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

24VDC Power Supply .........................................................................................201
Removing the 24VDC Power Supply ................................................................201
Installing the 24VDC power supply..................................................................204
5/12VDC Power Supply .....................................................................................205
Removing the 5/12VDC power supply ............................................................205
Installing the 5/12VDC power supply..............................................................207
120VDC Power Supply.......................................................................................208
Removing the 120VDC power supply ..............................................................208
Installing the 120 VDC power supply...............................................................209
Head Components ......................................................................................................210
Head Cooling Fan..............................................................................................210
Removing the head cooling fan.......................................................................210
Installing the Head Cooling fan.......................................................................211
Toggle Head Assembly .......................................................................................212
Removing the toggle head assembly ................................................................212
Installing the toggle head assembly .................................................................217
Substrate Sensor ................................................................................................220
Removing the substrate sensor.........................................................................220
Installing the substrate sensor..........................................................................222
Z Foam Level Assembly .......................................................................................223
Removing the Z Foam Level Assembly: .............................................................223
Installing the Z Foam Level Assembly: ..............................................................224
Toggle Sensor....................................................................................................225
Removing the toggle sensor ............................................................................225
Installing the toggle sensor .............................................................................226
Toggle Bar ........................................................................................................227
Removing the toggle bar: ...............................................................................228
Installing the toggle bar:.................................................................................232
Head Board ......................................................................................................233
Removing the head board ..............................................................................233
Installing the head board ...............................................................................238
TC Amp board...................................................................................................239
Removing the TC Amp board..........................................................................239
Installing the TC Amp board ...........................................................................241
Umbilical Hose ..................................................................................................241
Removing the umbilical hose...........................................................................241
Installing the umbilical hose ............................................................................245
Material Tubes...................................................................................................246
Removing the material tubes ...........................................................................246

Installing the material tubes ............................................................................246
Umbilical Cable .................................................................................................247
Removing the umbilical cable .........................................................................247
Installing the umbilical cable...........................................................................248
XY Table Components .................................................................................................249
Y Home Sensor ..................................................................................................249
Removing the Y home sensor ..........................................................................249
Installing the Y Home Sensor...........................................................................250
Y EOT (End of Travel) Sensor ...............................................................................250
Removing the Y EOT sensor............................................................................250
Installing the Y EOT Sensor.............................................................................251
X Motor ............................................................................................................252
Removing the X motor ....................................................................................252
Installing the X motor .....................................................................................256
Y Motor ............................................................................................................260
Removing the Y motor....................................................................................260
Installing the Y motor .....................................................................................262
Y Motor Belt ......................................................................................................263
Removing the Y Motor Belt .............................................................................263
Installing the Y Motor Belt...............................................................................271
Y Drive Rod .......................................................................................................272
Removing the Y Drive Rod ..............................................................................272
XY Table ...........................................................................................................281
Removing the XY table ...................................................................................282
Installing the XY table ....................................................................................291
Z Stage Components...................................................................................................304
Z Home Sensor ..................................................................................................304
Removing the Z home sensor ..........................................................................304
Installing the Z home sensor............................................................................305
Z EOT (End of Travel) Sensor ...............................................................................305
Removing the Z EOT sensor ............................................................................305
Installing the Z EOT sensor .............................................................................306
Chamber Fans ...................................................................................................307
Removing the right side chamber fan ...............................................................307
Installing the right side chamber fan ................................................................308
Removing the left side chamber fan .................................................................308
Installing the left side chamber fan...................................................................309
Chamber Heaters ...............................................................................................310
Removing the right side heater ........................................................................310

Installing the right side heater .........................................................................312
Removing the left side heater ..........................................................................312
Installing the left side heater............................................................................314
Thermal Fuses ....................................................................................................315
Removing the right side thermal fuse ................................................................315
Installing the right side thermal fuse .................................................................316
Removing the left side thermal fuse ..................................................................317
Installing the left side thermal fuse ...................................................................318
Chamber Thermocouple ...................................................................................... 319
Removing the chamber thermocouple...............................................................319
Installing the chamber thermocouple ................................................................319
Z Motor ............................................................................................................321
Removing the Z motor ....................................................................................321
Installing the Z motor .....................................................................................324
Z Stage.............................................................................................................325
Removing the Z stage ....................................................................................326
Installing the Z stage......................................................................................327
Service Calibrations & Adjustments ...............................................................337
Offset Calibrations ......................................................................................................338
Adjusting Z Calibration and XY Tip Offset ........................................................338
Z Calibration ................................................................................................338
Entering Z Calibration values manually (Firmware version 9.1 or newer)..............338
Z tip to base (ZT2B).......................................................................................338
Z tip to tip (ZT2T) ..........................................................................................339
XY Tip Calibration .........................................................................................340
Entering XY Tip Calibration values manually (Firmware version 9.1 or newer).......341
Part Based Calibration.................................................................................................343
When to Perform Part Based calibration...........................................................343
Performing part based calibration for HP Designjet 3D from the Service Calibration
menu (Firmware version 9.1 or newer).............................................................343
Performing part based calibration for HP Designjet 3D with the HP Designjet 3D Diag-
nostic Software .............................................................................................352
Part Measurement Equations...........................................................................359
Performing part based calibration for HP Designjet Color 3D from the Service Calibra-
tion menu (Firmware version 9.1 or newer).......................................................360
Performing part based calibration for HP Designjet Color 3D with the HP Designjet Di-
agnostics Software ........................................................................................371
Part Measurement Equations...........................................................................380
Tensioning the X & Y Drive Belts ...................................................................................381
Zero the Dial Indicator ...................................................................................381
Checking/Adjusting the X-Drive Belt Tension.....................................................382

Checking/Adjusting the Y-Drive Belt Tension.....................................................384
Get/Send Calibration Files ..........................................................................................386
Get Calibration..................................................................................................386
Send Calibration................................................................................................386
When this button is pressed a dialog box appears that allows you to browse for and select
the calibration file to send to the printer. ...............................................................386
XY Table Leveling........................................................................................................386
Checking the XY Table Level ...........................................................................386
Adjusting the XY Table Level ...........................................................................390
Head Alignment Procedure ..........................................................................................392
Drive Wheel Alignment ..................................................................................392
Idler Wheel Check/Adjustment .......................................................................395
Liquefier Alignment........................................................................................397
Verify Liquefier Alignment...............................................................................398
Complete the Re-Assembly of the Toggle Head Assembly ...................................401
Tip wipe assembly..............................................................................................402
Adjusting tip wipe assembly height:.................................................................402
Appendix ....................................................................................................405
Appendix Overview ....................................................................................................405
Front door area components.........................................................................................406
Electronics bay components .........................................................................................407
Head area components ...............................................................................................409
XY Table area components...........................................................................................413
Z Stage area components ............................................................................................415
Chamber heater area components ................................................................................416
Cables.......................................................................................................................417
Material Bay Components............................................................................................418
Tools .........................................................................................................................419
Consumables..............................................................................................................419
Hard Drive Installation Checklist ...................................................................................420
Toggle Head Assembly Installation Checklist ..................................................................421
XY Table Assembly Installation Checklist ........................................................................422
Controller Board Checklist............................................................................................423
HP Designjet 3D Diagnostic Software Help ....................................................................424
Overview ..........................................................................................................424
Select a Modeler................................................................................................424
Modeler States...................................................................................................425
Modeler Setup ...................................................................................................425
Display Units .....................................................................................................425
Printer Status......................................................................................................425

Position and Temperatures...................................................................................426
Versions ............................................................................................................426
Travel Limits.......................................................................................................426
Material............................................................................................................427
Door.................................................................................................................427
Setting the Serial Number ...................................................................................427
Materials...........................................................................................................427
Adjusting XY Tip Offset .......................................................................................427
Gantry ..............................................................................................................428
Temperatures ..................................................................................................... 428
Temperature Limits..............................................................................................428
Outputs.............................................................................................................429
Get Calibration..................................................................................................429
Send Calibration................................................................................................430
Get Configuration ..............................................................................................430
Test Parts...........................................................................................................430
Reset Password ..................................................................................................430
Connect ............................................................................................................430
Tera Term ..................................................................................................................431
Using Tera Term.................................................................................................431
Connecting with Tera Term..................................................................................431
Tera Term Commands.........................................................................................434

-12

-1
Introduction
HP Designjet 3D and HP Designjet Color 3D are designed with
ultimate simplicity in mind. The printer enables you to build parts
quickly and easily, even if you’ve never used a 3D printer before.
The printers build models with ABSplusTM material so parts are
strong and durable. ABSplus material also ensures you will be
able to drill, tap, sand and paint your creations. With Soluble
Support Technology (SST), your completed parts are quickly
available for review and test. Designjet 3D and Designjet Color
3D are an innovative combination of proprietary hardware,
software and material technology.
Welcome to the new dimension of 3D modeling!
How to use this guide
This User Guide is laid out in easy to follow sections which cover
Set-up, Operation, Maintenance, and Troubleshooting. Read each
section carefully so that you will get the best performance from
your printer.
Throughout this User Guide, text representing Interface Messages
that appear on the display panel are presented in a bold font.

-2
Safety
The following classifications are used throughout this guide.
CAUTION: Indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury.
WARNING: Indicates a potentially hazardous situation which, if
not avoided, could result in serious injury.
Hot Surface: The hot surface sign indicates the presence of devices
with high temperatures. Always use extra care, and wear safety
gloves, when working around heated components
GLOVES: When performing some maintenance procedures, the
machine may be hot and gloves will be required to avoid burns.
SAFETY GLASSES: Wear safety glasses to avoid injury to your
eyes.
LIFTING HAZARD: Hazard: Lift with two or more people to avoid
serious injury.
RECYCLE: Use proper recycling techniques for materials and pack-
aging.
ESD: Use standard electrostatic discharge (ESD)
precautions when working on or near electrical
components.

-3
Overview
What happens when...
Powering up:
Power Switch turned to ON
Chamber lights (dim mode), display backlight
and fans turn on. Material bay drive homes.
Performs Power On Self Test (POST).
POST looks at voltages, checksum
and memory, etc.
Performs basic hardware setup such
as checks for number of material
bays and loads gantry parameters,
etc.
Once printer software is loaded to
RAM the controller runs the POST
test again.
Controller receives updated
parameters from SBC.
Power enabled to the XYZ motors, via
the XP command.
• Chamber lights on (full power)
• Load globals
• Door locks
• Performs “Calibrate” (home) sequence:
1. Moves Z stage down to Z EOT
sensor
2. Moves head to X home (BOT) sen-
sor
3. Moves head to Y home (BOT) sen-
sor
4. Moves head to Y EOT sensor
Head and chamber heaters begin to
heat up, via the th, tr and tx
commands
BIOS starts and loads the OS
(operating system) from the
hard drive to the SBC RAM.
OS boots - performs check
disk (chkdsk) and loads Linux
OS from hard drive to RAM.
Loads printer software from
hard drive to RAM. SBC send
second reset (in) command to
controller.
Loads parameters to controller
(Coldfire chip) (e.g. extrusion
parameters).
SBC enables power to XYZ
motors
“Calibrate” (home) by issuing
move commands to the
controller
After chkdsk is complete,
“Copyright” screen will
be displayed.
“Starting Up”
“Initializing” is
displayed.
“Starting Up”
“Calibrating” is
displayed
“Idle” is
displayed
Controller SBC
Commands head and chamber to
heat to “Idle” temperature (sets
temperatures)

-4
Once the unit is ready to build, the display will show Idle (no part in the
queue) or Ready to build followed by the part name. Once a part is started
the appropriate liquefier will begin to heat. Once the liquefier and chamber
reach the operating temperature (310C model, 300C support, 77 Chamber)
the system will begin to build a part.
Powering Down
When the Power Switch is turned off the unit begins a controlled shut down.
The software processes are stopped and the power to the liquefier and
chamber heaters are turned off. The controller board continues to monitor
the temperature of the liquefier and the fans will continue to run. During this
time the display will show “Shutting down”. The head blower fan continues
to run to cool the liquefier down quickly to prevent back flow of material from
the liquefier. If the material is not cooled down during power down the
system may experience a loss of extrusion due to material build up at the
liquefier. Once the liquefier temperature drops below 102°C the SBC
changes the display to “Shut down” and turns off.
Loading Material
When the load material button is pressed with carriers installed the SBC will
ask the controller board to unload the carriers requested by the operator.
The most recent value for material remaining is written to the cartridge
EPROM. The material is run in reverse to unload the liquefier. When filament
is clear of the filament sensor the controller board tells the SBC that the
command is complete. The SBC sends “REMOVE CARRIER” to the
display, the carriers are unlatched, and the unit waits for you to respond.
If there are no carriers in the printer when the material button is pushed, or if
an unload has just been completed, the SBC will ask the operator to
“INSERT CARRIER”. The unit will look for a valid carrier EPROM. If there
is no change to the EPROM status in 30 seconds, you are asked if you want
to RETRY. Once valid carriers are read, the unit begins the material load
sequence.
Building a Part
How to start building a part build is dependent upon whether or not a part
is in the printer queue:
1. If a part has not been sent to the printer for building (the build queue is
empty):
A. The panel displays Idle and Queue Empty.
B. Wait for Part is blinking. Choose whether you want to start
the build process from a ‘remote’ location or from the
display panel at the printer.
i. At Printer ‘Start Model’ - You send a part to the printer
from your HP Designjet 3D Software Solution work station.
You start the build of the part from the printer.