Ultimaker S3, S5 R2 Repair Manual

Introduction

Due to Chipageddon, some changes were implemented to the S-line electronics. The SOM board now no longer has integrated Ethernet functionality, so the addition of a separate USB dongle is required. The Wi-Fi connector has changed, which means the Wi-Fi antenna also must be replaced

Requirements

Tools

• ESD prevention supplies
• Torque screwdriver (0.5 Nm)
• 2.0 mm hex bit
• 2.0 mm hex screwdriver
• Safety plug (recommended)
• Door fixation tools (recommended)

Parts
1x 234906 – S-line electronics assembly, including the following parts

• SMARC Mainboard + SOM + Wi-Fi module assembly
• USB dongle
• Wi-Fi antenna

Notes

Ultimaker S-line printers are powered by mains voltage, which is hazardous when touched. Turn off the printer and disconnect the power cable before starting this procedure.

This repair involves working with or exposing sensitive electronic components. Take ESD precautions before starting this procedure.

Note: When replacing this complete electronics assembly, the USB dongle must be installed to ensure Ethernet functionality. Due to the different sized connector on the Wi-Fi module, also replace the Wi-Fi antenna or transfer the old Wi-Fi module to the new mainboard.

Tip: All orientations are as seen from the front in the upright orientation, unless specified otherwise.

Disassembly

1. Secure the door(s).
   Place the door fixation tools between the glass doors (Ultimaker S5) or between the door and front panel (Ultimaker S3) to keep the door(s) in place.
   Tip: This prevents the door(s) from falling open when handling the printer.
2. Lay down the printer.
   Gently place the printer on its left side, with the bottom facing towards you. Do not place the printer on its back; this could damage the feeders.
3. Remove the bottom cover.
   Remove the two bolts to loosen the bottom cover. Pull the cover away from the printer and place it aside.
   Note: If the bottom cover contains a speaker, disconnect this from the mainboard first.
4. Open the terminals.
   Push open the orange latches of the gray terminals on either side. Remove the two white heater wires from 'HEATED BED' and remove the 24V wires from 'RED BLACK'.
5. Disconnect all wires.
   Carefully disconnect all wires from the mainboard, SOM, and Wi-Fi module. Ensure to pull on the connector, not the wires.
   Tip: You do not have to open any of the cable clips.
6. Remove the Wi-Fi antenna.
   Peel the Wi-Fi antenna away from the side panel and discard it.
   Note: If you want to keep the Wi-Fi antenna and transfer the old Wi-Fi module, see the instructions in the appendix.
7. Remove the mainboard.
   Remove the six M3x12 bolts that secure the mainboard to the bottom panel. Pull the electronics assembly away from the bottom panel.
8. Check the thermal conductive pads.
   If they stuck to the bottom panel, leave them in place. If they stuck to the mainboard, remove them from the board.
   Tip: Instructions were to place them on the new board are in the reassembly section.

Reassembly

1. Place the thermal conductive pads.
   Align the two thermal conductive pads with the markings on the bottom panel. Firmly push them so they stick to the panel.
   Tip: If the thermal conductive pads remained stuck to the bottom panel, skip this step. Ensure they are firmly stuck before proceeding.
   
2. Secure the board.
   Align the electronics assembly with the six holes in the bottom panel. Secure it in place with the M3x12 bolts and tighten them to 0.5 Nm.
3. Place the Wi-Fi antenna.
   Remove the liner from the back of the Wi-Fi antenna. Stick the antenna to the side panel in the marked area, with the wire toward the front of the printer.
   Note: If you want to keep the Wi-Fi antenna and transfer the old Wi-Fi module, see the instructions in the appendix.
   
4. Prepare the USB dongle.
   Take the USB dongle from the packaging. Place a piece of double-sided tape (max. 20 x 90 mm) on the bottom of the dongle.
5. Connect the USB dongle.
   Connect the wire of the USB dongle to the USB port on the mainboard. Connect the USB cable from the front panel to the first USB port on the dongle. Connect the Ethernet cable from the back panel to the end of the dongle.
   
6. Place the USB dongle.
   Stick the USB dongle to the bottom panel (EMC plate) in the location as indicated below. Please note the correct orientation

Ultimaker S3
Place the dongle straight against the power supply, with the Ethernet port towards the back of the printer.

Ultimaker S5 R2
Place the dongle at an angle in the middle of the printer as indicated, with the Ethernet port towards the front.

8. Connect all wires.
   Reconnect all the wires to the new electronics assembly according to the overview on the next page.
   Note: When connecting the wires, place the camera and HDMI cable over the USB dongle wire. This helps to ensure the dongle stays in place.

When connecting the heated bed and 24V wires, ensure they are fully inserted into the terminals. Firmly push the latches to close them. Gently pull at each individual wire in the terminals to ensure they are securely connected.

8. Place the bottom cover.
   When all wires are correctly reconnected, align the bottom cover with the printer. Secure it with the two bolts. If the bottom cover has a speaker, reconnect this first.
9. Place the printer upright.
   Carefully place the printer in its upright position again. You can now remove the door fixation tools.
   Tip: Do not connect the power cable and turn on the printer yet. First follow the instructions for provisioning on the next page.

Overview

Ultimaker S3/S5-R2

Provisioning and firmware update

After installing the new electronics assembly, the board must be provisioned with the correct file to set the printer's identity: Ultimaker S3 or Ultimaker S5R2.

1. Download the article number
   Download the correct article number file. Ensure to select the correct printer type (Ultimaker S3 or Ultimaker S5) and the version with the USB dongle. Unzip the file. Do not make any changes to the file or file name.
2. Prepare the USB drive
   The USB drive does not need to be empty, but ensure no other provisioning files are on the USB drive. Place the file named "article_number" in the root directory of a USB drive.
3. Insert USB drive
   Insert the USB drive with the article number file into the USB port at the front of the printer.
4. Provisioning process
   Insert the power cable into the power entry at the back of the printer. Turn on the printer with the power switch. As the machine boots up, the board will be provisioned automatically.

Note: As the printer is booting up, you might see the machine type shown on the display change. This is normal.

Tip: Remove the USB drive from the printer and delete the article number file from the USB drive after the provisioning is finished. This eliminates the risk of accidentally wrongly provisioning other printers.

Once the printer has finished powering on, check if the latest firmware is installed. It is recommended to connect the printer to a network and update the firmware via the display menu. This will ensure the correct version is installed.
If you prefer to install the firmware via USB, it is important to use the firmware version for the printer with the USB dongle.

Unit calibrations

Replacing the electronics will have reset all printer functions, including those set by the factory. After powering on the printer for the first time, the following calibrations must be redone:

• Lift switch calibration. This sets the correct position for the switch bay. Perform this calibration first to enable correct print core switching.
  Go to Preferences – Maintenance – Print head – Calibrate lift switch. Follow the instructions on the display or visit the support page for more information.
• Manual build plate leveling. To set the correct base level for the printer to use in the active leveling process, perform a manual calibration.
  Go to Preferences – Maintenance – Build plate – Manual leveling. Follow the instructions on the display or visit the support page for more information.
• XY calibration. The XY offset for all print core combinations must be recalibrated to ensure that the nozzles align well in dual extrusion prints. Ensure you have two materials loaded. Go to Preferences – Maintenance – Print head – Calibrate XY offset. Follow the instructions on the display or visit the support page for more information.

Transfer the Wi-Fi module

The Wi-Fi module on the new electronics assembly has a different sized connector. For this reason, it is not compatible with the older Wi-Fi antenna.
If you do not want to replace the Wi-Fi antenna and Wi-Fi module, you can transfer the old Wi-Fi module from the old mainboard to the new board.

Note: If your printer already has the USB dongle and the new Wi-Fi antenna prior to replacing the electronics, you do not need to transfer the Wi-Fi module.

To keep the old Wi-Fi antenna, you can skip step 6 of the disassembly process and step 3 of the reassembly process.

Removing the Wi-Fi module

After removing the old electronics assembly, place it in front of you with the Wi-Fi card towards you. The module is held in place with a small clip. Carefully pull this back a bit and move the module upwards to remove it.
Repeat this for the Wi-Fi module on the new board.

Installing the Wi-Fi module

Take the old Wi-Fi module and align it with the new mainboard. Slide the side with the golden connection points into the connector on the mainboard. Lower the other side of the Wi-Fi module and give it a small push to lock it into the clip.

After installing the new electronics assembly, reconnect the Wi-Fi antenna to the connector marked 'M', as indicated in the Overview.

Questions?
If you have any questions or comments about this repair process, please contact the support team by submitting a case via support.ultimaker.com.

Ultimaker HQ
Stationsplein 32
3511 ED Utrecht
The Netherlands
info@ultimaker.com
ultimaker.com
+31 883 83 40 00

Documents / Resources

References

• Support Community
• UltiMaker: Professional 3D Printers that Empower Innovation

Download manual

Here you can download full pdf version of manual, it may contain additional safety instructions, warranty information, FCC rules, etc.

Download Ultimaker S3, S5 R2 Repair Manual