picture. NOTE: The three middle screws may not be present in some models. Free the Front bar sheet metal. NOTE: The three middle screws may not be present in some models. Lift the metal sheet as shown in the following image and wipe it with a lint-free cloth dampened with deionized water.
  • Page 196 Clean the material extraction system Clean the material extraction system with a vacuum cleaner. Locate the material extraction system doors on both sides of the printer, and choose one to start with. Unscrew the two screws. Clean the material extraction system...
  • Page 197 Prepare for cleaning Ensure that you have a lint-free cloth, a general-purpose industrial cleaner (such as Simple Green industrial cleaner), and a razor scraper (these things are not provided by HP). WARNING! Sharp knife blade. Handle with care. When scraping a part, do not hold the part in your hand.
  • Page 198 Open the top cover. Move the print carriage manually over the build-unit space. CAUTION: When moving the print carriage manually, do it slowly, and be careful not to crash it into any other component or the sides of the printer. Remove the fusing-lamp module Table 11-11 Warning labels...
  • Page 199 Pull the print carriage handle to open the cover. Remove the print carriage cover. Chapter 11 Hardware maintenance...
  • Page 200 ● The safety and functional reliability of the IR heating device are guaranteed only if you are using original accessories and spare parts from HP. ● After an emitter break, a dangerous voltage may be exposed to contact by the heating spiral.
  • Page 201 Clean the fusing-lamp glasses Turn the assembly upside down and unscrew the four screws of the exterior glass frame. Carefully remove the frame of the exterior glass. CAUTION: When you remove the frame, the glass may stick to it. Take care that the glass does not fall out of the frame as you pick it up.
  • Page 202 Moisten both sides of the glass with a lint-free cloth dampened with a general-purpose industrial cleaner, such as Simple Green industrial cleaner. Remove any remaining soap foam with a lint-free cloth dampened with distilled water, and dry it with a dry cloth. Continue cleaning until the glass is clean.
  • Page 203 Add the bottom glass and then the frame, securing it with four screws. IMPORTANT: The bottom glass must be centered when placed. WARNING! While securing the frame, do not sit on the lateral walls. They can break easily. Reassemble the fusing-lamp module Turn the assembly upside down and put it back into the print carriage.
  • Page 204 Open the top enclosure and the machine door to get access to the side wall. Remove the two screws shown in the following image. Remove the rear wiper and vacuum the wiper area when the wiper is removed. Recoating unit curtain wipers...
  • Page 205 Remove the two screws on the front side. Remove the front wiper and vacuum the wiper area when the wiper is removed. Chapter 11 Hardware maintenance...
  • Page 206 Prepare for cleaning Ensure that you have a lint-free cloth, a general-purpose industrial cleaner (such as Simple Green industrial cleaner), and a razor scraper (these things are not provided by HP). WARNING! Sharp knife blade. Handle with care. When scraping a part, do not hold the part in your hand.
  • Page 207 Remove the bottom glass of the heating lamps Open the top cover. Locate the bottom glass of the heating lamps. Chapter 11 Hardware maintenance...
  • Page 208 Unscrew the four captive screws to remove the bottom glass. Pull the bottom glass out of the top cover and place it gently on a table. Remove the bottom glass of the heating lamps...
  • Page 209 Clean the bottom glass of the heating lamps Moisten both sides of the glass with a lint-free cloth dampened with a general-purpose industrial cleaner, such as Simple Green industrial cleaner. Remove any remaining soap foam with a lint-free cloth dampened with distilled water, and dry it with a dry cloth. Scrub both sides of the glass with the razor scraper.
  • Page 210 Remove the build unit from the printer. Turn off the printer. Clean the recoater’s left box and left rod Table 11-12 Warning labels Risk of burns Crush hazard Risk of trapped Hazardous moving Light radiation Electric shock fingers part hazard hazard For more safety information, see Safety precautions on page 4...
  • Page 211 Locate the recoater’s left box. Remove the eight screws to open the recoater’s left box. Chapter 11 Hardware maintenance...
  • Page 212 Remove the spittoon and the plate underneath it. Clean the dust from the recoater’s left box, using an explosion-protected vacuum cleaner with a narrow nozzle. Wipe the left rod with a lint-free cloth dampened with a general-purpose industrial cleaner, such as Simple Green industrial cleaner.
  • Page 213 Ensure that all windows, covers, and doors are closed and remain in their original positions. Turn on the printer. Clean the printhead contacts Clean the contacts with a brush, a cloth, industrial cleaner, and deionized water. Prepare for cleaning Ensure that you have several dry cloths, a general-purpose industrial cleaner (such as Simple Green industrial cleaner), and deionized water.
  • Page 214 Pull the print-carriage handle to open its cover. Lift the print-carriage cover. Clean the printhead contacts in the carriage Carefully remove the three printheads from the carriage. See Replace a printhead on page 113 Turn off the printer. Move the print carriage manually over the build unit space. CAUTION: When moving the print carriage manually, do it slowly, and be careful not to crash it into any other component or the sides of the printer.
  • Page 215 Illuminate the printhead slot in the carriage and check the electrical connections to the printhead for dirt. Clean the right side of the printhead slot (not the side with the contacts) with a soft brush, such as a toothbrush. Wipe the printhead contacts as instructed in the front panel, moving the cloth up and down (not side to side).
  • Page 216 Clean the printhead contacts on the printhead Place the printheads on a table. Clean the parts of the printhead away from the contacts with a soft brush; and then with a cloth moistened with water. Clean the contact side of the printhead with a lint-free cloth moistened with a general-purpose industrial cleaner, such as Simple Green industrial cleaner.
  • Page 217 Align the printheads. See Align the printheads on page 328. Clean the print-zone window Clean the window with a cloth and deionized water. Figure 11-15 Safety warnings Prepare for cleaning Ensure that you have an absorbent all-purpose cloth. Ensure that the printer is not printing. Turn off the printer.
  • Page 218 Locate the print-zone window. Wipe the glass with an absorbent all-purpose cloth dampened with deionized water. Close the top cover and clean the external part of the print-zone window. Clean the print-zone window...
  • Page 219 Switch off the printer. If a job has just been printed, wait approximately 20 minutes for the printer to cool down. HP recommends that you wear gloves to carry out this procedure. Clean underneath the reflective recoating unit plate Clean underneath the reflective recoating unit plate and ball bearing area using a vacuum cleaner.
  • Page 220 Remove the four screws shown in the following image (two on each side). Remove the reflective plate by pulling it to the right. Vaccuum the entire area, including the ball bearing area. It should look as shown in the following image once properly cleaned.
  • Page 221 If a job has just been printed, wait about 20 minutes for the printer to cool down. You are recommended to wear gloves and mask. Ensure that all windows, covers, and doors are closed and remain in their original positions. Turn off the printer.
  • Page 222 Remove the six screws and slide out the filter assembly. CAUTION: The filter will fall out unless you hold it. Slide the filter out of its frame. Remove and dispose of the old filter according to local regulations. Insert the new filter into its frame. Put back the filter grid and tighten its six screws.
  • Page 223 If a job has just been printed, wait about 20 minutes for the printer to cool down. You are recommended to wear gloves, mask, and safety goggles. Ensure that all windows, covers, and doors are closed and remain in their original positions. Remove the build unit from the printer.
  • Page 224 Unscrew four screws and remove the plastic filter cover. Remove and dispose of the old filter according to local regulations, and insert the new one. Replace the e-cabinet filter...
  • Page 225 Carefully insert the new filter cover and secure it with the screws. Finish replacement Ensure that all windows, covers, and doors are closed and remain in their original positions. Turn on the printer. Replace the power-box fan filters Remove the filters and replace them with new ones. Prepare for replacement Replacement fan filters are provided with your printer in the printer yearly maintenance kit.
  • Page 226 Table 11-15 Warning labels Risk of burns Crush hazard Risk of trapped Hazardous moving Light radiation Electric shock fingers part hazard hazard For more safety information, see Safety precautions on page 4 Open the build-unit door. Locate the power-box left fan filter and loosen the four captive screws. Replace the power-box fan filters (8VJ66A)
  • Page 227 Remove the filter grid. Remove and dispose of the old filter and insert the new one. Put back the filter grid and tighten the screws. Locate the power-box right fan filter. Chapter 11 Hardware maintenance...
  • Page 228 Loosen the two captive screws and remove the filter case. Remove and dispose of the old filter and insert the new one. Put back the filter case and tighten the screws. Replace the power-box 3 filter (2E7N3A) The following steps explain how to replace the power-box fan filter 3 on 3FW25A model printers: Replace the power-box 3 filter (2E7N3A)
  • Page 229 Table 11-16 Warning labels Risk of burns Crush hazard Risk of trapped Hazardous moving Light radiation Electric shock fingers part hazard hazard For more safety information, see Safety precautions on page 4 Locate the power-box filter to be removed. Remove by hand the 4 Southco screws. Chapter 11 Hardware maintenance...
  • Page 230 Remove the filter cover sheet metal. Pull by the Mylars to remove the filter. Install the filter paying attention to the filter’s directional arrow (it should point inside). Put back the filter case and tighten the screws. Replace the power-box fan filter (348C5A) The following steps explain how to replace the power-box fan filter on 3FW25B model printers.
  • Page 231 Table 11-17 Warning labels Risk of burns Crush hazard Risk of trapped Hazardous moving Light radiation Electric shock fingers part hazard hazard For more safety information, see Safety precautions on page 4 ■ Follow step 1 to step 5 in Replace the power-box fan filters (8VJ66A) on page 218.
  • Page 232 Locate the fan filters at the rear left of the printer. Remove eight screws, then remove the grid. Replace the print-zone filter...
  • Page 233 Pull the filter out of the frame and dispose of it according to local regulations. Insert the new filter provided in the kit. Put back the filter grid and its screws. Finish the replacement The following steps provide the complete procedure for this topic. Ensure that all windows, covers, and doors are closed and remain in their original positions.
  • Page 234 When the filter has just been cleaned and the printer shows the alert during the next job, HP recommends replacing the filter. Prepare to replace Top-enclosure left and right fan filters are provided with your printer in the printer initial maintenance kit.
  • Page 235 Unscrew the captive screws. Remove the filter cover. Chapter 11 Hardware maintenance...
  • Page 236 Remove each filter and dispose of it according to your local laws. Put each new filter into its corresponding place in the top cover (with the arrow pointing upwards), place the filter cover, and tighten the screws. Turn on the printer. At the front panel, tap the Maintenance icon , then Cooling system calibration.
  • Page 237 Table 11-19 Warning labels Risk of burns Crush hazard Risk of trapped Hazardous moving Light radiation Electric shock fingers part hazard hazard For more safety information, see Safety precautions on page 4 Open the top cover. Pull the print-carriage handle to open its cover. Chapter 11 Hardware maintenance...
  • Page 238 Remove the print-carriage cover. Replace a primer The following steps provide the complete procedure for this topic. NOTE: You can replace a primer while the printheads are installed. Disconnect the primer cable, by disconnecting the white connector that you can find at the left side of the printhead whose primer is to be replaced.
  • Page 239 Open the printhead latch. Remove the old latch and dispose of it according to local regulations. Chapter 11 Hardware maintenance...
  • Page 240 Connect the new latch primer cable. Install the new latch with the primer. Check that the new latch can move freely through the whole stroke. Close the new latch. Finish the replacement The following steps provide the complete procedure for this topic. Close the print-carriage cover.
  • Page 241 At the front panel, tap the Settings icon , then Utilities > System tools > System checks > Primer check, to test the primer functionality. Tap tap the Settings icon , then Utilities > Maintenance > Replace parts > Printer reset counter >...
  • Page 242 Open the top cover to access the capping station. Remove the service-station cap, by pushing both snaps at the same time and rotating the cap about the y axis. Dispose of the old cap according to local regulations. Replace a service-station cap module...
  • Page 243 Place the new cap. Finish the replacement The following steps provide the complete procedure for this topic. Close the top cover. Ensure that all windows, covers, and doors are closed and remain in their original positions. At the front panel, tap the Settings icon , then Utilities >...
  • Page 244 The height of the new blade will need adjusting, so you should also perform the height adjustment in this case. Adjustment procedure The following steps provide the complete procedure for this topic. At the front panel, tap the Settings icon , then Utilities >...
  • Page 245 When you see the question, Do you want to perform the wiper height and tilt adjustment?, tap OK. The printer prints a pattern on the cleaning roll. This pattern is coarse, but it gives a rough idea of the rubber-blade height. When prompted, open the cover to evaluate the pattern. Chapter 11 Hardware maintenance...
  • Page 246 Look at the lines at the right side of the pattern (blue box) and, from right to left, count the number of complete lines, which may range from 0 to 9. In the example below, the number is 1. NOTE: A line is complete if it extends across the width of the roll.
  • Page 247 The printer prints a second pattern on the cleaning roll. This pattern is finer, designed to fine-tune the adjustment. When prompted, open the cover to evaluate the pattern. Chapter 11 Hardware maintenance...
  • Page 248 Once again, look at the lines at the right side of the pattern (blue box) and, from right to left, count the number of complete lines, which may range from 0 to 7. In the example below, the number is 4. NOTE: A line is complete if it extends across the width of the roll.
  • Page 249 Use the UP and DOWN keys on the front panel to enter the number of complete lines, and tap OK to continue. On reaching the final screen, tap OK to complete the adjustment procedure. Replace the printhead cleaning roll’s rubber blade Chapter 11 Hardware maintenance...
  • Page 250 Prepare for replacement Ensure that you have the printhead cleaning roll rubber blade kit, which is included in the printer initial maintenance kit, but can also be purchased separately. Ensure that the printer is not printing. Turn off the printer. If a job has just been printed, wait about 20 minutes for the printer to cool down.
  • Page 251 Pull the black knob at the top left and move the pinch system aside. Chapter 11 Hardware maintenance...
  • Page 252 Move the printhead cleaning material aside to uncover the rubber blade. Replace the rubber blade The following steps provide the complete procedure for this topic. Use a Torx 15 screwdriver to remove two screws. While you unscrew them, you must hold the two spacers on the inside (otherwise, they will fall and might get lost).
  • Page 253 Remove the two spacers. Be careful not to lose them! Pull out the old rubber blade from the two pins at the back, then remove and dispose of it according to local regulations. Insert the new rubber blade, carefully aligning the two pins at the back. At the front, reinsert and tighten each screw with one hand, while holding the spacer on the other side with the other hand.
  • Page 254 Tap the Settings icon , then System tools > Calibrations > Rubber-blade height adjustment. Rubber-blade height adjustment on page 236 for more details. Replace a service-station drop-detector module The following sections provide details for this topic. Prepare for replacement The following steps provide the complete procedure for this topic. Ensure that you have the service-station drop-detectors kit.
  • Page 255 Open the agent door and the external cleaning-roll door. Locate the drop-detector cable to be replaced. Chapter 11 Hardware maintenance...
  • Page 256 Disconnect the drop-detector cable from both connectors. Replace a service-station drop-detector module...
  • Page 257 Remove the cable from its holder. Open the top cover to access the drop-detection station. Chapter 11 Hardware maintenance...
  • Page 258 Use a Torx screwdriver to remove the screw. Rotate and remove the old drop detector, and dispose of it according to local regulations. Perform the same operations in reverse to install the new drop detector. CAUTION: Be careful to place the new drop detector on the right side of the belt. Replace a service-station drop-detector module...
  • Page 259 Route the cable through its holder. Connect the new drop-detector cable to its connectors. Finish the replacement The following steps provide the complete procedure for this topic. Close the top cover. Close the printhead cleaning roll door and agent door. Ensure that all windows, covers, and doors are closed and remain in their original positions.
  • Page 260 You are recommended to wear gloves. Ensure that all windows, covers, and doors are closed and remain in their original positions. Open the top cover. Remove the build unit from the printer, if it is present. Move the recoating unit manually to the front, slowly and carefully. Replace the recoating roller and recoating plates The following steps provide the complete procedure for this topic.
  • Page 261 Remove the front lid. Slide the top sheet to one side until you can see the holes; do not remove it completely. Chapter 11 Hardware maintenance...
  • Page 262 Remove two T10 screws from the reflecting plate. Repeat steps 3 and 4 on the other side. Replace the recoating roller and recoating plates...
  • Page 263 Remove the roller by pulling it towards you, and place it gently on a table or flat surface. Insert the new recoating plates. Carefully insert the new recoating roller by placing it and pushing it to the end. NOTE: The gears should be on the right when placing the roller. Chapter 11 Hardware maintenance...
  • Page 264 Align the plates with the line as shown below. Secure the recoating roller with the top four screws. TIP: Hold the plate up while tightening the top screws. Put back the front lid of the recoating unit, but do not insert the screws yet. Slightly rotate the recoating unit in both directions with your hand, ensuring that the roller gears are correctly engaged.
  • Page 265 Finish the replacement The following steps provide the complete procedure for this topic. Close the top cover. Ensure that all windows, covers, and doors are closed and remain in their original positions. Replace the bottom glass of the heating lamps The following sections provide details for this topic.
  • Page 266 Table 11-22 Warning labels Risk of burns Crush hazard Risk of trapped Hazardous moving Light radiation Electric shock fingers part hazard hazard For more safety information, see Safety precautions on page 4 ■ Remove the fusing-lamp module on page 127. Replace the fusing-lamp external glass The following steps provide the complete procedure for this topic.
  • Page 267 Insert the new glass into the frame. Add the bottom glass and then the frame, securing it with four screws. Reassemble the fusing-lamp module The following steps provide the complete procedure for this topic. ■ Reassemble the fusing-lamp module on page 132.
  • Page 268 Avoid any pressure on the flat base. When installing IR emitters ● HP recommends that you wear protective goggles when installing or replacing emitters, to protect yourself from broken glass that you may come into contact with. ● The safety and functional reliability of the IR heating device are guaranteed only when using original accessories and spare parts from HP.
  • Page 269 Remove the exterior glass. Pull the metallic clip and remove the internal glass. Remove the lamp, by pulling it upwards. Insert the new lamp. Chapter 11 Hardware maintenance...
  • Page 270 Insert the new internal glass into the two rear brackets, and pull the metallic clip to insert the other side. Add the frame with the bottom glass, securing it with four screws. Reassemble the fusing-lamp module The following steps provide the complete procedure for this topic. ■...
  • Page 271 At the printer’s front panel, tap the Maintenance icon , then Heating lamps to see the status of each lamp. Any lamp identified as faulty should be replaced by a functional lamp: tap the Settings icon , then Utilities > Maintenance > Replace parts > Replace heating/fusing lamps. The lamps are numbered;...
  • Page 272 Unscrew four captive screws to remove the heating-lamp bottom glass. Pull the bottom glass out of the top cover and place it gently on a table. Remove a heating lamp...
  • Page 273 Identify which lamp you intend to replace. Remove the two screws. Remove the old lamp by sliding it out to disconnect it from its connector, then dispose of it according to local regulations. CAUTION: It is important not to touch the lamps with your fingers. Always wear cotton gloves to handle the lamps.
  • Page 274 Avoid any pressure on the flat base. When installing IR emitters ● HP recommends that you wear protective goggles when installing or replacing emitters, to protect yourself from broken glass that you may come into contact with. ● The safety and functional reliability of the IR heating device are guaranteed only when using original accessories and spare parts from HP.
  • Page 275 At the front panel, tap the Settings icon , then Utilities > Maintenance > Replace parts > Heating lamps replacement. Next time you switch on the printer, you can check the heating lamp status in the front panel’s Supplies app. Replace an intermediate tank The following sections provide details for this topic.
  • Page 276 Follow strictly the instructions on the front panel. First you will need to remove the F1 or D1 tank and replace it by a new one. After a while, the front panel will tell you to do the same with the F2 or D2 tank.
  • Page 277 Prepare for replacement Ensure that you have the printer user maintenance kit. Ensure that the printer is not printing. Turn off the printer. If a job has just been printed, wait about 20 minutes for the printer to cool down. You are required to wear gloves and goggles.
  • Page 278 Slide in the new collector. CAUTION: Proper maintenance and genuine HP consumables are required to ensure that the printer operates safely as designed. The use of non-HP consumables (supplies, filters, accessories) may present a risk of fire. Finish the replacement The following steps provide the complete procedure for this topic.
  • Page 279 Consult your local authorities to determine how to dispose of the old collector. Cooling plate maintenance The cooling plates should be cleaned after each job printed (daily maintenance), but after the fifth consecutive job, the weekly maintenance should be performed. These are the cooling plates: Maintenance steps (daily maintenance) Perform this cooling plate maintenance procedure after every job.
  • Page 280 Wipe the area with a cloth dampened with deionized water. Cooling plate maintenance (Weekly) Perform this maintenance procedure weekly on the cooling plates. ■ Wipe the area with a cloth dampened with an industrial cleaner like Simple Green. Replace the material extraction system The following steps provide the complete procedure for this topic.
  • Page 281 Locate the material extraction system doors on both sides of the printer, and choose one to start with. Unscrew the two screws. Open the door. Chapter 11 Hardware maintenance...
  • Page 282 Remove four more screws. Move the material extraction system 5 mm to the front to disengage the positioning pins, and remove it vertically. Insert the new kit and position it using the pins. Attach it with the four new screws provided with the kit. Close the door.

  • Page 283: Processing-Station Maintenance

    Test that the RCCB works correctly by pressing the test button. ● If the RCCB does not trip when the test button is pressed, this indicates that it has failed. The RCCB must be replaced for safety reasons; call your service representative to remove and replace the RCCB.

  • Page 284: Quick Graphical Reminders Of Frequent Operations

    Table 11-25 Summary of maintenance operations (continued) Frequency Maintenance operation Once a week Clean the exterior of the processing station on page 282 Clean the sieve lid on page 279 Once a year Replace an e-cabinet fan filter on page 293 Safety maintenance of the processing station on page 296 When requested Clean the sieve mesh on page 286...

  • Page 285: Maintenance Operations

    Maintenance operations Clean the sieve The following sections provide details for this topic. NOTE: Before some tasks, the front panel may ask you to clean the sieve. At that point, tap Start and proceed. IMPORTANT: If you do not clean the sieve when requested, the loading time may be affected. Prepare for cleaning The following steps provide the complete procedure for this topic.
  • Page 286 If your vacuum hose is different in diameter from the processing station’s connector, there are three files for adaptors (50, 60, and 65 mm) that you can find in http://www.hp.com/go/jetfusion3Dprocessingstation/support. To use them, first print them out, then remove two screws as indicated below, introduce the printed adaptor, and secure it with the removed screws.
  • Page 287 Clean the loading nozzle sensor Take the loading nozzle and use the hand air blower to blow air on the inner part. IMPORTANT: Do not touch the sensor. If you can see that the sensor is still dirty, or if you accidentally touched it with your hand, wipe the sensor glass clean by rubbing the surfaces lightly with a lint-free cloth moistened with a general- purpose industrial cleaner, such as Simple Green industrial cleaner.
  • Page 288 Ensure that you have an explosion-protected vacuum cleaner and an absorbent all-purpose cloth (these things are not provided by HP). Remove the build unit. You are recommended to wear gloves and goggles. Clean the working area The following steps provide the complete procedure for this topic.
  • Page 289 Clean the inner side of the hood using the same kind of cloth, then close the hood. Clean the outside of the hood using the same kind of cloth. Put back the perforated metal sheet. Clean the build-unit housing The following steps provide the complete procedure for this topic. Open the build-unit door.
  • Page 290 Check the whole processing station for dust, material, or aerosol on covers, doors, and so on. If necessary, clean the processing station further using a vacuum cleaner with a soft brush nozzle. Additionally, you can wipe it with a dry cloth. Clean the processing station The following steps provide the complete procedure for this topic.
  • Page 291 IMPORTANT: Make sure the reusable material collector is properly connected. Disconnect the material cartridge connectors. Place each cartridge connector in the parking area. Tap Continue on the front panel. When prompted by the front panel, remove the external tank collector pipe. Tap Continue on the front panel.
  • Page 292 Take the purge tool from the drawer and place it on the side of the working area. Connect the material loading nozzle to the reusable material collector with the purge tool. CAUTION: Ensure that the hoses are connected properly. The loading nozzle should be connected to the top and the material collector to the side.
  • Page 293 Tap Continue on the front panel. IMPORTANT: Do not disconnect the tubes until the cleaning process has finished. Remove the purge tools and place the material collector and material loading nozzle in the parking position. Tap Continue on the front panel. Clean the sieve.
  • Page 294 Open the vacuum-pump filter door. Disconnect the Ultrasonic converter cable and hang it from the indicated hook. CAUTION: To disconnect the Ultrasonic converter cable, grip the plug and pull it out. Do not pull the cable, which could damage the cable, causing a risk of fire and electric shock. Clean the sieve mesh...
  • Page 295 Use the provided torque wrench tool to release the Ultrasonic converter, by using a fixed wrench to hold the lower shaft and the torque wrench to unfasten the hexagonal adapter. CAUTION: Not using the fixed wrench to hold the lower shaft could damage the mesh irreversibly. Leave the Ultrasonic converter very carefully where indicated, over the foam.
  • Page 296 Unscrew the six knobs to open the sieve cover and hang it from the two hooks. Vacuum the interior of the sieve with a soft-brush nozzle. Unlock the mesh. CAUTION: If you see accumulated material on the mesh, vacuum it using a soft-brush nozzle before unlocking it.
  • Page 297 Remove the sieve mesh and vacuum it. Clean the cone. Vacuum the screw holes and the screws hanging from the cover. Vacuum the sieve perimeter, being careful of the sensors. CAUTION: Damage to the sensors can cause a sieve malfunction. Put back the mesh and lock it..
  • Page 298 Tighten each of the six knobs until you hear a click. CAUTION: Make sure all knobs are properly tightened, to avoid material spillages outside the sieve. Clean the exterior of the sieve area to remove any material that may have fallen there during this procedure.
  • Page 299 Release the connector from the hook and plug it into the converter. Make sure it is well connected. Close the door. Turn on the processing station. Chapter 11 Hardware maintenance...
  • Page 300 Replace the sieve mesh You may sometimes decide to replace the mesh if there is material stuck in it that cannot be removed by cleaning. Follow the same steps as in the reference below, but replace the mesh with a new one, instead of cleaning the old one.
  • Page 301 Remove and dispose of the old filter according to local regulations, and insert the new one. Carefully put back the filter cover. Finish replacement The following steps provide the complete procedure for this topic. Ensure that all windows, covers, and doors are closed and remain in their original positions. Turn on the processing station.
  • Page 302 Locate the e-box fan filter. Remove the indicated screws (x4). Remove the filter cover. Replace an e-box fan filter...
  • Page 303 Remove the filter. Finish replacement The following steps provide the complete procedure for this topic. Install the new filter. Notice that the arrow should appear in the upper part of the filter. Place the cover. Put back the 4 screws. Reset the filter after installation.
  • Page 304 Start the replacement from the front panel, when requested. Clean the door with an explosion-protected vacuum cleaner. HP recommends cleaning the filters through the door grid, to avoid splashing the material when extracting the filters. Ensure that the build unit is inserted.
  • Page 305 Do not touch the filter papers, and always follow the instructions from the manufacturer. Remove the cover locking screws by hand, and open the cover to access the filters. Pull the right-hand filter out of its enclosure. Chapter 11 Hardware maintenance...
  • Page 306 Pull the left-hand filter out of its enclosure. Dispose of the old filters according to local regulations. Vacuum the area with an explosion-protected vacuum cleaner. Insert the two new filters. Take care to insert the filter correctly: the arrow on the side of the filter should point towards the interior of the processing station.
  • Page 307 Clean the handle parking area and the top surface of the material cartridges with an explosion- protected vacuum cleaner. NOTE: Material may leak from the handles. Open the cover. Completely unscrew the knob to release the filter. Rotate the container clockwise to release it. CAUTION: Be careful with the sensor when removing the container.
  • Page 308 Remove the filter and dispose of it according to local regulations. Clean the inside of the container with an explosion-protected vacuum cleaner. Replace the vacuum-pump filter...
  • Page 309 Insert the new filter between the container and the central tube, with the closed end at the top and the open end at the bottom. Rotate the container anti-clockwise. CAUTION: Be careful with the sensor when removing the container. Damage to the sensors can cause a sieve malfunction.
  • Page 310 Clean the sieve lid and bottom area cover with an explosion-protected vacuum cleaner. Close the cover. Place and connect the material cartridges. Replace the external tank The following steps provide the complete procedure for this topic. Start the replacement from the front panel by tapping the Maintenance icon , then External tank >...
  • Page 311 Open the lid by pulling it up, and hang it on the structure. Get the storage lid that came with the external tank when purchased and use it to close the tank. Latch the lid. Use a lift trolley to remove the tank to a storage area. IMPORTANT: The tank should be stored in the same environmental conditions as specified for the processing station, otherwise the material may become unusable.
  • Page 312 Clean the inner side of the lid using an explosion-protected vacuum cleaner. Use a lift trolley to bring the tank that you intend to use. IMPORTANT: Use a trolley only to move the external tank. When the processing station is working, the external tank should be on the floor, at the same level as the processing station.

  • Page 313: Build-Unit Maintenance

    Check that the external-tank collector is connected to the storage-tank cover. The front panel displays the status as ready. CAUTION: Use HP-certified external tanks only. The use of third-party external tanks can cause safety risks, material leakages, and malfunctions in the processing station; and may affect your system warranty.

  • Page 314: Quick Graphical Reminders Of Frequent Operations

    Prepare for cleaning Prepare to clean the surface of the build unit. Ensure that you have a lint-free cloth (not provided by HP). Ensure that you have unpacked any build. Ensure that the platform is in the highest position and the build unit is empty.
  • Page 315 The following steps provide the complete procedure for this topic. Vacuum the build-unit printing platform with the reusable material collector. After using certain materials, such as TPU Ultrasint, HP recommends using an ATEX external vacuum cleaner instead of the reusable material collector.
  • Page 316 Remove the front and rear vane feeders by pressing each feeder against the wall and moving it aside. Clean the build unit...
  • Page 317 Use the reusable material collector to vacuum the vane feeders that you removed. Attach the crevice nozzle to the reusable material collector. Vacuum the front and rear feed trays. Pay special attention to the corners of the trays and underneath the mesh shaker. IMPORTANT: Do not use the wide nozzle for this operation.
  • Page 318 Clean the build unit...
  • Page 319 Clean the feed tray cavities with a cloth, making sure that no solidified material is left. Try to remove as much material as possible. The result should be at least as clean as shown below. Clean the recoating unit wiper at the rear. Chapter 11 Hardware maintenance...
  • Page 320 Clean the front and rear vane feeders with a cloth. Also use a spiral scourer if necessary to remove all material. Vacuum the feed trays again, making sure there is no material left. Vacuum the overflow trays. Clean the build unit...
  • Page 321 Attach the wide nozzle to the reusable material collector. Vacuum the build unit platform. Finish cleaning The following steps provide the complete procedure for this topic. Chapter 11 Hardware maintenance...
  • Page 322 Put the vane feeders back into their original positions. Finish cleaning...
  • Page 323 The following steps provide the complete procedure for this topic. Ensure that you have an explosion-protected vacuum cleaner, an absorbent all-purpose cloth, and deionized water (these things are not provided by HP). You are recommended to wear gloves, mask, and goggles.
  • Page 324 Ensure that the bottom part of the machine resembles the picture on the right. Remove the bottom of the Build Unit flat sump by removing the four screws that secure it to the rest of the sump parts; two are in the front and two are in the rear. Empty the powder accumulated in the bottom flat sump and clean it with a cloth if needed.
  • Page 325 Use a vacuum cleaner to remove the powder from the bottom area around the lead screw and platform transmission. WARNING! Be careful not to damage any cable with the vacuum cleaner. If needed, clean the surface of the ground and the area around the lead screw with a cloth, to remove the mix of powder and grease that is stuck to the various surfaces.
  • Page 326 Remove the build unit from the printer. Replace the build-unit material-chamber filters The following steps provide the complete procedure for this topic. Locate the filters at the bottom left and right of the build chamber. Pull off the filter assembly. Replace the build-unit material-chamber filters...
  • Page 327 Separate the felt of the filter from the grid retainer and the guard. Dispose of the old felt according to local regulations, and carefully insert the new felt between the grid retainer and the guard. Put the fan filter assembly back in place. Clean the column gasket The following sections provide details for this topic.
  • Page 328 The following steps provide the complete procedure for this topic. Ensure that you have an explosion-protected vacuum cleaner, an absorbent all-purpose cloth, and deionized water (these things are not provided by HP). You are recommended to wear gloves, mask, and goggles.
  • Page 329 Loosen the screws that secure the left Build Unit window to the Build Unit structure. There are six screws on the HP Jet Fusion 5200 3D Build Unit. Remove the left Build Unit window. Chapter 11 Hardware maintenance...
  • Page 330 Clean the surface of the column gasket, if necessary. The following images shows an example of a column gasket with powder that needs to be cleaned. Visually inspect the column gasket sealing. Ensure that there is no powder on top of the gasket, as seen in the following image.

  • Page 331: Move Or Store The Product

    This topic explains the concepts involved in this subject. IMPORTANT: If your HP Jet Fusion 3D Printing Solution needs to be moved to a different location or room, you should contact your reseller for assistance. This product has sensitive components that can be damaged during transportation: special transportation features and tools are needed.
  • Page 332 Check that your material cartridges and printheads have not passed their expiration dates. ● Check that you are using the most appropriate settings for your purposes. For the latest information, go to the HP website at the following links: ● http://www.hp.com/go/jetfusion3D5200/support ●...
  • Page 333 Entering the Diagnostics menu (service boot-mode) The following steps provide the complete procedure for this topic. Read all steps before starting. Ensure that the printer is switched off using the power button on the side of the front panel, and not with the main power switch of the printer.
  • Page 334 The CBA sequence is as shown in the following image: After five seconds, if the diagnostic input sequence is successful, the printer will boot in the diagnostics bootmode. If the sequence fails, the printer will boot in default printer bootmode. Wait until the printer completes the initialization sequence and shows the Diagnostics menu.
  • Page 335 Printhead health troubleshooting Align the printheads The following sections provide details for this topic. Printhead alignment is recommended in these situations: ● After replacing or reseating a printhead ● After a printhead crash ● When there are print-quality problems that could be caused by printhead misalignment, such as: –...
  • Page 336 – Printhead-to-printhead misalignment along the Y axis If there is a printhead-to-printhead misalignment along the Y axis, parts that are printed in the printhead-to-printhead boundary area may be larger or smaller than parts printed by a single printhead. NOTE: If the paper is moved out of the printer by mistake during the alignment process, restart the process.
  • Page 337 Semi-automatic printhead alignment Tools required This topic explains the concepts involved in this subject. ● HP OfficeJet Pro 7740 multi-function printer or HP OfficeJet 7612 scanner (for Japan and Asia/ Pacific regions) ● HP OfficeJet Pro 9010 / 9015 and 9020 scanners.
  • Page 338 Figure 12-2 Poorly aligned examples Troubleshooting The printer may display the following message: ERROR during the analysis of the plot, printheads are not aligned. The plot scanned will be displayed. To respond to this message, read this section. An example of a correctly scanned plot is shown below. Troubleshooting...
  • Page 339 ● If the image is blank, probably the printed plot is not present in the scanner, or it is facing up. Ensure that the plot is in the scanner, facing down, and aligned according to the instructions; then try again. ●...
  • Page 340 In order to perform the alignment, a pattern is printed. Check the pattern. For every letter, choose the line that is continuous (with no break in the middle), and enter at the front panel the number next to the continuous line. If you see several lines that seem continuous, choose the middle one.
  • Page 341 Check that the alignment has been done correctly by tapping Print diagnostic plot from the settings icon on the Printheads page. Place the tool covered by paper in position 1 again; and, after printing, check that the triangle is next to the continuous line in all cases. If it is, the alignment is correct.
  • Page 342 The printhead Health Gauge has three levels: ● There is no problem with the printhead nozzles. ● The printhead has relatively few clogged nozzles. This is unlikely to produce any defects in the printed parts, but it could happen. ● The printhead has more clogged nozzles, which may produce defects in the printed parts.
  • Page 343 Tap the Maintenance icon , then Printheads > Settings > Printhead status plot, then follow the instructions on the front panel. The following screen appears. The lists show the number of clogged nozzles in each die for each agent, Detailing Agent (DA) and Fusing Agent (FA).
  • Page 344 ● There could be a connection problem in the affected printhead. Try reseating the affected printhead, Replace a printhead on page 113 (after removing the printhead, you can reinsert the same printhead). After these actions, run a printhead recovery 1 routine to force a health status update. See Recover (clean) the printheads on page 350.
  • Page 345 Random nozzles out have a much lower impact on mechanical properties than consecutive nozzles out. It is not easy to estimate the percentage of nozzles out visually; therefore some aids are provided in the table below. Table 12-2 Nozzles Nozzles out Effect on mechanical properties View No risk of defects...
  • Page 346 Table 12-2 Nozzles (continued) Nozzles out Effect on mechanical properties View Low risk of defects High risk of defects High risk of defects Identify: Fusing This section shows small groups of consecutive nozzles. A group of more than a certain number of consecutive nozzles out can produce a flaw in the part.
  • Page 347 You are more likely to see a small number of consecutive nozzles out. The identify pattern allows you to check in which areas there could be a problem and decide whether the number of consecutive missing nozzles could produce defects. The table below summarizes the impact. Table 12-3 Consecutive nozzles out Low risk of impact on mechanical properties: 1 to 4 sequential...
  • Page 348 An example is shown below. The yellow lines represent areas with possible defects; the red lines represent areas with probable defects; the blue ellipses enclose parts affected by the defective nozzles. On the left, a number of parts are affected by yellow and red lines; on the right, the parts have been rearranged so that only one part is affected by a yellow line.
  • Page 349 Cross contamination troubleshooting What is cross contamination Cross contamination can manifest as grey light melted burrs or fins, light lines, or areas on the surface of parts going along the carriage axis (right to left of the bed). How can we detect it Cross contamination can be detected on the parts printed, the printhead status plot, or via automatic detection.
  • Page 350 On parts printed...
  • Page 351 Figure 12-4 Light marks or lines Figure 12-5 Areas On a printhead status plot Zooming in on the status plot (focusing on Printhead 3 in this example), we can see that the part which should be completely clean of fusing agent instead contains some amount of it. Once seen, the printhead troubleshooting must be started.
  • Page 352 Automatic detection During the warmup process we do the Heimann Optical Calibration, where we print a pattern of 11x10 circles with Detailing Agent. When finishing the calibration, we run a script which takes images of the calibration and looks for hot 0085-0008-0099 –...
  • Page 353 Possible causes and solutions Detailing agent is dirty due to a dense wide part with its edge(s) aligned to the defect This topic describes what to do if the detailing agent is dirty due to a dense wide part with its edge(s) aligned to the defect.
  • Page 354 Solution: move the parts slightly off one from the other so that their edges are not exactly aligned, as shown (the same would be done for the other two groups not highlighted). Detailing agent has a group of clogged nozzles in that area Check the printheads Health Gauge through the Front Panel.
  • Page 355 Solution: Check the printhead caps (rubber caps) at the right side of the printer: they should be flat and well-adjusted on their supports. Detailing agent is dirty due to an internal printhead problem Run the “Detailing agent cleanliness” diagnostic: Settings > Part Quality troubleshooting > Other diagnostics >...
  • Page 356 Solution: when the detailing agent is clean, only black fusing lines appear in the pattern. The dirty detailing agent appears as dots or grey lines parallel to the left side of the black ones. A clean detailing agent (leftmost image) indicates that the cross-contamination detected was external and the dirtied agent has been ejected from the printhead.
  • Page 357 However, If the pen rubber caps are detected to be wrongly adjusted, it is recommended to run a second DA cleanliness routine. A wrongly adjusted rubber cap in combination with an idle printhead for a long period of time (a few days) can contaminate a volume of agent big enough that a single DA cleanliness execution is not able to clean the pen completely.
  • Page 358 After every job, observe the powder surface and check for horizontal lines. After every job and before cleaning, check the undercarriage and look for powder traces on the printheads. Remove the printheads and inspect the printhead seals from the top. If any defects are detected, take pictures and report the issues to Remote Support Service.
  • Page 359 Build Unit to print chamber seal gaps (recoater seal) Follow the steps in the exact order presented. Turn the printer off. Inspect the left and right corners of the Build Unit seal and verify that there are no gaps. Chapter 12 Troubleshooting...
  • Page 360 Ensure that the white rubber seal is intact, undamaged, and remains continuous along its entire length. If any defects are detected, take pictures and report the issues to Remote Support Service. Hatch under curtain (curtain cap) Follow the instructions in the exact order presented. Turn the printer off.
  • Page 361 Verify that the curtain cap sheet is flat, has all screws installed, and is otherwise well installed. Verify that there are no lines on top of the recoater carriage after a job. In the following picture,some lines that indicate a potential air leakage in the curtain cap are visible. If any defects are detected, take pictures and report the issues to Remote Support Service.
  • Page 362 HP 3D HR PA 12 300 L / 130 kg Material V1R18A HP 3D HR PA 11 300 L / 140 kg Material V1R34A HP 3D HR PA 12 300 L / 130 kg P Material V1R36A HP 3D HR PA 11 300 L / 140 kg P Material V1R20A...
  • Page 363 System errors The following sections provide details for this topic. Introduction The system may occasionally display a system error, consisting of a numerical code of 12 digits followed by the recommended action that you should take. In most cases you will be asked to restart the equipment. When the printer or processing station starts, it can diagnose the issue better and may be able to fix it automatically.
  • Page 364 Table 14-1 Troubleshooting system errors When required System error 0010-0159-0001 Power Box - Interlock chain malfunction 0010-0159-0001 Power Box - Interlock chain malfunction on page 358 0016-0002-0005 Top Heating - Build bed temperature not 0016-0002-0005 Top Heating - Build bed temperature not reached reached on page 359 0050-0060-0142 Cooling - Exhaust system fan 1 out of...
  • Page 365 Table 14-1 Troubleshooting system errors (continued) When required System error 1030-0021-1001 Build Unit heating - BU heating control 1030-0021-1001 Build Unit heating - BU heating control PCA 3 fan fault PCA 3 fan fault on page 377 0010-0159-0001 Power Box - Interlock chain malfunction Error locking doors to rearm.
  • Page 366 If the issue cannot be fixed, no issues are found, or the system error reappears in the next print, then open a case with HP support. Provide details of the findings and actions taken from the above steps, along with the images.
  • Page 367 Check if the powder surface on the platform of the Build Unit is uniform and powder is spread all over the BU platform. Issues with the powder spreading or an air leakage in the system could cause irregularities in the powder surface. Take a picture of the powder surface after the error for HP support to analyse.
  • Page 368 If the issue cannot be fixed, no issues are found, or the system error reappears in the next print, then open a case with HP support. Provide details of the findings and actions taken from the above steps, along with the images.
  • Page 369 ● Check the sealing between the covers that connect the right cooling tower with the exhaust inlet (the black covers on top of the top cover), the foam needs to be correctly placed. ● Go to Settings → Utilitites→ System Tools → System Checks → Check Exhaust to verify that the external extraction system works correctly if one is installed.
  • Page 370 If the issue cannot be fixed, no issues are found, or the system error reappears in the next print, then open a case with HP support. Provide details of the findings and actions taken from the above steps, along with the images.
  • Page 371 If the issue cannot be fixed, no issues are found, or the system error reappears in the next print, then open a case with HP support. Provide details of the findings and actions taken from the above steps, along with the images.
  • Page 372 0085-0008-0193 Carriage - Printhead 1 (rear) electrical error Printhead voltage out of range (FAILS_CONTINUITY). 0085-0008-0293 Carriage - Printhead 2 (middle) electrical error Printhead voltage out of range (FAILS_CONTINUITY). 0085-0008-0393 Carriage - Printhead 3 (front) electrical error Printhead voltage out of range (FAILS_CONTINUITY). Suggested steps: ●...
  • Page 373 If the error stays with the position and doesn’t move with the Printhead, in the diagnostic mode perform the 0085-01 “Check electronics” for each of the Printhead Interconnect boards and take a picture of the front panel in case an error occurs. Then contact HP Support. Printhead troubleshooting tree: 0085-0008-0182 Carriage - Printhead 1 (rear) data communication error Printhead CSDATA not responding.
  • Page 374 If the issue cannot be fixed, no issues are found, or the system error reappears in the next print, then open a case with HP support. Provide details of the findings and actions taken from the above steps, along with the images.
  • Page 375 If the issue cannot be fixed, no issues are found, or the system error reappears in the next print, then open a case with HP support. Provide details of the findings and actions taken from the above steps, along with the images.
  • Page 376 If the issue cannot be fixed, no issues are found, or the system error reappears in the next print, then open a case with HP support. Provide details of the findings and actions taken from the above steps, along with the images.
  • Page 377 ● Perform the cleaning of the recoater curtain wipers. See Clean the recoating unit curtain wipers on page 196 ● With the printer Off, Remove the recoater right box cover which protects the recoater motor and chain and take some pictures from different angles and distances. ●...
  • Page 378 If the issue cannot be fixed, no issues are found, or the system error reappears in the next print, then open a case with HP support. Provide details of the findings and actions taken from the above steps, along with the images.
  • Page 379 ● Perform the weekly cleaning of the recoater roller and especially take care of the right side where the gears are located. See Clean the recoating roller and recoating plates on page 167. ● Check the recoater roller for wear, in particular the gear on the right side. ●...
  • Page 380 If the issue cannot be fixed, no issues are found, or the system error reappears in the next print, then open a case with HP support. Provide details of the findings and actions taken from the above steps, along with the images.
  • Page 381 ● If you print with a non PA powder and one of the material trays has less powder than expected, the root cause is probably a “rathole” in the material tank (powder compaction in the tank which inhibits the material flow to the material lifters). In this case empty the Build Unit, manually clean the inside to break compacted powder, and fill again.
  • Page 382 If the issue cannot be fixed, no issues are found, or the system error reappears in the next print, then open a case with HP support. Provide details of the findings and actions taken from the above steps, along with the images.
  • Page 383 ● Check if the vanes are inserted correctly and turning freely without touching or scratching the material trays. ● Check if the vane couplings on both sides of the vanes are loose or damaged. ● Check if the vane lockers provide enough strength to keep the vanes in position. ●...
  • Page 384 If the issue cannot be fixed, no issues are found, or the system error reappears in the next print, then open a case with HP support. Provide details of the findings and actions taken from the above steps, along with the images.
  • Page 385 This can easily be achieved by rotating the part at a certain angle: HP recommends rotating the part more than 20 degrees to minimize stair-stepping.
  • Page 386 Where X is the number of the printhead. Clean the printhead contacts: see Clean the printhead contacts on page 206. If the problem persists, swap the printhead with another to check whether the problem moves to the new location of the original printhead. If this is the case, replace the printhead: see Replace a printhead on page 113.
  • Page 387 If the problem persists, swap the printhead with another to check whether the problem moves to the new location of the original printhead. If this is the case, replace the printhead: see Replace a printhead on page 113. 0085-0008-0X93 Carriage – Printhead – Fails continuity The following steps provide the complete procedure for this topic.
  • Page 388 If the problem persists after fixing the connection, it is also possible that the primer itself is broken. In this case, replace the corresponding primer. See Replace a primer on page 229. 0085-0013-0X33 Carriage – Primer – Current too high Where X is: Primer on Printhead 1 Primer on Printhead 2...
  • Page 389 This topic explains the concepts involved in this subject. Support is provided by your support representative: usually from the company from which you bought the printer. If this is not the case, contact HP Support on the HP Web site at the following links: ●...
  • Page 390 Accessibility Front panel If required, the front-panel display brightness and the loudspeaker volume can be changed. Change system options on page 29 Accessibility...
  • Page 391 Index unit selection 29 front-panel options administrator password 30 options, system 29 date and time options 29 agents 107 order supplies 355 restore factory settings 29 replace 108 fusing lamps troubleshoot 111 replace 126 air conditioning 11 part air extraction 12 clean 96 airflow check 350 postprocess 96...
  • Page 392 SolidWorks settings 45 status center 28 STL file repairs 46 STL problems 46 storage tank 145 support 382 system options 29 tank 145 tesselation 44 tools 14 unpacking 77 ventilation 11 warning labels 15 warnings 15 Index...

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