HP DESIGNJET 3D User manual

HP Designjet 3D
HP Designjet Color 3D
Service Guide

Legal Notice
The information contained herein is subject
to change without notice.
The only warranties for HP Products and
services are set forth in the express warranty
statement accompanying such products and
services. Nothing herein should be
construed as constituting an additional
warranty. HP shall not be liable for technical
or editorial errors or omissions contained
herein.
© 2012 Hewlett-Packard Development
Company, L.P.
Rev. C
Microsoft®and Windows®are U.S. registered
trademarks of Microsoft Corporation.
.
Conforms to ANSI/UL std. 60950-1-2003
Certified to CAN/CSA C22.2 no. 60950-1-03
HP Designjet 3D and HP Designjet Color 3D
conform with the following standards, in accordance with the
EU Machinery, Low Voltage and Electromagnetic
Compatibility Directives: EU 98/37/EEC, EU 73/23/EEC
amended by 93/68/EEC, EU 89/336/EEC

-3

Table of Contents
Introduction .....................................................................................................1
How to use this guide ......................................................................................................1
Safety............................................................................................................................2
Overview .........................................................................................................3
What happens when... ...........................................................................................3
Powering up: .........................................................................................................3
Powering Down .....................................................................................................4
Loading Material....................................................................................................4
Building a Part .......................................................................................................4
Electronics Overview ..............................................................................................6
Single Board Computer...........................................................................................7
Controller Board ....................................................................................................8
Overview ..............................................................................................................8
Voltage Generation ................................................................................................8
Dual Port Memory Interface .....................................................................................8
X, Y, Z Axis Control................................................................................................8
Material Motor Control ...........................................................................................8
Temperature Control ...............................................................................................8
Liquefier Temperature Control ..................................................................................9
Actuators, Switches & Optical Sensors ......................................................................9
Safety Devices .....................................................................................................10
Controller Board Layout ........................................................................................10
Reset Button .........................................................................................................11
Dip Switches........................................................................................................11
SW2 ..................................................................................................................12
SW5 ..................................................................................................................12
SW6 ..................................................................................................................12
Memory ..............................................................................................................12
LEDs ...................................................................................................................12
Power Distribution Board (PDB) ..............................................................................14
Chamber Temperature Control...............................................................................15
Test Points and LED’s ............................................................................................16
I/O Card ............................................................................................................18
Head Board ........................................................................................................19
Printer overview ...................................................................................................20

Setup ............................................................................................................25
Installing software .........................................................................................................25
Installing HP Designjet 3D Software Solution:......................................................25
Installing firmware to the workstation: ................................................................25
Networking the printer...................................................................................................25
Connecting through a network: .........................................................................25
Connecting directly to a workstation: .................................................................25
Establishing network communication with the printer .........................................................26
Establishing communication on a dynamic network: ............................................26
Establishing communication on a static network: .................................................27
Setting the static network in Windows XP: ..........................................................27
Setting the static network in Windows Vista:.......................................................27
Setting the static network in Windows 7:............................................................28
Setting the static network on printer: ..................................................................28
Establish communication: .................................................................................29
Installing Firmware on printer .........................................................................................30
Adding the second HP Designjet 3D Material Bay.............................................................31
Installing the HP Designjet 3D Material Bay: ....................................................... 31
Operation ......................................................................................................37
Display panel and keypad .............................................................................................37
System firmware overview..............................................................................................38
HP Designjet 3D Software Solution overview ....................................................................39
Processing your STL file for printing .................................................................................40
Opening your STL file with HP Designjet 3D Software Solution:.............................40
Selecting layer resolution:.................................................................................40
Selecting model interior fill style: .......................................................................40
Selecting support style:.....................................................................................41
Selecting the scale of your STL file: ....................................................................41
Selecting the orientation of your STL file: ............................................................41
Adding your STL file to the pack:.......................................................................42
Printing your STL file: .......................................................................................42
Building a part .............................................................................................................43
Starting a build from a remote location: .............................................................43
Starting a build from the display panel:..............................................................43
The display panel during build .......................................................................................44
Chamber Lights.............................................................................................................44
Pausing a build.............................................................................................................45
Resuming after pause ....................................................................................................45
Canceling a build .........................................................................................................45

Removing a completed part............................................................................................46
Remove a part from the modeling base: .............................................................46
Removing support material.............................................................................................46
Emptying the purge bucket .............................................................................................47
Replacing material for single material bay .......................................................................47
Replacing material for dual material bays ........................................................................48
Material bay LEDs.........................................................................................................49
Replacing material spools ..............................................................................................50
Removing a spool of material from the carrier:....................................................50
Storing material spools ..................................................................................................50
Auto power down .........................................................................................................52
Cancelling auto power down:...........................................................................52
Powering off.................................................................................................................53
Resuming operations from Standby mode ........................................................................53
Updating printer firmware:.............................................................................................53
Installing the firmware:.....................................................................................53
Software ........................................................................................................55
Software Architecture ....................................................................................................55
Operating System .........................................................................................................55
Display Driver ..............................................................................................................55
Comm Server ...............................................................................................................56
System Manager...........................................................................................................56
Move Compiler.............................................................................................................56
Feeder.........................................................................................................................56
Event/Command Monitor...............................................................................................56
HP Designjet 3D Software Solution Help ..........................................................................57
HP Designjet 3D Software Solution overview ...........................................................57
Conventional help file ...........................................................................................57
Dynamic help ......................................................................................................57
Maintenance ..................................................................................................59
Startup kit tools.............................................................................................................59
Preventive Maintenance .................................................................................................59
Daily ..................................................................................................................59
Empty the purge bucket....................................................................................59
Inspect the tip wipe assembly............................................................................59
Inspect the tip shields.......................................................................................59
Remove debris buildup.....................................................................................59
Vacuum build chamber ....................................................................................59
Clean door.....................................................................................................59

500 Hour maintenance..................................................................................................60
Tip wipe assembly................................................................................................60
Tip shield replacement ..........................................................................................62
Remove debris from the Filament Present switch .......................................................64
2000 Hour maintenance................................................................................................66
Tip replacement and calibration.............................................................................66
Removing tips: ................................................................................................66
Installing tips:..................................................................................................68
Tip calibration: ...............................................................................................71
Chamber light bar replacement..............................................................................73
Troubleshooting .............................................................................................75
User Troubleshooting.....................................................................................................75
Fault determination codes......................................................................................77
Cycling power .....................................................................................................78
Diagnosing loss of extrusion ..................................................................................78
Clogged tip .........................................................................................................79
Material Jam........................................................................................................80
Recovering from loss of extrusion ...........................................................................82
Service Troubleshooting .................................................................................................86
1.0 How to use this Guide ....................................................................................86
2.0 Special Notes ................................................................................................87
3.0 Code Errors...................................................................................................88
Major Codes with Minor Codes .............................................................................90
4.0 Non-Code Errors ..........................................................................................107
What happens during Power Up / Boot................................................................119
5.0 Connector Pinouts and Signals.......................................................................129
Umbilical cable diagram.....................................................................................129
Umbilical cable pinouts.......................................................................................129
Upper harness ...................................................................................................131
Upper harness pinouts ........................................................................................132
Lower harness....................................................................................................133
Lower harness pinouts.........................................................................................133
Part Quality Troubleshooting ........................................................................................135
Embedded support strands in model .....................................................................135
Brown streaks (burn marks)..................................................................................136
Loss of Extrusion (LOE) ........................................................................................137
Model embedded in to support ............................................................................139
Moisture in material............................................................................................140
Open seams ......................................................................................................141

Part curling........................................................................................................142
Part fell over ......................................................................................................143
Part shifting .......................................................................................................144
Rough surface quality .........................................................................................146
Rough quality all over .........................................................................................147
Model strands on parts .......................................................................................148
Witness marks ...................................................................................................149
Wavy surface ....................................................................................................150
Wavy parts .......................................................................................................151
Under fill...........................................................................................................152
Material sagging on curved parts.........................................................................153
Fused layers ......................................................................................................154
Z layers inconsistent ...........................................................................................155
Removal and Installation ..............................................................................157
Maintenance Preparation.............................................................................................159
Tools needed for repair not order-able as a service part..........................................160
Tools needed for repair that are order-able as a service part ...................................160
Pre-Maintenance Procedures................................................................................160
Exterior Components ...................................................................................................161
Top Panel..........................................................................................................161
Removing the top panel .................................................................................161
Installing the top panel...................................................................................162
Side Panels........................................................................................................162
Removing the side panels ...............................................................................162
Removing the right side panel: ........................................................................164
Installing the side panels ................................................................................164
Display Panel.....................................................................................................165
Removing the display panel............................................................................165
Installing the display panel .............................................................................166
Front Panel ........................................................................................................166
Removing the front panel................................................................................166
Installing the front panel .................................................................................168
Door Solenoid ...................................................................................................168
Removing the door solenoid ...........................................................................168
Installing the door solenoid.............................................................................169
Door Sensor ......................................................................................................169
Removing the door sensor ..............................................................................169
Installing the door sensor................................................................................170
Electronics Bay Components.........................................................................................171

Lower Electronics Bay Cover................................................................................171
Opening the electronics bay ...........................................................................171
Closing the electronics bay.............................................................................172
Upper Electronics Bay Cover ...............................................................................173
Removing the upper electronics bay cover........................................................173
Installing the upper electronics bay cover .........................................................174
Removing the Electronics Bay...............................................................................175
Removing the electronics bay..........................................................................175
Installing the electronics bay ...........................................................................176
Electronics Bay Cooling Fan ................................................................................177
Removing the electronics bay cooling fan.........................................................177
Installing the electronics bay cooling fan ..........................................................178
Controller Board ................................................................................................179
Removing the controller board ........................................................................179
Installing the controller board..........................................................................181
Single Board Computer (SBC)..............................................................................182
Removing the single board computer ...............................................................182
Reinstalling the single board computer .............................................................184
Power Distribution I/O Card................................................................................184
Removing the I/O card ..................................................................................185
Installing the I/O card ...................................................................................186
Power Distribution Board (PDB) ............................................................................187
Removing the power distribution board............................................................187
Installing the power distribution board .............................................................190
Hard Drive ........................................................................................................191
Removing the hard drive ................................................................................191
Installing the hard drive..................................................................................193
Line Filter...........................................................................................................194
Removing the line filter...................................................................................194
Installing the line filter ....................................................................................195
Circuit Breaker...................................................................................................196
Removing the circuit breaker...........................................................................196
Installing the circuit breaker ............................................................................197
AC Input ...........................................................................................................197
Removing the AC Input ..................................................................................198
Installing the AC Input....................................................................................198
Power Switch.....................................................................................................199
Removing the Power Switch ............................................................................ 199
Installing the power switch..............................................................................200