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Module 5: Service and Repair

Module 5: Service and Repair. Module 5 agenda. Module 5 – Service and Repair. Lesson 1: Parts replacement Lesson 2: Calibrations Lesson 3: HP 3D Printer Diagnostic Software. Lesson 1 Parts replacement. Tools needed. * If prefer, obtain from local store.

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Module 5: Service and Repair

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  1. Module 5:Service and Repair

  2. Module 5 agenda Module 5 – Service and Repair • Lesson 1: Parts replacement • Lesson 2: Calibrations • Lesson 3: HP 3D Printer Diagnostic Software HP Designjet 3D Printer - Module 5

  3. Lesson 1 Parts replacement

  4. Tools needed * If prefer, obtain from local store HP Designjet 3D Printer - Module 5

  5. Make sure the power is disconnected when performing any of the disassembly or assembly instructions in this chapter. Failure to do so can cause severe personal injury or damage to the electronics. Use extreme caution when the door solenoid is disabled. Axes may move unexpectedly, which may cause serious injury. Always remember to enable the door solenoid once service is completed The Power Switch does NOT remove power from the printer. The Breaker Switch located on the rear of the printer MUST be off before service is performed on the printer. It is recommended that the AC power cord be disconnected before performing maintenance outlined in this chapter. Servicing instructions outlined in this chapter are intended for use by qualified personnel only. Failure to follow these guidelines can cause severe injury. Safety hazards Lesson 1: Parts replacement ! HP Designjet 3D Printer - Module 5

  6. Parts replacement notes Lesson 1: Parts replacement • After replacing the hard disk, you must perform a firmware update • XY table and Z Stage include necessary fixtures to install and level them properly When the special tools are used: HP Designjet 3D Printer - Module 5

  7. CSR Parts • This printer has several parts that are customer replaceable. See attached file for details • CSR parts include • Display panel • Y & Z sensors • Purge bucket • Tip wipe, tip shields and tips HP Designjet 3D Printer - Module 5

  8. Tools return • All special tools can be obtained through the WFM case • The following tools will need to be returned, otherwise you will be charged for the cost of the tool HP Designjet 3D Printer - Module 5

  9. Lesson 2Calibrations

  10. Calibrations Refer to Service Manual for complete step-by-step instructions Lesson 2: Calibrations HP Designjet 3D Printer - Module 5

  11. Z calibration: Automatically adjusts for differences in the height of the 2 tips Printer builds part; uses substrate sensor to measure height and adjust XY tip offset calibration: Adjusts for differences in X-Y coordinates; performed manually Failure to calibrate will result in poor part quality and possible loss of extrusion (LOE) When to perform: Whenever tips are replaced: Mandatory! Poor part quality issues Offset calibrations Refer to Service Manual for complete step-by-step instructions Lesson 2: Calibrations Example: XY Tip offset calibration results • Requires adjustment of: • X = + 2 mils • Y = - 4 mils HP Designjet 3D Printer - Module 5

  12. Z calibration Lesson 2: Calibrations • Adjusts for differences between the two tips in height (Z direction) • Builds two squares: • One uses a layer of model material and 10 layers of support material • Another uses 10 layers of model material • Substrate sensor measures height of both squares and calculates difference in height between the tips Tips HP Designjet 3D Printer - Module 5

  13. XY Tip Offset Calibration (1) Lesson 2: Calibrations • Compensates for differences in the X-Y direction between the two tips • X should be usual distance between tips • Y should be 0 Y X Tips seen from below (only the tip hole) HP Designjet 3D Printer - Module 5

  14. XY Tip Offset Calibration (2) Lesson 2: Calibrations • After building calibration pattern, enter the values in the display panel • Re-run calibration • Good values should be close to 0 now HP Designjet 3D Printer - Module 5

  15. Part based calibration (XY Calibration) Refer to Service Manual for complete step-by-step instructions Lesson 2: Calibrations • Build a test part (test_XY_cal) • Take 6 measurements of part, using digital caliper • Enter measurements in 3D Printer Diagnostic SW. Use parts measurement equation • Front, right, left, rear, left rear, left front • Perform after replacing any of following: • XY table • Y drive belt • Y drive assembly (motor) • Y pulley HP Designjet 3D Printer - Module 5

  16. Part based calibration Lesson 2: Calibrations G F E Example 1 EG is bigger than AC AE is slightly bigger than CG D C A B E F G Example 2: Table is correctly squared D B C A HP Designjet 3D Printer - Module 5

  17. Tensioning the X & Y Drive Belts Refer to Service Manual for complete step-by-step instructions Lesson 2: Calibrations • Use a tension gauge to adjust the belt tension • When to perform: • Error codes, poor part quality HP Designjet 3D Printer - Module 5

  18. Get/Send calibration files Lesson 2: Calibrations • The “.cal” file: Contains system calibration values • Obtained and copied through 3D Diagnostic Software • Get button: Copies .cal file from system HD to the computer • Send button: Copies. cal file from system calibration CD to system HD • Calibration file backed-up automatically in EEPROM located on printer frame HP Designjet 3D Printer - Module 5

  19. XY table leveling Refer to Service Manual for complete step-by-step instructions Lesson 2: Calibrations • To level table you need: • Dial indicator (included with the belt tensioner tool) • Table adjustment tool (included with the new XY tables) • “XY Level Calc.xls” file • Other tools, as listed in Service Manual • Perform when: • XY table is replaced • Z stage is replaced Dial indicator Table adjustment tool HP Designjet 3D Printer - Module 5

  20. Performing XY table leveling Refer to Service Manual for complete step-by-step instructions Lesson 2: Calibrations • Mark 4 corners of Z table • Raise Z table up to XY table • Use dial indicator, zero it on back left (BL) corner, then measure next 3 corners • Enter values in spreadsheet to calculate adjustments needed for a level table • Use knob adjust numbers and other tools to complete leveling Mark corners Z table HP Designjet 3D Printer - Module 5

  21. Head alignment Lesson 2: Calibrations • New head is already aligned • However, it is useful to be able to check alignment to troubleshoot when material does not enter tips properly • Head alignment tools: • Liquifier alignment rod • Drive wheel alignment • Shim set • Steps to follow • Adjust amount of tensionIdler Wheels apply to filament • Use the correct size shim according to Service Manual specification Right side Wheel Tension Adjust screw Drive Wheel rotated so set screw head is on the bottom. Use .003 and .005 feeler gauge (shim stock) check clearance HP Designjet 3D Printer - Module 5

  22. Head alignment (2) Lesson 2: Calibrations • Check Alignment of Idler wheel using wheel alignment rod • Check Alignment of liquefier using Liquefier alignment rod • See steps in the service manual • Liquefier at .010” misalignment from pinch point • Alignment FAILED • Pinch point is the same as the centerline of the Alignment Rod HP Designjet 3D Printer - Module 5

  23. Tip wipe assembly positioning Lesson 2: Calibrations • If XY Table or Z Stage have been replaced you might need to readjust height of wipe assembly • Insert Tip wipe height block in place of Tip wipe • Move the head over the tip wipe height block • Loosen screws and reposition so tip wipe assembly touches model and support tips • See instructions in the service manual HP Designjet 3D Printer - Module 5

  24. Lesson 1 and Lesson 2 lab Lesson 2: Calibrations • Open electrical panels • Replace XY Table and Z Stage • Perform all calibrations • Have printer operational again HP Designjet 3D Printer - Module 5

  25. Lesson 3 HP 3D Printer Diagnostic Software

  26. Used for printer configuration and troubleshooting For trained service personnel only Using this software you can: Select a modeler to work with Modify printer-specific configuration parameters Download new calibration file data Download new test parts Test the printer’s operation Save new test parts for demonstrations What is HP 3D Printer Diagnostic Software? Lesson 3: HP 3D Diagnostic Software HP Designjet 3D Printer - Module 5

  27. How to connect to the printer Lesson 3: HP 3D Diagnostic Software • If you have a printer installed in the HP Designjet 3D Software Solution, it automatically appears in the Diagnostic Software • If not, you can add a new one Refresh connection with printer Add a new printer HP Designjet 3D Printer - Module 5

  28. HP 3D Printer Diagnostic Software settings Lesson 3: HP 3D Diagnostic Software • Status button • Provides detailed information on current mechanical state of printer • Materials button • Provides manufacturing and quantities information on current materials • Tip Offset button • Used when changing the Head • Gantry button • Used to introduce value when doing a part based calibration • Get/Send Calibration button • Get a calibrations file or send a calibrations file to printer as single file HP Designjet 3D Printer - Module 5

  29. Diagnostic Software settings —continued Lesson 3: HP 3D Diagnostic Software • Get Config button • Obtain config file (same file obtained through the HP Designjet 3D Software) • Test Parts button • Used to send new part (.cmb.gz file) to be printed from display panel • Reset Password button • Removes password set by user through HP Designjet 3D SW. Used when customer forgets password • Outputs button • Send orders to change status of latches and motors and check if they work • Temperatures button • Change default temperatures for building and standby HP Designjet 3D Printer - Module 5

  30. Entering Z tip value Lesson 3: HP 3D Diagnostic Software When head is replaced, the new head has a tag that includes Z tip-to-tip data for replacement head. • Install new head • Connect to printer with diagnostic software • Click the Tip Offset button • In Z Tip-to-Tip field, enter offset value data from tag • Click green check box • Exit diagnostic software and cycle power on printer HP Designjet 3D Printer - Module 5

  31. Getting printer information: Status button Lesson 3: HP 3D Diagnostic Software • Can set printer serial number • Obtain: • Positions of X, Y, and Z • Temperatures of head, support material, and chamber • Current information on layers, curve, and vertex • Version information for product, build, and firmware • State of sensors, motors, latches HP Designjet 3D Printer - Module 5

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