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
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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 threedimensional 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.
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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
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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-
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
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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
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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
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
Y118040-3 Service Manual 2-5
DISPLAY UNIT
The figure below shows the display unit comprised of the jog dialer and the connector for the SD Card device
mounted on the printer side.
Figure 2-7
SAFETY SWITCHES
The printer is equipped with two safety switches.
1. The Emergency Stop key – this key can be activated whenever a dangerous situation arises.
After the Emergency Stop key is activated it must be reset by rotating it in the direction indicated by the
arrows.
2. The Reset key – this key must be pressed after a machine shutdown caused by abnormal pressure being
applied to the safety mat which blocks printer operation.
Figure 2-8
SD Card connector
Jog dialer
Emergency Stop key
Reset key
Direction to turn key for reset
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Y118040-3 Service Manual 3-1
Chapter 3 – INSTALLATION AND PRINT TEST
PACKAGE CONTENTS
The following items are contained in the Olivetti 3D S2 printer package:
- 1 3D S2 Printer
- 1 Printer Door Key
- 1 USB Cable. Type A-B
- 1 AC Power Cord
- 1 SD Card of 4GB or more
- 3 Allen Keys (1.5 mm, 2.5 mm and 5 mm)
- 3 Hex Wrenches, sizes 8, 10 and 12
- 1 PLA Bobbin, diameter 1.75 mm, weight 1 Kg
- 1 Feeler Gauge, 0.08 mm
- 1 Spatula for removing printed pieces
- 1 EC, WEEE and Safety Declarations Leaflet
General instructions for installation
To guarantee top printer operation and avoid the need for servicing operations - other than those necessary as
a result of product defects - adhere to the following instructions:
Electrical Power
Make sure that the socket to which the printer is connected is earthed and that it supplies the power level
required by the printer.
WARNING: an unearthed socket may cause faulty operation and create safety-related issues.
Do not connect the printer to power supply lines used in common with other types of apparatus that could
create electrical disturbances and excessive voltage variations (air conditioning systems and fans,
photocopiers, motors of goods lifts or person lifts, radio and TV transmitters and signal generators, high
frequency security devices, etc.).
Environmental conditions
The environmental conditions under which the product can be kept for an unlimited period of time are those
indicated by the AB quality objectives for a normal, air-conditioned, office environment (ambient temperature
15-35 °C, relative humidity 35-85% HU). During both storage and operation, it is necessary to prevent
variations in environmental conditions which could give rise to condensation phenomena. Dust, dirt, smoke
and excessive humidity can lead to excessive wear of moving parts, short circuits and read/write errors while
the printer is executing the different operations. High temperatures and low humidity levels can lead to static
electricity problems.
Printer location
The printer must be installed on a flat, vibration-free, surface.
Do not position the printer very close to air ventilation systems or heat sources, or in positions where it will be
exposed to direct sunshine. Install the printer in a position that is convenient and easy to reach for servicing
and removal operations.
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Operator Information
At the end of the installation, the Field Engineer must ensure that the Operator is in possession of all the
information necessary for operating the printer correctly, and is capable of carrying out the operations for
replacing the bobbin and printing nozzles, and for clearing clogging caused by the filament.
For this purpose, it is recommended that you provide a practical demonstration on how to perform the following
operations:
- Use of the console. Interpretation of error messages and, where possible, operations for removing a printer
jam.
- Illustration of methods for inserting and managing filaments.
- Bobbin replacement.
- Removal of filament clogging printer.
- Printing nozzle replacement.
- Printing of test file.
- Manual printer cleaning.
Make the Operator aware of the importance of environmental conditions when choosing the location for
installing and operating the printer.
Remember that the printer will function reliably over time if used correctly. In the case of any faults, contact
Technical Support immediately.
Y118040-3 Service Manual 3-3
UNPACKING AND RECOMMENDED OPERATIONS FOR PRINTER INSTALLATION ON WORK TABLE
1. With the printer resting on the ground (Figure 3-1) remove the top outer cover (Figure 3-2).
Figure 3-1 Figure 3-2
2. Remove the two pieces of protective padding (Figure 3-3) lifting them out (Figure 3-4).
Figure 3-3 Figure 3-4
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3. Remove the external cardboard packaging by lifting it upwards (Figure 3-5).
On the left side of the printer there are two boxes containing the printer accessories (Figure 3-6).
Figure 3-5 Figure 3-6
4. For the best, most ergonomic, use of the printer, choose a surface with a good level of staticity and
meeting the following specifications:
Work table height: ≥ 80 cm
Work table area: 100 cm x 100 cm
load resistance: ≥ 150 Kg
5. To place the printer on the work table, use a forklift truck of sufficient capacity to lift the printer up to the
height of the work table surface.
Y118040-3 Service Manual 3-5
It is recommended that two persons carry out this operation, proceeding as follows:
6. Unpack the printer, load it onto the forklift truck and lift it up to the height of the work table.
Figure 3-7
7. Lift the printer to the height of the work table (arrow 1) and manually rest it on the surface (arrow 2).
NOTE: The printer bottom must rest entirely on the surface
Figure 3-8
8. Move the forklift truck away.
Figure 3-9
1
2
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9. With a spirit level, ensure that the printer is level in the X axis (Figure 3-10) and Y axis (Figure 3-11) directions.
Figure 3-10 Figure 3-11
PRINTER PREPARATION
This Chapter describes the procedures necessary for correctly configuring and preparing the Olivetti
3D-S2 printer for printing.
Unblocking the hot-end group
To protect the printer during shipping, the hot-end group is anchored to the centre of the Z axis (at the machine
rear) using two packing straps. Before attempting to use the printer you must therefore unblock the hot-end
group by removing these straps.
Figure 3-12
Powering on the printer
Connect the printer to a 220V electrical outlet using the power cord provided and power it on at the power switch.
LCD Display
When the printer is powered on, the LCD display illuminates.
On the display is shown the most important printer status information.
Loading the filament bobbins
See the Chapter ”Loading the Bobbins with Filaments”.
Cut packing straps
Y118040-3 Service Manual 3-7
MENUS AND NAVIGATION
The User Interface of the Olivetti 3D S2 printer provides the commands for carrying out the calibration,
maintenance and printing operations. On powering on the printer, an initialisation screen is displayed for a few
seconds giving the firmware release version, date and time.
Figure 3-13 Initialisation page
This is followed by an information page with the following details:
Target temperature setting for extruders and printing plate (A).
Actual temperature of extruders and printing plate (B).
Position of extruders with respect to the three axes X, Y and Z (C).
Printing speed (D).
Information on insertion of SD Card (E).
Tool bar indicating percentage of work performed (F).
Time since printing began (G).
Figure 3-14 Start page
Figure 3-15 Jog dialer
To navigate between the menus, turn the jog dialer either in the clockwise or anti-clockwise direction.
To select a given command or menu, press the jog dialer.
A B C D G F E
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MAIN MENU
To access the main menu, press the jog dialer once when the printer is in rest mode with the Start page
displayed.
Figure 3-16 Main menu
From the Main menu you can return to the Start page by moving to the Info screen option using the jog dialer
and then pressing the jog dialer to confirm.
In any case, if the printer remains inactive for about 20 seconds, it returns automatically to the Start page.
From the main menu you can access the following submenus:
Prepare
Control
Print from SD
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