HP Designjet Color 3D service manual
HP Designjet 3D
Service Guide
HP Designjet Color 3D
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
Introducti on
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 ABSplus
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.
TM
material so parts are
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.
-1
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 packaging.
ESD: Use standard electrostatic discharge (ESD)
precautions when working on or near electrical
components.
-2
What happens when...
Powe r Switch turne d 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) sensor
3. Moves head to Y home (BOT) sensor
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)
Powering up:
Overview
-3
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.
-4
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.
a. Do not press the Wait for Part button
b. From your HP Designjet 3D Software Solution work
station, send a part to the printer.
c. The printer panel displays the name of the first
model in the printer queue and Start Model is
blinking.
d. From the printer, press the Start Model button to
begin building the displayed part.
ii. Remote ‘Start Model’: - You send a part to the printer
from your HP Designjet 3D Software Solution work
station. The part automatically begins to build.
a. From the printer, press the Wait for Part button
Note: Make sure an empty modeling base is installed, then answer
Yes to the prompt Is Model Base Installed?
b. Wait for Part is displayed in the upper window.
Press Cancel if you wish to exit the remote start
mode.
c. From your HP Designjet 3D Software Solution work
station, send a part to the printer. The printer will
automatically start to build the model.
3. If a part has been sent to the printer for build (there is at least one part
in the build queue), but is not building:
A. The panel displays Ready to Build.
B. The name of the first model in the build queue is displayed.
C. Start Model is blinking. Press the Start Model button to
begin building the displayed part.
Regardless of the method used to start building a part, the printer will
perform the same sequence of steps:
1. The printer drops (lowers) the substrate sensor.
2. System “touches down” six times which measures the height of the sub-
strate.
3. SBC converts the model file (CMB) into the motion commands that the
controller will execute to build the model.
4. System completes substrate measurement.
5. Z stage moves to bottom of Z travel.
6. Head moves over the purge bucket and prepares to build purging the
appropriate tip.
7. Once purge is complete, the printer will start to build the model.
During model construction, the printer will display the percentage of material
remaining on each spool. During building the keypad will allow you to
pause the printer, or turn on the chamber lights. The printer will stay in the
Building State until the model is finished or the printer pauses. If the printer
pauses, it will enter a Pending Pause state until the current road is finished.
-5
PDB
Controller
Board
SBC
AC Input
+5 and
+12 VDC
Power
Supply
Support
heater
+120
VDC
power
supply
+24 VDC
power
supply
120-240
VAC in
120-240
VAC
I/O
Once that road is complete, the head will move over the purge bucket, and
the Z stage will descend to the bottom of the envelope. In the Pause State the
printer can be resumed, material can be loaded and unloaded, the build
can be canceled, and printer maintenance may be performed.
Electronics Overview
Figure 1: Electronics Overview detail
-6
Single Board Computer
J2 power
input
SATA
Connector
P104
Connector
Display Panel
DB-9
Connector
RJ-45
Network
Connector
The single board computer (SBC) is the main processor in the system. See
(Figure ) showing the board layout.
The TCP/IP network interface connects directly to the RJ-45 connector on the
SBC. The network interface supports both 10baseT and 100baseT operation.
The hardware differentiates automatically. There are two LED’s at the RJ-45
connector. These show the status of the network connection as follows:
• Green LED: Indicates there is a network connection present.
• Amber LED: Indicates there is a network communication.
The Hard Disk Drive (HDD) connects to the SBC with a standard IDE
interface (ribbon cable). The HDD contains the Linux operating system and
all the control software needed to run the system (except the controller
firmware). This is also where all the downloaded models are stored in the
queue.
The LCD Control Panel connects to the I/O Card. The signals then travel
though the PDB and on to the SBC. All user entered commands from the
control panel buttons are routed through the I/O and PDB and then on to the
SBC.
The P104 connector on the top edge of the board is a bus level interface to
the controller board. This allows the SBC to read and write to the dual port
ram on the controller board, which forms the communication channel
between the two boards.
Figure 2: Single board computer detail
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Controller Board
Overview
The controller board provides all of the low level hardware control and
sensing for the system. The firmware runs on the controller CPU and is flash
resident (rather than on the HDD and SBC).
Voltage Generation
• +/-15 VDC is used for PMD DACs
• 10 VDC is used for DAC reference
• 3.3 VDC is used for controller board logic
Dual Port Memory Interface
The dual port memory located on the controller board provides the
communication channel with the single board computer (SBC) through the
P104 connector. The SBC provides the coordinates, velocities, and flow rate
commands for modeling to the controller. The controller board provides the
status/error information about the hardware back to the SBC.
X, Y, Z Axis Control
The controller takes the flow rate information from the SBC and sends it to
the PMD processor. The PMD 2840 processor services the X and Y stepper
motors and the model and support head servo motors. The 3410 processor
services the Z axis stepper motor. There is no feedback from the stepper
motors to the system (they are open-loop controlled).
Material Motor Control
The controller takes the flow rate information from the SBC and sends it to
the PMD 2840 processors. The PMD uses this information along with the
encoder signals from the material motors to generate an output signal to
drive the servo motors in the head assembly. Since the encoders provide
feedback the material motors have a closed-loop control. Their position and
rotation are precisely known at all times.
Temperature Control
The controller board reads the three thermocouple (T/C) inputs/signals - 2
for the head, 1 for the chamber.
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Liquefier Temperature Control
The liquefier T/C connects to the controller board through the power
distribution board. The T/C generates a variable low level current that
depends on the temperature of the T/C. This analog signal from the T/C is
amplified by the head distribution. It is then sent down the umbilical cable to
the PDB, and then to the controller board. An A to D converter in the
ColdFire chip converts the analog signal to digital. In order to improve
temperature resolution, this signal is biased. The lowest reading possible is
109.5° C. The highest reading is 330° C.
The liquefier temperature is maintained at: Model: 310 ° C, Support: 300° C
Temperature control is accomplished using “pulse wide modulation” (Figure
3).
Figure 3: Pulse Width Modulation (PWM)
Actual power to the liquefier heater is supplied by the PDB, which is
controlled by the controller board. The head heaters are turned off and on
1000 times a second (pulses). The duration of the 120 VDC pulse
determines the average power being supplied to keep the liquefier at
temperature. Temperatures can be read using a volt meter at test points TP5
for model, and TP4 support on the PDB (10 mV per degree C).
Actuators, Switches & Optical Sensors
The input and output signals are passed through the PDB and then
processed by the controller board. The non-motor actuators on a uPrint
system are 24 volt solenoids. The 24 volt power is supplied by the PDB which
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in turn is controlled by the controller board. The following is a list of
actuators:
• Door solenoid – locks the door to the modeling chamber.
• Carrier latches – holds carriers in the material bays.
• Material bay solenoids – engage the motor that feeds filament from
carrier to the liquefier during auto load.
The controller board reads and updates the remaining material information
on the spool e-prom. This is accomplished through a serial interface to the
material bay encryption board. The material encryption board in turn
connects to the e-prom on the carrier/spool via two pogo pins.
The controller board monitors these switches:
• Z limit switches – upper and lower
• X end of travel (EOT) switch
• Y end of travel (ETO) switch
The controller board monitors the following optical sensors:
• X home (BOT) sensor
•Y home (BOT) sensor
• Top of modeling base sensor
Safety Devices
The controller board monitors the following safety devices:
• Chamber T/C alarm – activated for a bad or missing T/C
• Liquefier T/C alarm – activated for a bad or missing T/C
• Head and chamber “snap” switches
• Two main thermal fuses
• Door open switch
• Door latch solenoid
Controller Board Layout
(Figure 4) Shows the layout of the controller board connectors with labels
indicating where each of the functions described previously are connected.
In addition to those functions, the figure shows a reset button, a set of dip
switches, and the LEDs (D1-D3 and D6-D13).
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Reset Button
Figure 4: Controller board connection detail
Located on the lower right side of the board, the reset button will do a hard
reset of the controller board. Before continuing with normal operation after
resetting the board, system power must be cycled before building. The reset
button should only be used after using Tera Term.
Dip Switches
There are three dip switch banks (SW2, SW5, SW6) located on the top right
side of the board. Dip switches are factory set and should not be changed
unless noted to be in another position.
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SW2
Number (in white) Description Default
16 -24 U n us e d O f f
SW5
Number (in white) Description Default
8-15 Unused Off
SW6
Number (in white) Description Default
0 Run built-in self test (BIST) Off
1 Load Firmware (turn on when using SND-
BIN.EXE)
2 Disable door latching Off
3Unused Off
4 Don’t reset controller when in command is
issued
5 Disable WatchDog timer Off
6 Enable use of dc commands Off
7Unused Off
Off
Off
Memory
There are three types of memory contained on the controller board.
• Dual Port RAM: The communication buffer between the controller
board and the single board computer. Events (from the controller),
commands (from the SBC), and motion control vertices (from the
SBC) are passed through the P104 connector joining the two
boards.
• Flash Memory: Where the executable code resides.
Battery backup RAM; Where the controller board stores the following system
parameters:
1. Results of last power-on self test (POST)
2.Results of certain built-in diagnostic tests, if used
3.Exception trace, which is a list of the most recent exception messages
logged on the controller board
4.State information, which stores printer state when it is powered off
(includes things like the type of gantry, whether material is loaded,
the UDN, etc.).
LEDs
There are 11 LEDs located on the controller board. A grouping of three (D1D3) are located on the lower left side. The other group of eight (D6-D13) are
located on the upper right side. D1-D3 are lit when their associated voltage,
as shown in table below, is present. The 3.3 VDC supply is generated on the
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controller board, +5 and +12 VDC come from the PDB. One function of the
D6-D12 LEDs is that they turn on sequentially to show software download
progress. During normal operation, D13 will blink approximately once every
two seconds to indicate that the watchdog is monitoring the system and
everything is operational.
LED Label Description
D1 +3.3 VDC Supply
D2 +5 VDC Supply
D3 +12 VDC Supply
D6-D12 Debug LEDs (software use only)
D13 Coldfire processor heartbeat
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Power Distribution Board (PDB)
Figure 5: PDB Detail
AJ1AC Power In
BJ2Power Switch/Thermostat
C J3 Chamber Heaters
D J22 Auxillary 120VDC power supply
E J8 Z BOT, Z EOT, Chamber Fans, Frame ID, Filament detect
sensor (not used)
FJ9Z motor
G J10 I/O board connection
H J11 I/O board connection
IJ724VDC input
J Test points and LEDs (see detail in this section)
KJ45/12VDC input
L Voltage indicator LEDs (see detail in this section)
M J12 To material bay
N J16 To external UPS (optional)
O J18 LCD display from SBC
P J15 To controller board (ribbon cable)
Q J14 To controller board (ribbon cable)
R J13 To controller board (ribbon cable)
This board provides the power required to run the system. AC line voltage,
+5 VDC, +12 VDC, and +24 VDC feed into the PDB. An additional +120
VDC input feeds into the PDB for the support head heater.
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