HP Metal Jet S100 User manual

HP Metal Jet S100 Powder Management
Station
Product Documentation
User Guide
SUMMARY
How to use your product.

About this edition
© Copyright 2023 HP Development
Company, L.P.
Draft 3 - 29, May 2023
Legal notices
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.
Safety notice
Read and follow the operating and
safety instructions before turning on the
equipment.

Table of contents
1 Introduction............................................................................................................................................................................................................................................... 1
Documentation................................................................................................................................................................................................................................ 1
Product usage requirements ................................................................................................................................................................................................ 1
HP Metal Jet process.................................................................................................................................................................................................................. 1
Safety precautions...................................................................................................................................................................................................................... 2
Main components...................................................................................................................................................................................................................... 22
2 Networking............................................................................................................................................................................................................................................ 33
Connectivity requirements—remote monitoring.................................................................................................................................................33
Configuration................................................................................................................................................................................................................................34
Troubleshooting ..........................................................................................................................................................................................................................35
3 System operation ............................................................................................................................................................................................................................36
Open knobs....................................................................................................................................................................................................................................36
Feed the station with powder............................................................................................................................................................................................36
4 Maintenance .......................................................................................................................................................................................................................................54
Preventive maintenance....................................................................................................................................................................................................... 54
Hardware maintenance ........................................................................................................................................................................................................64
5 Customer Self-Repair................................................................................................................................................................................................................. 102
Replace the manual powder intake hose ............................................................................................................................................................... 102
6 Troubleshooting..............................................................................................................................................................................................................................104
Material management and material filling............................................................................................................................................................104
Build-unit load.............................................................................................................................................................................................................................105
Ordering information.............................................................................................................................................................................................................105
7 System errors ....................................................................................................................................................................................................................................107
Introduction...................................................................................................................................................................................................................................107
0015-0016-0115 E-Cabinet Prepost - Residual Current Circuit Breaker (FB2) tripped.............................................................107
0081-0008-0378 BU Interface - Latching pneumatic actuator (MMB206) Valve not opened...........................................107
0035-0013-0386 Feeding system - Transport from aspiration Timeout..........................................................................................108
0048-0004-0005 Sieve - Deposit Sieve Timeout .............................................................................................................................................108
0081-0002-0105BU Interface - Door interlock (QSA201) Timeout ........................................................................................................108
8 When you need help ....................................................................................................................................................................................................................109
Request support.......................................................................................................................................................................................................................109
Service information ...............................................................................................................................................................................................................109
iii

9 Accessibility .......................................................................................................................................................................................................................................110
Front panel.....................................................................................................................................................................................................................................110
Index................................................................................................................................................................................................................................................................ 111
iv

Introduction1
Your HP Metal Jet S100 system consists of the print station, the build unit, the powder management
station, and the powder removal station. This guide describes the use of the powder management
station.
Documentation
Full documentation is available for your product.
The following documents are available:
●Site preparation guide
●Introductory information
●User guide (this document)
●Legal information
●Limited warranty
Product usage requirements
The products, services, and consumables are provided subject to various conditions.
●The customer agrees to use only HP-branded consumables and HP-certified powders in the HP
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. The customer agrees not to use the product and/or consumables for uses not permitted
by US, EU, and/or other applicable law.
●The customer agrees not to use the product and/or consumables for the development, design,
manufacture, or production of nuclear weapons, missiles, chemical or biological weapons, and/or
explosives of any kind.
●The customer agrees to comply with the connectivity requirement outlined below.
●The customer may use firmware embedded in the product only to enable the product to function in
accordance with its published specifications.
●The customer agrees to comply with the user guide.
●Products, services, and/or technical data provided under these terms are for the customer’s
internal use and not intended for further resale.
HP Metal Jet process
The process of building a metal part with HP Metal Jet is described schematically in the illustration
below. A detachable build unit, containing the powder bed and powder supplies, is rolled into the print
station for part production.
Introduction 1

NOTICE: Throughout the printing process, the powder bed may be heated—as shown by the Energy
element—to evaporate volatile components and cure the HP Binding Agent.
Stages of the process
●Spread powder: The build begins with a scanning recoater laying down a uniform, thin layer of metal
powder across the working area. The recoater is refilled from supply bins of powder located at each
end of the scan. This enables bi-directional recoating for increased productivity.
●Print agent: HP printheads jet HP Binding Agent at precise locations onto the powder bed to define
the geometry of single or multiple parts. At one end of the scan, a printhead service station tests,
cleans, and services the printheads for reliable operation.
●Evaporation: The liquid components of the HP Binding Agent evaporate.
●Retract the bed, print next layer: The powder bed is retracted the thickness of the printed layer, and
the process repeats until the build is completed.
●Cure the bed: The powder bed with its printed parts is heated to complete the evaporation of liquid
components from the HP Binding Agent and to cure the polymers to achieve strength in the green
part(s).
●Unpacking: The powder bed is now cooled, and parts can be removed. Unpacking is the process
of removing loose powder from the surfaces of the part. Once the parts have been unpacked
and removed, the remaining powder can be processed and reused for economical consumables
management.
●Sintering: The green parts are now moved into a furnace. At sintering temperatures, atomic diffusion
at the surfaces of the metal particles binds them.
●Finishing: The part(s) may now undergo machining and polishing to meet dimensional and surface-
finish requirements.
Safety precautions
Before using the equipment, read the safety precautions and operating instructions to make sure you
can use it safely.
Customer operators must have successfully obtained the HP Operator Certification and Training to
operate the equipment.
Introduction
Perform the recommended maintenance and cleaning tasks to ensure the correct and safe operation of
the equipment.
2Chapter 1 Introduction

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.
Operations must be supervised at all times.
The equipment is stationary, and should be located in a restricted-access area, for authorized personnel
only.
General safety guidelines
Follow the advice at all times for your personal safety.
Turn off all equipment, using the branch circuit breakers located in the building's Power Distribution Unit
(PDU), and call your service representative (see When you need help on page 109) in any of the following
cases:
●The electrical supply cable is damaged.
●The equipment has been damaged by an impact.
●Liquid has entered the equipment.
●The heating subsystem and enclosures are damaged, the glass is missing or broken, or the sealing
is defective.
●There is smoke or an unusual smell coming from the equipment.
●The built-in Residual Current Circuit Breaker (Ground Fault Circuit Interrupter) has been repeatedly
tripped.
●Fuses have blown.
●The equipment is not operating normally.
●There is any mechanical or enclosure damage.
Turn off the equipment using the branch circuit breakers in either of the following cases:
●During a thunderstorm.
●During a power failure.
Operate the equipment only within the specified ranges of operating temperature and humidity; see the
site preparation guide.
The equipment should always be kept in the same environmental conditions.
Use HP-certified and HP-branded agents only. Do not use unauthorized third-party agents.
The area in which the equipment is installed should be free from liquid spillage and environmental
condensation.
Users and operators must be trained for explosive atmospheres and associated hazards during
cleaning and maintenance operations, according to local laws and company requirements.
Ensure that there is no condensation inside the equipment before turning it on.
Take special care with zones marked with warning labels.
General safety guidelines 3

Use HP-certified equipment and accessories only. The use of third-party equipment and accessories
can cause safety risks, powder leakages, and malfunctions in the equipment; and may affect your
system warranty.
In case of unexpected malfunction, anomaly, ESD (ElectroStatic Discharges), or electromagnetic
interference, press the emergency stop button and disconnect the equipment. If the problem persists,
contact your support representative.
Do not repair or replace any part of the equipment or attempt any servicing unless specifically
recommended in the user-maintenance instructions or in published user-repair instructions that you
understand and have the skills to carry out.
Do not attempt to repair, disassemble, or modify the equipment by yourself; and do not use any part
other than original HP spare parts.
To repair or reinstall the equipment, please contact your nearest authorized service provider; otherwise
you may experience electric shock, fire, problems with the product, or injury.
Final parts/builds
The customer assumes all risk relating to or arising from the 3D printed parts.
The customer is solely responsible for the evaluation of and determination of the suitability and
compliance with applicable regulations of the products and/or 3D printed parts for any use, especially
for uses (including but not limited to medical/dental, food contact, automotive, heavy industry, and
consumer products) that are regulated by US, EU, and other applicable governments.
Explosion hazard
Your product may produce combustible metal dust.
WARNING! Combustible dust clouds and flammable vapors 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, and so on).
NOTICE: The equipment is not intended for hazardous locations or ATEX classified zones: ordinary
locations only.
To avoid the risk of explosion, take the following precautions:
●The customer takes full responsibility for assessing the customer's site according to the Explosion
Protection Document (EPD), Dust Hazard Analysis (DHA), or any required document of the local
jurisdiction of the country where the equipment is installed, to avoid the risk of explosion.
●Users and operators conducting cleaning operations must have training in explosive atmospheres
and associated hazards, according to local laws and company requirements.
●Smoking, candles, welding, and open flames should be forbidden close to the equipment or powder
storage area.
●Hot surfaces, hot flames and gases, and mechanical and electrical sparks, only can be generated
during maintenance or repair operations (use of a permit work system according to the service
manual).
CAUTION: If there is a massive spillage, immediately clean the bulk of the spilled powder by using
conductive, non-sparking scoops and soft brushes that have natural fiber bristles. Residual
4Chapter 1 Introduction

amounts of material remaining after preliminary cleanup, must be removed using an explosion-
protected vacuum cleaner.
●Inside and outside the equipment should be cleaned regularly with an explosion-protected vacuum
cleaner to avoid dust accumulation. 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 metal dust is
required for cleaning. Take measures to mitigate powder spillage and avoid potential ignition
sources such as ESD (ElectroStatic Discharges), flames, and sparks. Do not smoke nearby.
●An explosion-protected vacuum cleaner compliant with the following normative specifications:
–Europe/International Electrotechnical Commission (IEC): Zone 22 or better, temperature Class
200°C (392°F) maximum.
–United States/National Electrical Code (NEC): Class II, division 2 or better, temperature Class
200°C (392°F) maximum.
–Suitable for conductive powder (IIIC and/or group E).
–Refer to the material safety data sheet (MSDS) and meet local regulations.
–Recommended equipment fitted with wet filter (vacuum with submerged flow inches inert liquid)
or High Efficiency Particulate Air (HEPA) filter grade.
●The equipment and accessories must be properly grounded at mains outlets only; do not
manipulate internal bonding. If static discharges or electrical sparks are noticed, stop operation,
disconnect the equipment, and contact your support representative.
●The auxiliary equipment (that is, the oven for the rebaking process) (not provided by HP) must
be explosion-protected for combustible dust and flammable vapors, according to the explosion
protection document (EPD) or explosion hazard analysis covering the probability of an explosive
atmosphere and presence of effective ignition sources as per local laws requirements. Refer to the
safety data sheet of the powder being processed.
●The tanks or drums have to be electrically conductive or dissipative, and the powder cannot
generate mechanical sparks. In addition, the earthing clamps are necessary to ground the tanks
or drums during use.
●Follow the cooling time and ensure a maximum powder temperature of 70°C (158°F) before putting it
into the load station.
●Ground the Portable Tank and drums using static earthing clamps during unloading. The Portable
Tank is secured with a tri-clamp and earthed using a metal chain. When in motion, the Portable Tank
is earthed through the chain. To ensure effective dissipation with the metal chain, the resistance of
the floor to leakage must be less than 100 MOhms.
●HP recommends the use of HP equipment for unpacking 3D parts and refilling the Build Unit. If other
methods are used, read the following notes:
–Dust clouds generated during handling and/or storage can form explosive mixtures with air.
Dust explosion characteristics vary with the particle size, particle shape, moisture content,
contaminants, and other variables.
Explosion hazard 5

–Check that all equipment is properly grounded and installed to satisfy electrical classification
requirements. As with any dry powder, pouring this powder or allowing it to fall freely or be
conveyed through chutes or pipes can accumulate and generate electrostatic discharges,
potentially causing ignition of the powder itself, or of any flammable materials which may come
into contact with the powder or its container.
●Powder, agents and solvents storage, handling, and disposal as per local laws. See the Safety Data
Sheets of your processed powder and solvent powder for adequate handling and storage. Follow
your Environmental, Health, and Safety processes and procedures.
●Do not place the equipment in a hazardous location area, keep it separated from other equipment
that could create a combustible dust cloud or explosive gas atmospheres during its operation.
●Auxiliary post-processing equipment must be suitable for combustible and conductive metal dust.
●Stop operation immediately if sparks, flames, or powder and/or liquid spillage is seen and call your
HP service representative before continuing.
●All personnel, when handling combustible dust, should be freed from static electricity by using
conductive or dissipative footwear and clothing, and a conductive or dissipative floor.
●Keep the safety lid on top of the Build Unit at all times when it is outside of host equipment,
especially when it is in motion.
Use powder complying with HP guidelines, as follows:
●Explosion characteristics acceptance criteria:
–Minimum Ignition Temperature (MIT) 360°C or higher
–Layer Ignition Temperature (LIT) 375°C or higher
–Auto Ignition Temperature (AIT) 375°C or higher
–Minimum Ignition Energy (MIE) 100 mJ or higher at process temperature
–Minimum Explosion Concentration (MEC) 350 g/m³ or higher
–Kst 200 bar·m/s or less
–ST grade 1 or less
●Minimum particle size (d10) > 2 μm
●Non-reactive with other materials or HP agents (see the safety data sheets for the agents on the HP
website at the following link: http://www.hp.com/go/msds), stable
Electric shock hazard
The internal circuits of the electrical cabinet, motors, ultrasounds converter, heating systems and build
unit operate at hazardous voltages capable of causing death or serious personal injury.
WARNING! High leakage current! The equipment must be connected to earth at all times.
DANGER! Risk of electric shock. Power cabinet access to HP trained personnel only.
Turn off the equipment using the branch circuit breakers located in the building's Power Distribution Unit
(PDU) before servicing. The equipment must be connected to earth at mains outlets only.
6Chapter 1 Introduction