Olivetti 3D S2 User manual

Olivetti 3D S2
Printer
SERVICE MANUAL
Code: Y118040-3

PUBLICATION ISSUED BY:
Olivetti S.p.A.
Telecom Italy Group
Via Jervis, 77 - 10015 Ivrea (TO)
Italy
Copyright © 2016 Olivetti
All rights reserved

Y118040-3 Service Manual iii
PREFACE
This document is intended to be used by technicians responsible for installing and servicing the Olivetti 3D S2 printer.
The aim of the manual is to supply all the information necessary for installing and maintaining the product
correctly.
CONTENTS
This manual comprises of 7 Chapters and an Appendix:
Chapter 1 –Provides a general introduction to the Olivetti 3D S2 printer
Chapter 2 –Provides an illustrated description of the printed circuit boards
Chapter 3 –Provides an illustrated description of installation procedures and printing tests
Chapter 4 –Describes the disassembly/reassembly procedures necessary for printer servicing
Chapter 5 –Provides the planned maintenance procedures
Chapter 6 –Describes the firmware and firmware updating
Chapter 7 –Describes the troubleshooting procedures
Appendix A –Provides a description of the printer accessories
This Manual is completed by a number of video clips, listed below, which can be accessed directly from within
the associated chapters. For this to be possible, the Service Manual and all the video clips must be copied to
the same folder.
Video clip ”Plastic layer bobbin and plastic layer settings”
Video clip “Plastic layer –hot-end group insertion”
Video clip ”Soft glue application method”
Video clip “Nozzle-print plate calibration procedures”
Video clip “Y axis belt replacement”
Video clip ”X axis belt replacement”
Video clip “Print plate calibration”
All the .gcode format files related to the tools and templates referred to in this Manual are available both on the
technical info site www.olinet.biz and on the SD Card supplied with the printer.
PRE-REQUIREMENTS
The approach adopted to the various subjects covered in this manual presumes that the reader has previous
knowledge of similar products.
REFERENCES
Spare Parts Catalogue –code Y117900-2
Product Support Plan –code 808795-00
User Manual German version code 589802
Spanish version code 589701
French version code 589600
Italian version code 589303
English version code 589402
DISTRIBUTION: General
FIRST EDITION: June 2016

vi Service Manual Y118040-3
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Y118040-3 Service Manual iii
CONTENTS
PREFACE..................................................................................................................................................iii
CHAPTER 1 –OVERVIEW.................................................................................................................... 1-1
PRODUCT DESCRIPTION .................................................................................................................... 1-1
MAIN TECHNICAL FEATURES............................................................................................................. 1-2
TECHNICAL SPECIFICATIONS ............................................................................................................ 1-9
CHAPTER 2 –PCB ASSEMBLY DESCRIPTION ................................................................................. 2-1
DESCRIPTION OF PRINTED CIRCUIT BOARD ASSEMBLIES........................................................... 2-1
POWER UNIT......................................................................................................................................... 2-2
ARDUINO PCB ASSEMBLY .................................................................................................................. 2-2
RAMPS PCB ASSEMBLIES................................................................................................................... 2-3
DISPLAY UNIT ....................................................................................................................................... 2-5
SAFETY SWITCHES.............................................................................................................................2--5
CHAPTER 3 –INSTALLATION AND RUNNING THE PRINTING TEST ............................................. 3-1
PACKAGE CONTENTS.......................................................................................................................... 3-1
UNPACKING AND RECOMMENDED OPERATIONS WHEN INSTALLING PRINTER
ON WORK TABLE.................................................................................................................................. 3-3
PRINTER PREPARATION..................................................................................................................... 3-6
MENUS AND NAVIGATION................................................................................................................... 3-7
MAIN MENU....................................................................................................................................... 3-8
PREPARE MENU............................................................................................................................... 3-9
CONTROL MENU .............................................................................................................................3-11
SD CARD MENU.............................................................................................................................. 3-13
LOADING THE BOBBINS WITH FILAMENTS..................................................................................... 3-14
PRINTING A TEST PIECE ................................................................................................................... 3-15
CALIBRATING THE EXTRUDER OFFSET ......................................................................................... 3-20
CHAPTER 4 –DISASSEMBLING PARTS AND MAINTENANCE ....................................................... 4-1
TOOL KIT AND TEMPLATES ................................................................................................................ 4-1
REPLACING THE BAKELITE BLOCKS................................................................................................. 4-3
REPLACING THE NOZZLES................................................................................................................. 4-7
NOZZLE - PRINT PLATE CALIBRATION PROCEDURE.................................................................... 4-10
CLEANING AND LUBRICATING THE GUIDE RAILS OF THE X AND Y AXES.................................4-13
CLEANING THE FOUR COOLING FANS OF THE EXTRUDER BLOCK...........................................4-13
VERIFYING AND ADJUSTING THE DRIVER VOLTAGES................................................................. 4-14
CHECKING THE WIRING OF THE EXTRUDER BLOCK AND HOT-END MOTORS......................... 4-17
CHECKING THAT HEATING ELEMENTS MAINTAIN OPERATING TEMPERATURE......................4-18
UNMOUNTING THE UPPER BODY AND PANELS............................................................................ 4-19
Y AXIS BELT REPLACEMENT............................................................................................................4-22
REPLACING THE Y AXIS MOTOR AND IDLE PULLEY..................................................................... 4-23
X AXIS BELT REPLACEMENT............................................................................................................4-27
REPLACING THE X AXIS MOTOR AND IDLE PULLEY..................................................................... 4-28
UNMOUNTING THE EXTRUDER BLOCK MOTORS.......................................................................... 4-32
UNMOUNTING THE Z AXIS MOTOR..................................................................................................4-36
UNMOUNTING THE PRINTING PLATE..............................................................................................4-38
UNMOUNTING THE END-OF-TRAVEL SENSORS............................................................................4-43
UNMOUNTING THE SAFETY MAT..................................................................................................... 4-44
CLEANING THE HOT-END GROUP ................................................................................................... 4-46

vi Service Manual Y118040-3
CHAPTER 5 –PLANNED MAINTENANCE .......................................................................................... 5-1
GENERAL CLEANING ........................................................................................................................... 5-1
PLANNED MAINTENANCE EVERY 6 MONTHS OR EVERY 1000 HOURS OF OPERATION ........... 5-1
PLANNED MAINTENANCE EVERY 2 YEARS OR 4000 HOURS OF OPERATION............................ 5-1
CHAPTER 6 –FIRMWARE.................................................................................................................... 6-1
UPDATING THE FIRMWARE ................................................................................................................ 6-1
CHAPTER 7 –TROUBLESHOOTING................................................................................................... 7-1
ERROR MESSAGES.............................................................................................................................. 7-1
TROUBLESHOOTING............................................................................................................................ 7-1
FAULT CATEGORIES............................................................................................................................ 7-2
DIAGNOSTIC MESSAGES.................................................................................................................... 7-3
APPENDIX A ACCESSORIES............................................................................................................A-1
FILAMENT BOBBIN TYPES...................................................................................................................A-1

Y118040-3 Service Manual 1-1
Chapter 1 –OVERVIEW
PRODUCT DESCRIPTION
The Olivetti 3D S2 printer exploits the Fused Filament Fabrication (FFF) deposition technology to create three-
dimensional objects by sequentially depositing layers of material in 2-D.
The Olivetti 3D S2 printer is specially designed for small to medium-sized businesses on a digital
transformation path.
In this Chapter the printer components are described and the terminology used in the manual is introduced.

1-2 Service Manual Y118040-3
MAIN TECHNICAL FEATURES
Printer design
The main machine controls are located on the front of the printer where there is also a door for accessing the
inside of the printer.
The safety keys are located on the left side of the printer.
Figure 1-1
REFERENCE
DESCRIPTION
1
LCD Display
2
Jog Dialer
3
SD Card slot
4
Access door
5
Access door lock
6
Switch for fan for cooling material
6-Fan switch
7-Internal light
switch
8 - ON Led
1-LCD
3-SD Card Slot
2-Jog dialer
4-Access door
5-Lock
9-Emergency
stop key
10-Safety mat reset key

Y118040-3 Service Manual 1-3
7
Internal light switch
8
Printer power on LED
9
Emergency stop push-button
10
Reset key for safety sensitive mat after activation.
On opening the front door, the hot-end group comprising of extruder 1 and extruder 2 is clearly visible.
Figure 1-2 Hot-end group
REFERENCE
DESCRIPTION
1
Extruder 1
2
Extruder 2
3
Extruder 1 cooling fan
4
Extruder 2 cooling fan
5
Cooling fan for material being printed by Extruder 1
6
Cooling fan for material being printed by Extruder 2
7
Printing plate in tempered glass
4 –Extruder 2
Cooling Fan
2 –Extruder 2
6 –Cooling Fan for
material printed by
Extruder 2
7 –Tempered glass
plate
5 –Cooling Fan for
material printed by
Extruder 1
1 –Extruder 1
3 –Extruder 1
Cooling Fan

1-4 Service Manual Y118040-3
Figure 1-3 Hot-end group detail
REFERENCE
DESCRIPTION
1
Nozzle
2
Hot-end
3
Hot-end unlocking setscrew
4
Filament feeder unit
1 - Nozzle
2 –Hot-end
3 –Setscrew di blocco hot-
end
4 –Gruppo di trascinamento
filament
4 –Filament Feeder Assembly
3 –Hot-end Unlocking Setscrew

Y118040-3 Service Manual 1-5
Figure 1-4 Feeder assembly terminals and pressure adjustment screw
REFERENCE
DESCRIPTION
1
Bowden quick release couplings
2
Filament pressure adjustment screw
The bobbins with the filament are installed at the rear of the machine, where there is also the power switch,
power socket and USB port.
1 –Bowden Quick
Release Couplings
2 –Filament Pressure
Adjustment Screws

1-6 Service Manual Y118040-3
Figure 1-5 Rear View
Figure 1-6 Rear view detail
REFERENCE
DESCRIPTION
1
Bobbin holders
2
Feeder
3
Power Switch
4
Power Socket
5
USB Port
1-Bobbin Holders
2-Feeder
5-USB Port
3-Power Switch
4-Power Socket

Y118040-3 Service Manual 1-7
IMPORTANT: Labels are displayed on some parts of the printer with hazard symbols. The meaning
of these symbols is described in the paragraph “Label positions and meanings”.
Printer axes orientation
The printer moves along three axes: X, Y and Z.
The hot-end group moves in the X and Y axes directions, while the printing plate moves in the Z axis direction.
The origin of the printer axes, known as the extruder Home position, is located at the front left corner of the
printing plate.
Figure 1-7 Orientation of Olivetti 3D S2 printer axes
Starting from the origin, the X axis is oriented from left to right of the work table, the abscissa increasing in this
direction. The positive direction of the Y ordinate axis, starting from the front door, is towards the rear of the
machine, while the positive direction of the Z axis –oriented vertically with respect to the printing plate –is
downwards.
X axis
Z axis
Y axis
Extruder Home Position

1-8 Service Manual Y118040-3
Label positions and meanings
On the front top part of the printer the following labels can be seen displayed. The meaning of these symbols is
given in the table below.
Figure 1-8 Labels on front of printer
SYMBOL
COLOUR
WARNING
MEANING
TRIANGLE
YELLOW
DANGER
HOT SURFACES
CIRCLE
BLUE
REGULATIONS APPLY
READ INSTRUCTIONS
CIRCLE
BLUE
REGULATIONS APPLY
USE GLOVES
BARRED CIRCLE
RED
PROHIBITED
DO NOT REMOVE GUARDS
Inside the printer, on the safety sensitive mat, the following labels are displayed. For the meaning of these
symbols see the table below.
Figure 1-9 Internal labels on lower side
SYMBOL
COLOUR
WARNING
MEANING
TRIANGLE
YELLOW
DANGER
CRUSHING
TRIANGLE
YELLOW
DANGER
MOVING PARTS
At the back of the printer, near the on/off switch, the following label is displayed. See the table below for its
meaning.
Figure 1-10 Label on external switch on printer rear
SYMBOL
COLOUR
WARNING
MEANING
TRIANGLE
YELLOW
DANGER
HIGH VOLTAGE
The following label is displayed on the printing plate glass and on the extruder block. For the meaning of this
symbol see the table below.
Figure 1-11 Label on internal heated plate
SYMBOL
COLOUR
WARNING
MEANING
TRIANGLE
YELLOW
DANGER
HOT SURFACE

Y118040-3 Service Manual 1-9
TECHNICAL SPECIFICATIONS
Case: Radiused anodised aluminium 45 x 45 with methacrylate panels
Power supply: input 100-240V 50-60 Hz 125-250V / 2.8A
output 12V 8.34A 100W
Display: Front LCD 128 x 64 dot matrix.
Printing plate: 5 mm tempered glass, heated. Maximum temperature 120°C.
Extruders: 2 extruders. Maximum temperature 280°C.
Filament: ø 1.75 mm
Print mode: Cartesian, horizontal dimension along X and Y axes,
Vertical, vertical dimension along Z axis.
Maximum printing speed: 150 mm/sec.
Min layer thickness: 0.05 mm (50 micron).
Min. thicknesses with different nozzles:
Nozzle diameter 0.30 mm min. layer thickness 0.05 mm recommended layer thickness 0.10
mm
Nozzle diameter 0.40 mm min. layer thickness 0.10 mm recommended layer thickness 0.20
mm
Nozzle diameter 0.80 mm min. layer thickness 0.20 mm recommended layer thickness 0.40
mm
N.B.: Nozzles with a diameter of 0.50 mm are mounted on the machine, while nozzles of diameters 0.30,
0.4, 0.50, 0.60 and 0.80 mm can be purchased separately.
Precision tolerance: 0.08 mm (80 microns) on X/Y axes.
0.01 mm (10 microns) on Z axis.
Max. printing volume: 400x400x400 mm
Firmware: Marlin Open source.
Machine code: Movement and printing operations are executed by GCODE machine
code.
Software: Compatible with the most popular printing software that supports
Marlin firmware such as: Repetier-Host, Simpllify3D, Cura, Slic3r, Kisslicer, for
generating GCODE machine code.
Safety devices: Emergency stop key.
Safety mat on bottom floor of printer.
Safety mat reset key.

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Y118040-3 Service Manual 2-1
Chapter 2 –PCB ASSEMBLY DESCRIPTION
DESCRIPTION OF PRINTED CIRCUIT BOARD ASSEMBLIES
The figure below shows the metal plate with the electronic components of the printer:
Figure 2-1
REFERENCE
DESCRIPTION
A
Input/output wire terminals
B
RAMPS Card
C
Arduino MEGA 2560 Card (positioned under the RAMPS card)
D
Cooling fan for RAMPS card
E
SD Card connector and display card
F
Fuse holder
G
Emergency stop key relay
H
Safety mat relay
I
Power unit
I
G
A
B
C
F
H
E
D

2-2 Service Manual Y118040-3
POWER UNIT
The figure below shows the power unit and the terminal board for the wire connections.
Figure 2-2
ARDUINO PCB ASSEMBLY
The illustration below shows the A side of the Arduino card.
Figure 2-3

Y118040-3 Service Manual 2-3
RAMPS PCB ASSEMBLIES
In the illustrations below can be seen the A side of the RAMPS card and its related block diagram.
NOTE: The two enlarged views show the jumpers located under the five driver chips
(circled in white) - all of which must have the same setting - and the power selection jumper
(circled in dark blue).
Figure 2-4
Extruder 1 Driver
Extruder 2 Driver
Y Axis Motor Driver
X Axis Motor Driver
Z Axis Motor Driver
Power selection
jumper
alimentatione
Jumpers under driver IC

2-4 Service Manual Y118040-3
The figure below shows one of the five Driver chips mounted on the RAMPS card.
Figure 2-5
Figure 2-6