hp 5420W 3D Printer User Guide

5420W 3D Printer

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Specifications:

• Product: HP Jet Fusion 5200 Series 3D Printing Solution and HP
  Jet Fusion 5420W 3D Printer

• Edition: 1, September 2023

Product Information:

The HP Jet Fusion 5200 Series 3D Printing Solution and HP Jet
Fusion 5420W 3D Printer offer cutting-edge technology for additive
manufacturing. Using Multi Jet Fusion (MJF) technology, these
printers enable the creation of complex and high-quality 3D printed
parts.

Main Components:

The main components of the printer include the processing
station, material cartridges, build unit, and software for design
preparation and job submission.

Usage Recommendations:

1. Prepare your design for printing: Open your 3D model and check
   for errors using HP software.

2. Pack models and send to printer: Submit the job to the printer
   with multiple models in the software.

3. Add materials: Insert HP Branded Consumables and HP Certified
   Materials into the processing station.

4. Automated mixing: Materials are loaded into the build unit
   through an enclosed and automated process.

5. Remove the build unit from the processing station once printing
   is complete.

Product Usage Instructions:

Step 1: Prepare Design

Open your 3D model using the HP software provided. Check for any
errors or issues that may affect the printing process.

Step 2: Pack and Submit Job

Select multiple models to be printed and submit the job to the
printer through the software interface.

Step 3: Add Materials

Insert HP Branded Consumables and HP Certified Materials into
the processing station of the printer.

Step 4: Automated Mixing

The processing station will automatically load and mix the
materials into the build unit, ensuring a clean and efficient
process.

Step 5: Printing

Once the materials are loaded, start the printing process.
Monitor the progress and remove the build unit from the processing
station once printing is complete.

FAQ:

Q: Can I use non-HP materials with this printer?

A: No, it is recommended to use only HP Branded Consumables and
HP Certified Materials for optimal performance and quality
output.

Q: How do I clean and maintain the printer?

A: Refer to Chapter 10 for part cleaning and postprocessing
instructions, and Chapter 11 for hardware maintenance guidelines
specific to the HP Jet Fusion 5200 Series 3D Printing Solution.

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HP Jet Fusion 5200 Series 3D Printing Solution and HP Jet Fusion 5420W 3D Printer Product Documentation User Guide
SUMMARY How to use your product.

Legal information
© Copyright 2023 HP Development Company, L.P.
Edition 1, September 2023

Legal notices
The information contained herein is subject to change without notice.
The only warranties for HP products and services are set forth in the express warranty statement accompanying such products and services. Nothing herein should be construed as constituting an additional warranty. HP shall not be liable for technical or editorial errors or omissions contained herein.
Safety notice
Read and follow the operating and safety instructions before turning on the equipment.

Trademarks
All products and company names are registered trademarks of their original owners. The use of any trademark is for identification and reference purposes only and does not imply any association between HP and the trademark owner or product brand.

Table of contents
1 Welcome to your MJF system……………………………………………………………………………………………………………………………………………………………………………… 1 Documentation…………………………………………………………………………………………………………………………………………………………………………………………………….. 1 Product usage requirements ………………………………………………………………………………………………………………………………………………………………………… 1 MJF technology…………………………………………………………………………………………………………………………………………………………………………………………………… 2 Usage recommendations………………………………………………………………………………………………………………………………………………………………………………. 3
2 Safety precautions …………………………………………………………………………………………………………………………………………………………………………………………………. 5 Introduction…………………………………………………………………………………………………………………………………………………………………………………………………………… 5 General safety guidelines………………………………………………………………………………………………………………………………………………………………………………. 5 Final parts/builds ……………………………………………………………………………………………………………………………………………………………………………………………….. 6 Explosion hazard ………………………………………………………………………………………………………………………………………………………………………………………………… 6 Electric shock hazard ………………………………………………………………………………………………………………………………………………………………………………………. 8 Heat hazard…………………………………………………………………………………………………………………………………………………………………………………………………………… 8 Fire hazard …………………………………………………………………………………………………………………………………………………………………………………………………………….. 9 Mechanical hazard …………………………………………………………………………………………………………………………………………………………………………………………..10 Light radiation hazard……………………………………………………………………………………………………………………………………………………………………………………..10 Chemical hazard ……………………………………………………………………………………………………………………………………………………………………………………………….10 Ventilation……………………………………………………………………………………………………………………………………………………………………………………………………………… 11 Air conditioning ………………………………………………………………………………………………………………………………………………………………………………………………….. 11 Extraction system……………………………………………………………………………………………………………………………………………………………………………………………… 11 Sound pressure level……………………………………………………………………………………………………………………………………………………………………………………….. 11 Build unit transport hazard ………………………………………………………………………………………………………………………………………………………………………….. 12 3D part unpacking……………………………………………………………………………………………………………………………………………………………………………………………. 12 Personal protective equipment …………………………………………………………………………………………………………………………………………………………………. 12 Use of tools………………………………………………………………………………………………………………………………………………………………………………………………………….. 13 Warnings and cautions………………………………………………………………………………………………………………………………………………………………………………….. 13 Warning labels …………………………………………………………………………………………………………………………………………………………………………………………………… 13 Emergency stop buttons ……………………………………………………………………………………………………………………………………………………………………………….18
3 Main components…………………………………………………………………………………………………………………………………………………………………………………………………..19
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Printer …………………………………………………………………………………………………………………………………………………………………………………………………………………….. 19 Processing station …………………………………………………………………………………………………………………………………………………………………………………………… 21 Build unit………………………………………………………………………………………………………………………………………………………………………………………………………………. 22 Accessories……………………………………………………………………………………………………………………………………………………………………………………………………….. 23 Front panel……………………………………………………………………………………………………………………………………………………………………………………………………………24 Software………………………………………………………………………………………………………………………………………………………………………………………………………………. 28 4 Power on and off……………………………………………………………………………………………………………………………………………………………………………………………………. 34 Turn the printer on and off…………………………………………………………………………………………………………………………………………………………………………… 34 Turn the processing station on and off………………………………………………………………………………………………………………………………………………….36 Circuit-breaker labels………………………………………………………………………………………………………………………………………………………………………………………37 5 Printer and processing station networking ……………………………………………………………………………………………………………………………………………… 39 Connectivity and remote monitoring requirements……………………………………………………………………………………………………………………….. 39 Configuration …………………………………………………………………………………………………………………………………………………………………………………………………….. 40 Troubleshooting ………………………………………………………………………………………………………………………………………………………………………………………………… 41 6 Prepare a file for printing…………………………………………………………………………………………………………………………………………………………………………………… 42 Introduction………………………………………………………………………………………………………………………………………………………………………………………………………… 42 File preparation ………………………………………………………………………………………………………………………………………………………………………………………………… 42 7 Load material into the build unit ………………………………………………………………………………………………………………………………………………………………………47 Loading procedure……………………………………………………………………………………………………………………………………………………………………………………………47 Change to a different type of material………………………………………………………………………………………………………………………………………………….. 52 8 Print………………………………………………………………………………………………………………………………………………………………………………………………………………………………69 Job list app…………………………………………………………………………………………………………………………………………………………………………………………………………..69 Send a job to be printed ………………………………………………………………………………………………………………………………………………………………………………..69 Select a job to be printed ……………………………………………………………………………………………………………………………………………………………………………..69 Add job while printing………………………………………………………………………………………………………………………………………………………………………………………70 Cancel a job ………………………………………………………………………………………………………………………………………………………………………………………………………….71 Check status on the front panel ………………………………………………………………………………………………………………………………………………………………..72 Check status remotely……………………………………………………………………………………………………………………………………………………………………………………73 Possible errors while printing………………………………………………………………………………………………………………………………………………………………………73 Print modes ………………………………………………………………………………………………………………………………………………………………………………………………………….73 9 Unpack the build……………………………………………………………………………………………………………………………………………………………………………………………………..74 General advice and precautions……………………………………………………………………………………………………………………………………………………………….74 If the forklift does not fit…………………………………………………………………………………………………………………………………………………………………………………75 Extracting the build to the natural cooling unit……………………………………………………………………………………………………………………………………81 Unpacking with the natural cooling unit………………………………………………………………………………………………………………………………………………..85 Unpacking without the natural cooling unit…………………………………………………………………………………………………………………………………………85
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10 Part cleaning and postprocessing………………………………………………………………………………………………………………………………………………………………93 11 Hardware maintenance for HP Jet Fusion 5200 Series 3D Printing Solution………………………………………………………………………… 95
Safety precautions…………………………………………………………………………………………………………………………………………………………………………………………. 95 General cleaning instructions …………………………………………………………………………………………………………………………………………………………………… 95 Maintenance resources………………………………………………………………………………………………………………………………………………………………………………..96 Preventive maintenance…………………………………………………………………………………………………………………………………………………………………………….. 102 Consumables …………………………………………………………………………………………………………………………………………………………………………………………………..105 Printer maintenance…………………………………………………………………………………………………………………………………………………………………………………….. 145 Processing-station maintenance…………………………………………………………………………………………………………………………………………………………….271 Build-unit maintenance……………………………………………………………………………………………………………………………………………………………………………….299 Move or store the product………………………………………………………………………………………………………………………………………………………………………….316 12 Hardware maintenance for HP Jet Fusion 5420W 3D Printer……………………………………………………………………………………………………… 317 Summary of new maintenance operations………………………………………………………………………………………………………………………………………. 317 Printer maintenance……………………………………………………………………………………………………………………………………………………………………………………..318 13 Troubleshooting ………………………………………………………………………………………………………………………………………………………………………………………………… 326 General advice……………………………………………………………………………………………………………………………………………………………………………………………….. 326 Printhead health troubleshooting…………………………………………………………………………………………………………………………………………………………. 326 Cross contamination troubleshooting………………………………………………………………………………………………………………………………………………..340 Recover (clean) the printheads ………………………………………………………………………………………………………………………………………………………………348 Airflow check……………………………………………………………………………………………………………………………………………………………………………………………………348 14 Ordering information ………………………………………………………………………………………………………………………………………………………………………………………349 15 System errors……………………………………………………………………………………………………………………………………………………………………………………………………… 351 Introduction………………………………………………………………………………………………………………………………………………………………………………………………………. 351 0051-0008-0001 Mixer loading nozzle sensor PCA malfunction …………………………………………………………………………………………… 352 0085-0008-0X94 Carriage ­ Printhead ­ Temperature extremely high……………………………………………………………………………… 352 0085-0008-0X86 Carriage ­ Printhead ­ Temperature too high……………………………………………………………………………………………. 352 0085-0008-0X95 Carriage ­ Printhead ­ Temperature extremely low ……………………………………………………………………………….. 352 0085-0008-0X87 Carriage ­ Printhead ­ Temperature too low……………………………………………………………………………………………….353 0085-0008-0X82 Carriage ­ Printhead ­ Data not responding………………………………………………………………………………………………353 0085-0008-0X98 Carriage ­ Printhead ­ Transmit error……………………………………………………………………………………………………………353 0085-0008-0X96 Carriage ­ Printhead ­ Energy calibration failure …………………………………………………………………………………….354 0085-0008-0X93 Carriage ­ Printhead ­ Fails continuity………………………………………………………………………………………………………….354 0085-0008-0X85 Carriage ­ Printhead ­ Fails logical …………………………………………………………………………………………………………………354 0085-0008-0X10 Carriage ­ Printhead ­ Voltage out of range………………………………………………………………………………………………..354 0085-0013-0X01 Carriage ­ Primer ­ Malfunction…………………………………………………………………………………………………………………………355 0085-0013-0X33 Carriage ­ Primer ­ Current too high……………………………………………………………………………………………………………….355
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0085-0013-0X41 Carriage ­ Primer ­ Leakage…………………………………………………………………………………………………………………………………355 16 When you need help …………………………………………………………………………………………………………………………………………………………………………………………357
Request support……………………………………………………………………………………………………………………………………………………………………………………………..357 Customer Self- Repair…………………………………………………………………………………………………………………………………………………………………………………..357 Service information ……………………………………………………………………………………………………………………………………………………………………………………..358 17 Accessibility…………………………………………………………………………………………………………………………………………………………………………………………………………359 Front panel………………………………………………………………………………………………………………………………………………………………………………………………………..359 Index……………………………………………………………………………………………………………………………………………………………………………………………………………………………….360
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1 Welcome to your MJF system
An introduction to your product. The majority of the contents of this document applies to both the HP Jet Fusion 5200 Series 3D Printing Solutions and the HP Jet Fusion 5420W 3D printer. Information that is exclusively applicable to the 5420W 3D Printer is specifically indicated.
Documentation
Full documentation is available for your product. The following documents are available: Site preparation guide Introduction information User guide (this document) Legal information Limited warranty Declaration of conformity HP SmartStream 3D Build Manager User Guide HP SmartStream 3D Command Center User Guide These documents can be downloaded from the appropriate HP webpage at the following links: http://www.hp.com/go/jetfusion3D5200/manuals http://www.hp.com/go/jetfusion3D5210/manuals http://www.hp.com/go/jetfusion3D5210pro/manuals http://www.hp.com/go/jetfusion3D5420W/support http://www.hp.com/go/jetfusion355420W/manuals
Product usage requirements
The products, services, and consumables are provided subject to various conditions.
Welcome to your MJF system 1

The conditions are as follows: The customer agrees to use only HP Branded Consumables and HP Certified Materials in the 3D
HP printer product, and understands that use of any consumables other than HP consumables may cause serious product functionality and/or safety issues, including, but not limited to those outlined in the user guide. The customer agrees not to use the product and/or consumables for uses not permitted by US, EU, and/or other applicable law. The customer agrees not to use the product and/or consumables for the development, design, manufacture, or production of nuclear weapons, missiles, chemical or biological weapons, and/or explosives of any kind. The customer agrees to comply with the connectivity requirement outlined below. The customer may use firmware embedded in the product only to enable the product to function in accordance with its published specifications. The customer agrees to comply with the user guide. Products, services, and/or technical data provided under these terms are for the customer’s internal use and not intended for further resale.
MJF technology
HP Multi Jet Fusion technology offers speed advantages and control over part and material properties beyond those found in other 3D printing processes. HP Multi Jet Fusion technology starts by laying down a thin layer of material in the working area. Next, the carriage containing an HP Thermal Inkjet array passes from left to right, printing chemical agents across the full working area. The layering and energy processes are combined in a continuous pass of the second carriage from top to bottom. The process continues, layer-by-layer, until a complete part is formed. At each layer, the carriages change direction for optimum productivity.
1. The material is recoated across the work area. 2. A fusing agent (F) is selectively applied where the particles are to fuse together. 3. A detailing agent (D) is selectively applied where the fusing action needs to be reduced or amplified.
In this example, the detailing agent reduces fusing at the boundary to produce a part with sharp and smooth edges. 4. The work area is exposed to fusing energy. 5. The part now consists of fused and unfused areas.
2 Chapter 1 Welcome to your MJF system

The process is repeated until the complete part has been formed. NOTE: The sequence of steps above is typical, but may be changed in specific hardware implementations. HP Multi Jet Fusion technology can realize the full potential of 3D printing through the production of highly functional parts. Using HP Thermal Inkjet arrays, HP Multi Jet Fusion technology is built on HP’s technical core competency of rapidly and accurately placing precise (and minute) quantities of multiple types of fluids. This gives HP Multi Jet Fusion technology a versatility and potential not found in other 3D printing technologies. In addition to fusing and detailing agents, HP Multi Jet Fusion technology can employ additional agents to transform properties at each volumetric pixel (or voxel). These agents, transforming agents, deposited point-by-point across each cross-section, allow HP Multi Jet Fusion technology to produce parts that cannot be made by other methods. For example, taking advantage of HP’s in-depth knowledge of color science, HP Multi Jet Fusion printers could selectively print a different color at each voxel with agents containing cyan, magenta, yellow, or black (CMYK) colorants. The long-term vision for HP Multi Jet Fusion technology is to create parts with controllably variable– even quite different–mechanical and physical properties within a single part or among separate parts processed simultaneously in the working area. This is accomplished by controlling the interaction of the fusing and detailing agents with each other, with the material to be fused, and with additional transforming agents. HP Multi Jet Fusion technology can provide design and manufacturing possibilities that surpass the limits of our imagination. That’s what technological breakthroughs do.
Usage recommendations
A summary of the printing process.
1. Prepare your design for printing: Open your 3D model and check for errors with easy-to-use HP software.
2. Pack models and send to printer: Place multiple models into the software and submit the job to the printer.
3. Add materials: Insert the material cartridges into the processing station. 4. Automated mixing: You will have a clean loading and mixing experience because the processing
station is enclosed and automated. Materials are loaded into the build unit. 5. Remove the build unit from the processing station.
Usage recommendations 3

6. Slide the build unit into the printer. 7. Printing with voxel-level control: Just tap Start to get extreme dimensional accuracy and fine detail,
thanks to HP’s unique multi-agent printing process. 8. Streamlined workflow: The build unit can be removed from the printer–which is now ready for the
next build–and slid back into the processing station.
4 Chapter 1 Welcome to your MJF system

2 Safety precautions
How to use your product safely.
Introduction
Before using the equipment, read the following safety precautions and operating instructions to make sure you can use it safely. You are expected to have the appropriate technical training and experience necessary to be aware of hazards to which you may be exposed in performing a task, and to take appropriate measures to minimize the risks to yourself and to others. Perform the recommended maintenance and cleaning tasks to ensure the correct and safe operation of the equipment. Operations must be supervised at all times. The equipment is stationary, and should be located in a restricted-access area, for authorized personnel only.
General safety guidelines
Use the equipment only when it is in good working order and in the recommended environmental conditions. Turn off all equipment, using the branch circuit breakers located in the building’s Power Distribution Unit (PDU), and call your service representative (see When you need help on page 357) in any of the following cases: The power cord is damaged. The top heating and fusing lamp enclosures are damaged, the glass is missing or broken, or the
sealing is defective. The equipment has been damaged by an impact. Liquid has entered the equipment. There is smoke or an unusual smell coming from the equipment. The built-in Residual Current Circuit Breaker (Ground Fault Circuit Interrupter) has been repeatedly
tripped. Fuses have blown.
Safety precautions 5

The equipment is not operating normally. There is any mechanical or enclosure damage. Turn off the equipment using the branch circuit breakers in either of the following cases: During a thunderstorm During a power failure Operate the equipment only within the specified ranges of operating temperature and humidity. See the site preparation guide. The printer, build unit, and processing station should always be kept in the same environmental conditions. The print-production area in which the equipment is installed should be free from liquid spillage and environmental condensation. Ensure that there is no condensation inside the equipment before turning it on. Take special care with zones marked with warning labels. Use HP-certified and HP-branded material and agents only. Do not use unauthorized third-party material or agents. Use HP- certified external tanks only. The use of third-party external tanks can cause safety risks, material leakages, and malfunctions in the processing station; and may affect your system warranty. In case of unexpected malfunction, anomaly, ESD (ElectroStatic Discharges), or electromagnetic interference, press the emergency stop button and disconnect the equipment. If the problem persists, contact your support representative.
Final parts/builds
The customer assumes all risk relating to or arising from the 3D printed parts. The customer is solely responsible for the evaluation of and determination of the suitability and compliance with applicable regulations of the products and/or 3D printed parts for any use, especially for uses (including but not limited to medical/dental, food contact, automotive, heavy industry, and consumer products) that are regulated by US, EU, and other applicable governments.
Explosion hazard
Take precautions to avoid the risk of explosion. WARNING! Dust clouds can form explosive mixtures with air. Take precautionary measures against static charges, and keep away from sources of ignition. NOTICE: The equipment is not intended for hazardous locations or ATEX classified zones: ordinary locations only.
6 Chapter 2 Safety precautions

Take the following precautions:
Smoking, candles, welding, and open flames should be forbidden close to the equipment or material storage area.
Inside and outside the equipment should be cleaned regularly with an explosion-protected vacuum cleaner to avoid dust accumulation. Do not sweep the dust or or try to remove it with a compressedair gun.
An explosion-protected vacuum cleaner certified for collection of combustible dust is required for cleaning. Take measures to mitigate material spillage and avoid potential ignition sources such as ESD (ElectroStatic Discharges), flames, and sparks. Do not smoke nearby.
The equipment and accessories must be properly grounded at mains outlets only; do not manipulate internal bonding. If static discharges or electrical sparks are noticed, stop operation, disconnect the equipment, and contact your support representative.
Check the air filters and the sealing of the heating lamps regularly, as specified in Hardware maintenance for HP Jet Fusion 5420W 3D Printer on page 317. Do not remove filters or lamp glasses.
Use HP-certified and HP-branded material and agents only. Do not use unauthorized third-party material or third-party agents.
HP recommends the use of HP accessories for unpacking 3D parts and refilling the build chamber. If other methods are used, read the following notes:
­ Dust clouds generated during handling and/or storage can form explosive mixtures with air. Dust explosion characteristics vary with the particle size, particle shape, moisture content, contaminants, and other variables.
­ Check that all equipment is properly grounded and installed to satisfy electrical classification requirements. As with any dry material, pouring this material or allowing it to fall freely or be conveyed through chutes or pipes can accumulate and generate electrostatic sparks, potentially causing ignition of the material itself, or of any flammable materials which may come into contact with the material or its container.
Material storage, handling, and disposal as per local laws. See the Safety Data Sheets at http://www.hp.com/go/msds for adequate handling and storage. Follow your Environmental, Health, and Safety processes and procedures.
Do not place the equipment in a hazardous location area, keep separated from other equipment that could create a combustible dust cloud during its operation.
Auxiliary post-processing equipment, such as for sand blasting, must be suitable for combustible dust.
Stop operation immediately if sparks or material spillages are seen, and call your HP service representative before continuing.
All personnel, when handling combustible dust, should be freed from static electricity by using conductive or dissipative footwear and clothing, and a conductive floor.
Users and operators must be trained for explosive atmospheres and associated hazards during cleaning operations, according to local laws and company requirements.
Keep the safety lid on top of the build unit at all times, except when it is inside the printer or processing station.
Explosion hazard 7

Additionally, for the 5210 Pro processing station only: Use a bulk discharging system and drum rotator suitable for combustible dust and compatible with
the material that you intend to use. Keep an area of at least 2 m (79 in) around the bulk discharging system clear of electric/electronic
devices and any sources of ignition. Use rigid pipes and flexible hoses suitable for transporting combustible powder and properly
earthed. Use static earthing clamps to connect an external tank or a material loading tank (when used as a
bulk material supply) to an earthing point. HP recommends to use a standard grounding connection installed between the metalized earth
strap coming with the bulk material supply metalized liner/bag containing the powder and your facilities infrastructure.
Electric shock hazard
Take precautions to avoid the risk of electric shock.
WARNING! The internal circuits inside the e-cabinet, top heating, fusing lamps, build unit, and processing station operate at hazardous voltages capable of causing death or serious personal injury.
Turn off the equipment using the branch circuit breakers located in the building’s Power Distribution Unit (PDU) before servicing. The equipment must be connected to earth at mains outlets only. Take the following precautions: Do not attempt to dismantle the internal circuit enclosures, top heating, fusing lamps, build unit,
processing station, or e-cabinet except during hardware maintenance tasks. In that case, follow the instructions strictly. Do not remove or open any other closed system covers or plugs. Do not insert objects through slots in the equipment. Test the functionality of the Residual Current Circuit Breakers (RCCBs) every year. See Check the functionality of the Residual Current Circuit Breakers (RCCBs) on page 270 and Check the functionality of the Residual Current Circuit Breaker (RCCB) on page 289.
NOTE: A blown fuse may indicate malfunctioning electrical circuits within the system. Call your service representative (see When you need help on page 357), and do not attempt to replace the fuse yourself.
Heat hazard
Take precautions to avoid the risk of burns.
8 Chapter 2 Safety precautions

The top heating, fusing, and build chamber subsystems of the printer operate at high temperatures and can cause burns if touched. To avoid personal injury, take the following precautions:
Take special care when accessing the printing area. Let the printer cool down before you open the covers.
Take special care with zones marked with warning labels. Do not place objects inside the equipment while operating. Do not cover enclosures while operating. Remember to let the equipment cool down before performing some maintenance operations. Wait for at least the minimum cooling time (see Unpack the build on page 74) before extracting the
build unit from the printer after printing, or unpacking parts from the build unit.
Fire hazard
Take precautions to avoid the risk of fire. The top heating, fusing, and build chamber subsystems of the printer operate at high temperatures. Call your service representative if the built-in Residual Current Circuit Breaker (Ground Fault Circuit Interrupter) is repeatedly tripped. Take the following precautions:
Use the power supply voltage specified on the nameplate. Connect the power cord to a dedicated line, protected by a branch circuit breaker according to the
information detailed in the site preparation guide.
Do not insert objects through slots in the equipment. Take care not to spill liquid on the equipment. After cleaning, make sure all components are dry
before using the equipment again.
Do not use aerosol products that contain flammable gases inside or around the equipment. Do not operate the equipment in an explosive atmosphere.
Do not block or cover the openings of the equipment. Do not attempt to modify the top heating, fusing, build chamber, e-cabinet, or enclosures. Proper maintenance and genuine HP consumables are required to ensure that the equipment
operates safely as designed. The use of non-HP consumables may present a risk of fire.
Take special care with zones marked with warning labels. Do not place objects covering top cover, enclosures, or air ventilation. Do not leave tools or other materials inside equipment after maintenance or servicing. Suitable materials for fire-fighting include carbon dioxide, water spray, dry chemicals, or foam.
CAUTION: Do not use a jet of water, as it could scatter and spread the fire. WARNING! Depending on the material used, some unhealthy substances can be released into the air in case of incidental fire. Wear self-contained pressure-demand breathing apparatus and full
Fire hazard 9

protective gear. Your EHS specialist should consult the Safety Data Sheet (SDS) about each material, available at http://www.hp.com/go/msds, and advice on the appropriate measures for your location.
Mechanical hazard
The equipment has moving parts that could cause injury. To avoid personal injury, take the following precautions when working close to the equipment: Keep your clothing and all parts of your body away from moving parts. Avoid wearing necklaces, bracelets, and other hanging objects. If your hair is long, try to secure it so that it will not fall into the equipment. Take care that sleeves or gloves do not get caught in moving parts. Avoid standing close to the fans, which could cause injury and could also affect print quality (by
obstructing the air flow). Do not operate the equipment with covers bypassed.
Light radiation hazard
Infrared (IR) radiation is emitted from the top heating and fusing lamps. The enclosures limit radiation in compliance with the requirements of the exempt group of IEC 62471:2006, Photobiological safety of lamps and lamp systems. Do not modify the top-cover enclosure, nor the glasses or windows.
Chemical hazard
Take precautions to avoid the risk of exposure to hazardous substances. See the Safety Data Sheets available in the reference below to identify the chemical ingredients of your consumables (material and agents). Sufficient ventilation needs to be provided to ensure that potential airborne exposure to these substances is adequately controlled. Consult your usual air conditioning or EHS specialist for advice on the appropriate measures for your location. http://www.hp.com/go/msds Use HP-certified material and agents only. Do not use unauthorized third-party material or third-party agents.
WARNING! Hazardous substances could be released when processing material and using natural cooling units. To avoid this risk, install an air extraction system (see the site preparation guide) or ensure that you have at least the minimum recommended ventilation in the room (see the site preparation guide). WARNING! Hazardous substances–in the form of Volatile Organic Compounds (VOC) from agents– could condense on surfaces. To avoid the risk of chemical contact, wear personal protective equipment (see Personal protective equipment on page 12).
10 Chapter 2 Safety precautions

Ventilation
Fresh air ventilation is needed to maintain comfort levels. For a more prescriptive approach to adequate ventilation, see the latest edition of the ANSI/ASHRAE (American Society of Heating, Refrigerating and Air-Conditioning Engineers) document Ventilation for Acceptable Indoor Air Quality. Adequate ventilation needs to be provided to ensure that potential airborne exposure to materials and agents is adequately controlled according to their Safety Data Sheets. Ventilation should meet local environmental, health, and safety (EHS) guidelines and regulations. For the printer and processing station, follow the ventilation recommendations in the site preparation guide.
NOTE: The ventilation units should not blow air directly onto the equipment.
Air conditioning
Air conditioning in the work area should take into account that the equipment produces heat. For more information, see the air-conditioning section in the site preparation guide. Air conditioning should meet local environmental, health, and safety (EHS) guidelines and regulations.
NOTE: The air conditioning units should not blow air directly onto the equipment.
Extraction system
The printer has been designed to be able to work either exhausting air into the room or connected to an extraction system installed by the customer. There are various advantages of the latter: first, it’s a way to decrease the printer’s heat output into the room, so room temperature will be reduced. Additionally, with the extraction, room air ventilation requirements are lower, the presence of airborne materials is reduced, and the level of noise is lower. Therefore, HP highly recommends connecting the printer to an extraction system, and this may be obligatory depending on the material processed and local regulations. To install an extraction system that meets the printer’s requirements, follow the extraction system recommendations in the site preparation guide. As ventilation and air conditioning are related to the extraction system, you should also follow the ventilation and air- conditioning recommendations in the site preparation guide. In general, you should not need to adjust the extraction system after installation. However, if too much or too little aspiration occurs, system errors will be reported and some readjustment may be required. For that purpose, a maintenance procedure is provided to assist you.
Sound pressure level
Specifications of the sound emission levels you can expect from your products.
Ventilation 11

Printer and build unit Declared dual number noise emission values in accordance with ISO 4871, corresponding to the worst bystander position according to ISO 11202, located at the rear of the printer: LpA = 75 dB(A), measured with the fans turning at maximum speed KpA = 5 dB
Processing station and build unit Declared dual number noise emission values in accordance with ISO 4871, corresponding to the microphone position located in the dedicated operator area in accordance with ISO 11202: LpA = 73 dB(A), measured during the unpacking process KpA = 5 dB Hearing protection may be required as per local laws; consult your EHS specialist.
Build unit transport hazard
Special care must be taken to avoid personal injury when moving the build unit. Always wear personal protective equipment including boots and gloves. Keep the safety lid on top of the build unit at all times, except when it is inside the printer or
processing station. Steer the build unit using the handle only. Move the build unit over smooth, flat surfaces without steps. Move with care and avoid shocks during transport, which could spill the material. Lock the front casters when not moving the build unit. Remember to unlock them before moving it. If moving the build unit between different rooms, bear in mind that it should be kept in constant environmental conditions.
3D part unpacking
Wear heat-resistant gloves when unpacking 3D printed parts.
Personal protective equipment
In some situations, you will need equipment to protect yourself from hazards. HP recommends the following equipment, which may be used for material handling, unpacking parts, and certain maintenance and cleaning tasks: A pair of heat-resistant gloves per person, flexible and resistant up to 200°C (392°F) with an irregular
grabbing surface Chemical protection gloves for use when removing condensation
12 Chapter 2 Safety precautions

Conductive or electrostatic-dissipative footwear and clothing Mask to exclude vapors of organic compounds Mask or goggles if the environment is dusty Hearing protection if necessary
Use of tools
Tools may sometimes be needed for maintenance operations. Users: Daily operations including printer settings, printing, unpacking and refilling, replacement of
agent reservoirs, and daily checks. No tool is required. Maintenance personnel: Hardware maintenance tasks and replacement of Customer Self-
Replaceable (CSR) parts may require a screwdriver, as described in Hardware maintenance for HP Jet Fusion 5420W 3D Printer on page 317. WARNING! Use appropriate tools (anti-spark, for example) in hazardous locations or ATEX classified zones. NOTE: During installation, the designated personnel receive training for the safe operation and maintenance of the equipment. The equipment should not be used without this training.
Warnings and cautions
Warning and caution symbols are used to ensure the proper use of the equipment and to prevent it from being damaged. Follow the instructions marked with these symbols. WARNING! Failure to follow the guidelines marked with this symbol could result in serious personal injury or death. CAUTION: Failure to follow the guidelines marked with this symbol could result in minor personal injury or damage to the product.
Warning labels
You will find labels with safety advice on various parts of your printer.
Use of tools 13

Table 2-1 Warning labels Label
For service personnel only

Explanation
Electric shock hazard
Heating modules operate at hazardous voltage. Disconnect power source before servicing.
CAUTION: Double pole. Neutral fusing. Refer servicing to qualified service personnel.
In case of operation of the fuse, parts of the equipment that remain energized may represent a hazard during servicing. Before servicing, turn off the equipment using the Branch Circuit Breakers located in the building’s Power Distribution Unit (PDU).
WARNING! High leakage current. Current leakage may exceed 3.5 mA. Earth connection essential before connecting supply. Equipment to be connected to earthed mains only.
See installation instructions before connecting to the supply. Ensure that the input voltage is within the equipment’s rated voltage range.
Before starting
Read and follow the operating and safety instructions before starting the equipment.
Risk of burns. Let the equipment cool down before accessing internal parts.

14 Chapter 2 Safety precautions

Table 2-1 Warning labels (continued) Label

Explanation
You are required to wear gloves when handling material cartridges, agents, printheads, the printhead cleaning roll, and when performing maintenance and cleaning tasks. Chemical protection gloves are suitable, and should be tested according to EN 374. Glove material: NBR (nitrile rubber) Thickness > 0.11 mm (0.0043 in) Breakthrough time > 480 minutes
(permeation leave 6) You are recommended to wear a pair of heat-resistant gloves per person when unpacking parts in the processing station. The temperature can be up to 200°C (392°F), depending on the material being processed. You are recommended to wear a safety mask when replacing filters. During the first seven full-build-chamber jobs you are required to use a mask with filter type A (according to DIN 3181) for vapors of organic compounds.
You are required to wear tightly fitting safety goggles: For the first seven full-build-
chamber jobs When replacing filters For maintenance and cleaning
tasks Do not step over the support platform of the material cartridges.
Do not climb onto the external tank, which could cause the processing station to fall over.
Crush hazard. Keep your hands clear of the edge of the top cover. Open and close the top cover using the handle (highlighted in blue) only.
Warning labels 15

Table 2-1 Warning labels (continued) Label
For maintenance and service personnel only

Explanation
WARNING! Dust clouds can form explosive mixtures with air. Take precautionary measures against static charges, and keep away from sources of ignition.
No smoking, matches, or open flames close to equipment or material storage area.
An explosion-protected vacuum cleaner certified for collection of combustible dust is required for cleaning.
Take measures to mitigate material spillage and avoid potential ignition sources such as ESD (ElectroStatic Discharges), flames, and sparks. Do not smoke nearby.
Disposal as per local laws.
Electric shock hazard. Disconnect power before servicing. Heating modules and electrical cabinets operate at hazardous voltage.
Protective conductor current.
CAUTION: High touch current. Connect to earth before connecting to supply.

For service personnel only For maintenance and service personnel only
16 Chapter 2 Safety precautions

Hazardous moving parts. Keep away from moving fan blades.

Table 2-1 Warning labels (continued) Label
For maintenance and service personnel only
For service personnel only

Explanation Risk of trapped fingers. Do not touch gears or rollers while moving: your hands may be trapped between the gearwheels.
Hazardous moving part. Keep away from the moving print carriage and cable/ hose carriers. When printing, the print carriage travels back and forth.
Identifies the Protective Earth (PE) terminal for qualified electricians, and bonding terminals for maintenance/ service personnel only. An earth connection is essential before connecting to the supply. Do not disconnect the hoses during the purging process.
Firmly tighten all fasteners, ensuring that the assembly is well fixed together before turning on the build unit.

Warning labels 17

Emergency stop buttons
There is an emergency stop button on the printer and another on the processing station. If an emergency occurs, simply push the emergency stop button to stop all processes. In the case of the printer, the printer carriage, the recoater, the lamps, and the build unit are halted;
the build-unit door and top cover are locked until the internal temperature decreases. In the case of the processing station, the vacuum system, the motors, and the build unit are halted. A system error message is displayed, and the fans turn at maximum speed. Ensure that the emergency stop button is released before restarting the equipment.
For safety reasons, access to the print zone is not permitted while printing is in progress. Let the printer cool down before touching anything inside it. To stop the equipment completely, turn it off. See Turn the printer on and off on page 35 and Turn the processing station on and off on page 37.
18 Chapter 2 Safety precautions

3 Main components
These are the principal components of your 3D printing solution.
Printer
Parts of the printer.

1. Top cover 2. Heating lamps 3. Thermal camera 4. Recoating unit and recoating roller 5. Heating-lamps filter 6. Top-enclosure filters 7. Print bed

Main components 19

8. Printhead 9. Fusing lamps 10. Print carriage 11. Fusing agent 12. Agent door 13. Detailing agent 14. Printhead cleaning roll 15. Internal cleaning- roll door 16. Cleaning-roll collector 17. External cleaning-roll door 18. Build-unit door 19. Main switch 20. Circuit breaker 21. Rearm button 22. Emergency stop button 23. Front panel 24. Spittoon 25. Air exhaust
1. Print-zone filter 2. E-cabinet filter
20 Chapter 3 Main components

3. Network and electrical connections 4. Air exhaust system
Processing station
Parts of the processing station.

1. Hood 2. Mixer 3. Reusable material collector 4. Storage tank 5. Emergency stop button 6. Service switch 7. Sieve 8. External tank 9. Platform control buttons 10. Dust extractor 11. Material loading nozzle

Processing station 21

1. E-cabinet filters
Build unit
Parts of the build unit.
1. Material loading inlet 2. Safety lid 22 Chapter 3 Main components

3. Handle
1. Overflow trays (4) 2. Printing platform 3. Feed trays (2) 4. Vane feeders (2) 5. Build chamber 6. Material chamber 7. Material chamber filter 8. Build unit socket
Accessories
Accessories are not supplied with your printer, but are available for purchase separately. The following accessories are available: The natural cooling unit allows the job to cool outside the processing station, freeing the build unit
for another job.
Accessories 23

Table 3-1 Natural cooling unit specifications

Characteristic

Specification

Weight empty

11 kg (24.3 lb)

Weight full of PA12

34.5 kg (76.1 lb)

The RFID reader identifies individual natural cooling units and the jobs contained in them, by radio frequency, enabling job tracking for easier monitoring and analysis.
The semaphore indicates the status of the printer, providing efficient tracking of the printer’s functionality and requirements.
See also Ordering information on page 349.

Front panel
The front panel is a touch-sensitive screen with a graphical user interface.
There is a front panel on the front left of the printer and another on the front right of the processing station. Each front panel is attached to a movable arm, allowing you to adjust it to a comfortable working position.
The front panel gives you complete control of your printer and processing station: from the front panel, you can view information about the device, change device settings, monitor device status, and perform tasks such as supplies replacement and calibrations. The front panel displays alerts (warning and error messages) when necessary.

24 Chapter 3 Main components

It includes the following components: 1. A Hi-Speed USB host port, intended for connecting a USB flash drive, which can provide firmware
update files to the printer 2. The front panel itself: an 8 inch, full-color, touch-sensitive screen with a graphical user interface 3. The loudspeaker 4. The power key 5. The beacon The front panel has a large central area to display dynamic information and icons. On the left and right sides you can see some fixed icons at different times. Normally they are not all displayed at the same time. Left and right fixed icons Tap the Home icon to return to the home screen. Tap the Go back icon to go back to the previous screen. This does not discard any changes
made in the current screen. Tap the Cancel icon to cancel the current process.
Home screens There are two top-level screens that you can move between by sliding your finger across the screen, or tapping the appropriate button at the bottom of the screen: The first main screen provides direct access to the most important functions.
Front panel 25

Table 3-2 Front panel Printer

Processing station

The all-app screen displays a list of all available apps.

Table 3-3 All-app screen Printer

Processing station

Status center
At the top of the front panel is the status center, which can be expanded by swiping down from the top. This is visible on almost all screens, except when an action is taking place. In the status center, you can see the status of the printer or processing station, and can directly cancel its status (for example, Printing) and alerts. There are other actions you can perform fron the status center, such as moving the carriage and recoating unit for maintenance, ejecting the build unit, or unlocking the top cover.
Beacon
The printer has a beacon located on top of the front panel; it gives a summary of the printer status that can be seen from a distance.
IMPORTANT: The information provided in the beacon is for functional information purposes only, and is not relevant to your safety. Warning labels on the equipment should always be heeded, regardless of the status indicated by the beacon lights.
26 Chapter 3 Main components

Table 3-4 Beacon Graphics

State

Description

White light

The printer is ready.

White moving light

The printer is printing or preparing to print.

Yellow light

The printer can print, but there is something wrong. If the problem persists, contact your support representative. While printing, you will see a yellow instead of a white light.

Red light

The printer is unable to print and needs attention, or a major subsystem of the printer is not working.

Change system options
You can change various printer system options from the front panel.

Tap the Settings icon

, then System.

Date and time options to view or set the printer’s date and time.
Speaker volume to change the volume of the printer’s loudspeaker. Select Off, Low, or High.
Front panel brightness to change the brightness of the front-panel display. The default brightness is 50.
Unit selection to change the units of measurement in the front-panel display. Select English or Metric. By default, units are set to Metric.
Restore factory settings to restore the printer settings to their original values as set in the factory. This option restores all of the printer settings except the Gigabit Ethernet settings.

Change system options 27

Set the administrator password
You can set the administrator password from the front panel.

Tap the Settings icon

, then Security > Administrator password, and enter the password. If a

password has already been set, you will need to give the old password in order to set a new one.

The administrator password must be given in order to change printer settings.
Software
HP provides software to accompany your 3D printing solution. The software can be downloaded from the HP website: http://www.hp.com/go/jetfusion3D5200/software http://www.hp.com/go/jetfusion3D5210/software http://www.hp.com/go/jetfusion3D5210pro/software http://www.hp.com/go/jetfusion3Dprocessingstation/software

28 Chapter 3 Main components

HP SmartStream 3D Command Center

Each device is represented by a card that summarizes the most important information about the device. By default, the build status information is shown.

Table 3-5 Cards Card Information

Card information

The upper part of the card shows the following information: Icon that helps to identify the type of device. Shows the expected finish time, if a part is being built. Name of the device chosen by the user who registered it in Command Center. Current status of the device. You can use the drop-down menu to view information on builds and supplies.
HP SmartStream 3D Command Center 29

Table 3-6 Cards Builds

Supplies

Click the card for more detailed information about the device. Figure 3-1 The Build status tab
Figure 3-2 The Builds tab

30 Chapter 3 Main components

Figure 3-3 The Supplies tab
Figure 3-4 The About tab
Click Back or the breadcrumb to go back to the monitoring overview area.
Types of devices
Command Center can monitor all models of 3D printers, processing stations, build units, and cooling frames. 3D printers This topic explains the concepts involved in this subject. 3D printers have the following sections: Build status: Information about the ongoing activity of the printer.
While a job is being printed, you can see the following information: ­ JOB NAME ­ MATERIAL ­ PRINT PROFILE ­ LAYERS: The number of layers printed, and the total number of layers to print ­ HEIGHT: The height printed, and the total height to print
Types of devices 31

­ PARTS: The number of parts printed, and the total number of parts to print Builds: Information about the current job file that is being printed, the upcoming jobs, and the
pending jobs to be printed. ­ UPCOMING JOB: This appears only when a new job has been submitted while the current job is
printing, to be printed in the same build chamber ­ PENDING JOBS: Jobs that are already stored in the printer, waiting to be printed when selected Supplies: Information about the health of all your supplies, with further information in case of any warning or error.
NOTE: Different printer models may have different types of supplies.
­ BUILD UNIT: Shows the status of the build unit and type of material in the build chamber, if the printer supports build units.
­ FRESH MATERIAL: The percentage of material that is fresh (from a material cartridge); the rest of the material is from the storage tank.
­ AGENTS: A real-time display of the level of the agents. ­ PRINTHEADS: Displays alerts or errors if any. ­ OTHER SUPPLIES: Displays alerts or errors if any. ­ FUSING LAMPS: Displays alerts or errors if any. ­ HEATING LAMPS: Displays alerts or errors if any. About: Information about the printer, such as model and product number, as well as a link to activate the warranty, and a link to the printer’s user guide.
Processing stations This topic explains the concepts involved in this subject. Printed builds: Shows the job files that have been printed inside the inserted build unit. Supplies: Information about the health of all your supplies, with further information in case of any warning or error.
NOTE: Different printer models may have different types of supplies.
About: Information about the processing station, such as model and product number, as well as a link to activate the warranty, and a link to the processing station’s user guide.
Device alerts
The following steps provide the complete procedure for this topic. Cards may display warnings or errors, which may override the printer status, depending on their importance, which is determined by the printer. Warnings are about non-urgent issues, such as a maintenance routine. A warning about a particular
component is displayed on the icon representing that component.
32 Chapter 3 Main components

Errors are about urgent issues that could stop the printer from starting a job, such as a broken lamp. An error about a particular component is displayed on the icon representing that component.
HP SmartStream 3D Build Manager
Use the powerful 3D print-preparation capabilities of HP SmartStream 3D Build Manager to help make all of your 3D printing jobs successful: 1. Add parts to begin preparing the print job. 2. Rotate, size, and position the part on the bed. 3. Automatically locate and fix 3D geometry errors. 4. Send a printer- ready file to a connected 3D printer or save the printable file. You can find more information about the Build Manager in the HP SmartStream 3D Build Manager User Guide: see Documentation on page 1.
HP SmartStream 3D Build Manager 33

4 Power on and off
How to turn your printer and processing station on and off. NOTICE: Operate the equipment only within the specified ranges of operating temperature and humidity (see the site preparation guide). If the equipment or supplies are exposed to conditions outside the environmental operating range, wait at least 4 hours for everything to reach environmental operating conditions before turning on the equipment or using the supplies.
Turn the printer on and off
The correct procedure changes after the first time.
Turn on the printer for the first time
Follow these steps carefully, the first time that you turn on the printer. 1. Make sure that the two bottom rows of circuit breakers at the front right of the printer are all in the
up position and that the three green lamps are on. If any of them are off, check with your electrician.
34 Chapter 4 Power on and off

2. Turn the main switch to the on position.

3. Wait for the front panel to tell you that the printer is waiting for rearm.
4. Perform a visual check of the printer.
5. Press the blue rearm button at the front left of the printer. This enables all of the printer’s highpower subsystems.
6. Wait for the front panel to indicate that the printer is ready. This can take several minutes. When initialization is complete, the front panel displays a Ready message. If a system error message is displayed, see System errors on page 351.

Turn the printer on and off
After you have turned on the printer for the first time, you can use any of these methods to turn it on and off.

Table 4-1 Turn the printer on and off

Method

Turn off *

Turn on

Front panel Red switch

Soft: Select from menu Hard: Hold down the front-panel power button Hard: Turn the red power switch off

Hold down the front-panel power button 1. Turn the red power switch on

2. Hold down the front-panel power button

• Any of these methods will shut down the printer completely. HP strongly recommends not turning off the printer immediately after printing a job: you should leave the printer on while it cools down for at least 2 hours. If it will be idle for a long time and you want to turn it off, HP recommends the soft method from the front panel.

Turn the printer on and off 35

Turn the processing station on and off
The correct procedure changes after the first time.
Turn on the processing station for the first time
Follow these steps carefully, the first time that you turn on the processing station. 1. Make sure that the wheels are braked: the processing station should remain stationary while
operating. 2. Make sure that the two bottom rows of circuit breakers at the front right of the station are all in the
up position.
36 Chapter 4 Power on and off

3. Turn the service switch to the on position.

4. Perform a visual check of the station.
5. Wait for the front panel to indicate that the station is ready. This can take several minutes. When initialization is complete, the front panel displays a Ready message. If a system error message is displayed, see System errors on page 351.

Turn the processing station on and off
After you have turned on the processing station for the first time, you can use any of these methods to turn it on and off.

The processing station has two power-off levels. Level 1 is recommended if you intend to use it again soon. Otherwise, you are recommended to use level 2, which is complete shutdown.

Table 4-2 Turn the processing station on and off

Level

Turn off

Turn on

1: Standby (5 V)
2: All processingstation systems off

Front-panel power button off
1. Front-panel power button off 2. Red main power switch off

Front-panel power button on
1. Red main power switch on 2. Front-panel power button on

Circuit-breaker labels

You may see these labels on your circuit breakers.

Table 4-3 Circuit-breaker labels

Label

Description

Main power

Turn the processing station on and off 37

Table 4-3 Circuit-breaker labels (continued)

Label

Description

DC power

E-box

Build unit

Fusing lamps

Heating lamps

Rearm

LAN

38 Chapter 4 Power on and off

5 Printer and processing station networking
The printer provides a single RJ-45 port for a network connection. In order to meet Class B specifications, the use of shielded I/O cables is required. For optimal performance, you are recommended to use Cat 5/5e or Cat 6 cabling and gigabit-capable local network equipment. A correct network setup is required to operate the printer, as all communication with printing and management software happens through the network.
Connectivity and remote monitoring requirements
Your 3D printing solution requires a permanent Internet connection to the HP secure cloud.
Definitions Product(s) means the HP-branded 3D printing hardware and any related HP-branded 3D printing
accessories, including but not limited to the 3D printer, processing station, and build unit, as well as any accompanying HP-branded 3D software, listed in the customer order and excluding consumables or services. Site Preparation Guide means the site preparation guide for the Product that has been provided to the customer by HP or HP authorized personnel (either online or in paper form) in advance of the sale of the Product. Customer Computer means the computer, as further specified in the Site Preparation Guide, provided by the customer at the customer’s sole expense, which will be hosting the required HP 3D software necessary to manage the Product(s). Customer Machine Data means data collected from the customer’s Product that may include, but is not limited to the following: Product usage data; Product production data; Product system events; Product maintenance and calibration history; Product model number; Product serial number; Product firmware version; Product IP address; consumables status and history; sensors activity; quantity and type of printheads used; build ID; build duration; and/or print mode. Customer Machine Data does not include: design files, parts files, job names, job contents, part geometries, thermal maps, user names or part names.
Requirements The customer will allow HP to install the required HP 3D software on the Customer Computer, keep
the Customer Computer connected to the Product, and keep such HP 3D software running on the Customer Computer at all times.
Printer and processing station networking 39

The customer will provide, at the customer’s sole expense, HP 3D software connectivity to the HP secure cloud via permanent Internet connection through an HP-approved communications channel and will ensure such connectivity at all times as further specified in the Site Preparation Guide. The customer is responsible for restoring connectivity in a commercially reasonable timely manner in the event of unforeseen interruptions.
THE CUSTOMER AGREES THAT FAILURE TO MAINTAIN THE PRODUCT’S CONNECTION TO THE HP CLOUD AS SPECIFIED IN THE SITE PREPARATION GUIDE WILL RESULT IN LIMITED OR NO PRODUCT FUNCTIONALITY AND LIMITED SERVICE LEVEL.
Products may collect Customer Machine Data. The customer grants HP and/or an HP authorized agent permission to remotely access, via the HP 3D software, the Customer Machine Data from Products. The Customer Machine Data will be used by HP and/or an HP authorized agent for the purpose of providing remote support, enabling enhanced diagnostics, preventive maintenance, software updating, calculating supplies and consumables usage and statistics, and evaluating improvements to HP’s products and offerings in the future. In addition, the Customer Machine Data will help HP determine how Products are being used, which product features are used the most, and to calculate various aggregate Product usage statistics.
HP and/or HP authorized agents respect your privacy, are committed to protecting Customer Machine Data, and will take reasonable precautions to prevent unauthorized access or disclosure and ensure the appropriate use of Customer Machine Data. In the event that some data may be categorized as individual level data, HP and/or HP authorized agents will maintain the privacy of any such data, as well as all data collected, in accordance with the HP Privacy Statement (http://www.hp.com/go/privacy) and the Personal Data Rights Notice (http://welcome.hp.com/country/privacy/privacynotice) where applicable.

Configuration
Your network configuration requires some configuration.

To access the network settings, tap the Connectivity icon printer’s front panel.

and then the Settings icon on the

Hostname
You can assign a customized hostname to the printer.
If the network infrastructure supports it, the printer will attempt to register the hostname to the DNS service, making it possible to address the printer using the hostname rather than the IP address.
Similarly, you can assign the domain suffix, to define the printer’s fully qualified domain name.

IPv4 configuration
You can let the printer try to discover the IPv4 network settings automatically using the DHCP protocol, or choose to configure them manually. The IPv4 settings include:
IP address: The unique Internet Protocol address assigned to the printer. Subnet mask: The mask corresponding to the printer’s IP address. Default gateway: The IP address of the network gateway.

40 Chapter 5 Printer and processing station networking

DNS configuration method: Whether DNS servers should be assigned by DHCP service or manually. Primary and secondary DNS servers: The IP addresses of the DNS servers.
Link speed
When connected and powered on, the printer auto-negotiates with your network to operate with a link speed of 10, 100, or 1000 Mbps, and to communicate using full- or half-duplex mode. However, you can manually configure the link using the printer’s front panel, or through other configuration tools once network communication is established. The embedded network controller supports connection to IEEE 802.3 10Base-T Ethernet, IEEE 802.3u 100Base-TX Fast Ethernet, and 802.3ab 1000Base-T Gigabit Ethernet compliant networks.
Troubleshooting
Some suggestions in case you have trouble configuring your network connection successfully.
Link issues
The printer has status lights (LEDs) beside the network connector that indicate the link status and network activity. When the green light is on, the printer has successfully linked to the network. When the yellow light is blinking, there is transmission activity over the network. If the printer fails to connect to the network, both LEDs will be off. In this situation, try the following steps: 1. Check the cable connections at both ends. 2. Consider replacing the cables with ones that are known to work. 3. Consider switching to another network connector in the network switch, hub, or device to which the
printer is connected. 4. Manually configure the link setting to match the port configuration of the network hub or switch. 5. In case of doubt or misconfiguration of link settings, reset the network parameters to their factory
settings.
Restore factory settings
In the case of accidental misconfiguration, you can reset the network settings to the factory defaults. Tap Restore factory settings in the Network Settings configuration menu.
Link speed 41

6 Prepare a file for printing
The printer cannot interpret a 3D image file directly: you must use software to convert it into a format that the printer is designed to accept.
Introduction
You can create a print job using HP SmartStream Build Manager or various third-party programs. HP SmartStream 3D Build Manager supports STL and 3MF files. The software creates slices that the printer can convert to layers in order to prepare the job. This preparation process may take from 15 minutes to 2 hours depending on the complexity of the job. It can be done while printing other jobs. Once ready, you can select the job to be printed from the job queue on the printer’s front panel. If an error occurs while processing, a message appears on the front panel, and the printer cancels the job. To retry, you have to resubmit the job. The rest of this chapter may help you to avoid such errors.
File preparation
Tips to help you prepare files for printing.
Tessellation
Before sending a job to a 3D printer, the model to be printed needs to be tessellated. That means that its geometry needs to be converted into triangles, which are used by the printer to create layers. It is very important to pay attention to this step: if not done correctly, it can cause problems such as inaccuracy or slow processing. Standard formats in the additive manufacturing industry include 3MF (with more information about the model) and STL. A normal file size for a model is about 1­30 MB, but the size depends on the type of software that created it, the number of triangles, the number and level of details, and so on. When exporting to STL in a CAD package, you are often required to introduce some parameters such as angle tolerance and deviation chord height. These parameters define the resolution and file size of the part. The following tips may help you to export with the best surface to file size ratio.
Solid Designer settings
Solid Designer is one of the available software options.
42 Chapter 6 Prepare a file for printing

Save as STL, click Options, and check the ASCII option. The recommended values for the Distance and Angle box are 0.05 and 1.
SolidWorks settings
SolidWorks is one of the available software options. 1. Click File > Save As. 2. Select STL (*.stl) as the file type. 3. Click Options. 4. Choose the Binary option. Binary files are smaller than ASCII files for the same tessellation. 5. Choose Custom resolution. 6. Set the deviation tolerance to 0.05 mm. 7. Set the angle tolerance to 1°.
SolidWorks settings 43

Rhinoceros settings
Rhinoceros is one of the available software options. 1. Click File > Save As. 2. Select STL (*.stl) as the file type. 3. Click File Name > Save. 4. Select Binary. 5. Select Detail Controls from the Mesh Options. 6. Set the maximum angle to 1, the maximum aspect ratio to 6, and the minimum edge length to 0.05.
STL problems
You may experience these problems with your STL files. Too many or too few triangles
Too many triangles are difficult to process and, when a certain size is reached, the extra triangles do not provide any further accuracy. For this reason, an excess of triangles could increase processing time for no benefit. Triangulation of a surface causes faceting of the 3D model. The parameters used to output an STL model affect how much faceting occurs. Example of tessellation:
Holes in triangles STL models commonly suffer from surfaces that are not joined to their neighbors, and missing surfaces.
Repairing STL files
Software tools and common STL file errors STL-repairing software Magics ­ Materialise Netfabb HP SmartStream 3D Build Manager
44 Chapter 6 Prepare a file for printing

Common errors in STL files Triangles not joined
Overlapping triangles
Holes in parts

Flipped-direction triangles

Repairing STL files 45

Tiny shells 46 Chapter 6 Prepare a file for printing

7 Load material into the build unit

In order to print, you need material in the build unit.

Loading procedure
Follow these steps to load material into the build unit.
1. Ensure that the build unit is located on the processing station.
2. Ensure that the build unit printing platform is clean.
3. If you want to change the mix ratio, HP recommends cleaning the build unit first. See Empty the material from the build unit on page 58.

NOTE: If you do not clean the build unit, it will contain some remaining material with the previous mix ratio. In fact, some of the previous material may remain even after cleaning, so you may prefer to use a different build unit. Check the material compatibility specifications.

Table 7-1 Recommended mix ratios

Material

Reusable proportion

HP and Certified Polyamide 12

80%

HP and Certified Polyamide 11

70%

TPU Ultrasint

80%

HP 3D HR PP

80%

In some exceptional cases you may want to change this ratio; for example, when using the processing station for the first time you may need to use 100% fresh material.
4. If you want to change to a different type of material, you should first clean and then purge the processing station, or clean it manually. See Change to a different type of material on page 52.
NOTE: If you do not intend to change the type of material, you may sometimes decide to clean the processing station without purging it, perhaps because you think there is a problem with the particular material that you have been using. See Clean the processing station on page 277.
CAUTION: A small amount of material may remain after cleaning. If your new material cannot tolerate any contamination at all, you should clean the processing station manually. Contact your service representative if you are not trained to do this yourself.

Load material into the build unit 47

5. Ensure that the material cartridges are loaded. 6. At the front panel, tap Build unit > Load. 7. Clean the sieve when requested by the front panel. See Clean the sieve on page 272. 8. Clean the loading nozzle sensor. See Clean the loading nozzle sensor on page 274. 9. Ensure that the material loading inlet is clean. 10. Open the lid of the material loading inlet of the build unit.
11. Attach the material loading nozzle.
48 Chapter 7 Load material into the build unit

12. Define the height by scrolling up and down the right bar. You can change the mix ratio if required.

The loading time depends on the mix ratio used and the quantity to load; here are some approximate examples:
Table 7-2 Loading time

Estimated loading time (min)

Material

Mix ratio

Full print chamber

Half print chamber

HP 3D HR PA12

80% R ­ 20% F

45

25

HP 3D HR PA11

70% R ­ 30% F

50

30

TPU Ultrasint

80% R ­ 20% F

140

75

PA12 GB

70% R ­ 20% F

45

25

HP 3D HR PP

80% R ­ 20% F

70

40

NOTE: The percentage full assumes a 20% packing density.
13. Tap Load to continue.
14. Tap Start.
NOTE: To fill the build unit completely with a mix ratio of 80% reusable, 20% fresh, you may need to do it in two steps if the external tank is not automatic or if it does not contain enough reusable material.
15. The supply container of the unit is filled. Wait for front panel to report that it has been successfully loaded.

Loading procedure 49

16. Detach the material loading nozzle and leave it in parking position. NOTE: If the loading nozzle is not correctly parked, there could be a material spillage while the processing station is idle.
17. Close the material loading inlet.
18. At the front panel, tap Eject the build unit. 50 Chapter 7 Load material into the build unit

19. Extract the build unit from the processing station by pulling the handle, put the safety lid on top of the build unit, and move it to the printer.
20. Open the printer door.
21. Remove the lid of the build unit. a.
Loading procedure 51

b.
22. Insert the build unit by pushing the handles. 23. Close the printer door.

Change to a different type of material

When changing from one material to another, some special procedures may be needed, depending on the compatibility of the materials.

The processing station stores and moves the material from the cartridges to the build unit, and it may be difficult to remove all material particles from the loading path. Check the compatibility chart on the webpage and follow the procedures below, depending on the level of compatibility.

Download the material package from the HP webpage to a USB flash drive, connect it to the processing

station, and then to the printer. At the processing station’s front panel, tap the Maintenance icon

,

then Material > Settings > Change material.

52 Chapter 7 Load material into the build unit

Grade 1: Light cleaning
Light cleaning is sufficient when the materials are relatively compatible. Perform the following operations: See: Empty the material from the build unit on page 58 See: Check and clean the interior of the build unit on page 66 See: Clean the processing station on page 277 Daily printer maintenance: see Printer maintenance on page 145
Grade 2: Deep cleaning and material purge
Deep cleaning should be used when the materials are not compatible. Perform the following operations: See: Empty the material from the build unit on page 58 See: Check and clean the interior of the build unit on page 66 See: Clean the processing station on page 277 See: Purge the processing station on page 54
NOTE: You will need 30 liters of the new material (15 liters from each of the supplier connectors), to be used for purging. For the printer, follow these steps: 1. Turn off the printer (see Turn the printer on and off on page 35). 2. Clean the print zone, carriage, and housing structure on page 153. 3. Clean the inside of the carriage on page 175. 4. Clean the service-station caps on page 177. 5. Clean the top-enclosure fan filters on page 179. 6. Clean the print-zone window on page 205. 7. Clean the bottom glass of the heating lamps on page 194. 8. Clean the front bar on page 158. 9. Clean the scan-axis wipers on page 173. 10. Clean the bottom of the carriage and of the fusing lamps on page 162. 11. Clean the fusing-lamp glasses on page 186. 12. Clean the recoating roller and recoating plates on page 168. 13. Clean the spittoon on page 159. 14. Clean the thermal camera glass on page 164.
Grade 1: Light cleaning 53

15. Turn on the printer (see Turn the printer on and off on page 35).
16. Perform diagnostics:
a. Calibrate the cooling system.
b. Finish checking/cleaning the spittoon.
17. Clean the exterior of the printer on page 167.
Grade 3: Full deep clean
If your new material cannot tolerate any contamination at all, you should clean the processing station manually.
Contact your service representative if you are not trained to do this yourself.
Purge the processing station
The processing station should be cleaned and purged before changing to a different type of material.
NOTE: You will need 30 liters of the new material (15 liters from each of the supplier connectors), to be used for purging. This material will be disposed at the end of the purge process.
The purge process will use new material to recirculate it multiple times through all the subsystems and hoses of the processing station. The new material circulation will remove the remaining particles of the old material, and, eventualy, the purge process will get rid of it.
IMPORTANT: The processing station should always be cleaned before purging. See Clean the processing station on page 277.
IMPORTANT: If the system is switched off in the middle of the process, the process will need to be started again (cleaning included), and more fresh material will be needed.
CAUTION: It is important to keep the purge tool in the indicated position during the whole process. In case of system error, do not disconnect the hoses; restart the processing station and restart the process, or start an unpacking process to ensure that the material left in the hoses is properly cleaned. If it is not possible to do either of these things, remove the tool from its position, keeping it horizontal to avoid possible material spillages.

1. At the front panel, tap the Settings icon

, then Material management > Purge processing

station.

2. Replace the external tank by a new one, which will be used for waste material.

3. Put in place the new material cartridges containing the material that you want to use.

54 Chapter 7 Load material into the build unit

4. Take the purge tool from the drawer and place it on the side of the working area.
5. Connect the material loading nozzle to the reusable material collector with the purge tool. CAUTION: Ensure that the hoses are connected properly. The loading nozzle should be connected to the top and the material collector to the side. If the loading nozzle is correctly connected, the hose should slope gradually downwards; it should not have an `S’ shape. TIP: Tape the unpacking hose and the loading hose to the purge tool to prevent interruptions during the process. If the process is interrupted, the user should start it from scratch, cleaning included.
a.
Purge the processing station 55

b.
6. Tap Continue. 7. Unlatch and open the external tank lid.
8. Connect the external tank collector and pipe. You are recommended to wear gloves and goggles.
NOTE: The pipe sucks up material in its immediate vicinity. If you leave it in one position, it will consume all the material in that area, while there is still material elsewhere in the tank. You should therefore move the pipe around in the tank to access all the available material. 56 Chapter 7 Load material into the build unit

NOTE: You can insert the pipe with the vacuum switched off, if you like. 9. Start the process from the front panel to extract the material from the external tank. 10. Confirm that all the material has been removed from the external tank. 11. Tap Continue. The process will continue unattended almost until the final steps. 12. When prompted by the front panel, disconnect the material cartridge connectors.
13. Place the sieve connector on the reusable material collector, and connect it to the sieve.
a.
Purge the processing station 57

b.
14. Tap Continue, and follow the instructions on the front panel to complete the process. When it is complete, tap Finish.
15. Dispose of the material from the external tank according to local laws. 16. Clean the external tank with an explosion-protected vacuum cleaner. 17. Connect the material cartridges that you intend to use.
Empty the material from the build unit
Use the material collector to vacuum up any loose material in the build unit.

1. Insert the build unit into the processing station with no job inside it. 2. Clean the surface of the build unit, if you have not already done so. See Clean the surface of the
   build unit on page 300. 3. At the front panel, tap Build unit > Empty.
   58 Chapter 7 Load material into the build unit

4. Remove both vane feeders.
5. Follow the front panel instructions to vacuum the material inside the build unit. 6. Connect the material collector to the front material lifter, and tap Start on the front panel.
7. Repeat the same process with the rear material lifter. 8. Repeat again with the front material lifter until there is no material left inside. 9. Vacuum the build-unit printing platform with the reusable material collector.
Empty the material from the build unit 59

10. Vacuum the front overflow tray.
11. Vacuum the area below the cap of the build unit’s loading inlet.
12. Vacuum the feed trays, making sure there is no material left. 13. Vacuum the other overflow trays.
a. 60 Chapter 7 Load material into the build unit

b.
c. 14. Attach the wide nozzle to the reusable material collector. 15. Vacuum the build unit platform.

16. Go to the front panel and move down the platform of the build unit by 350 mm.

To do this, tap the Settings icon

, then Utilities > Maintenance > Lower build platform.

17. Remove the build unit from the processing station.

Empty the material from the build unit 61

18. Manually remove the screw on top of each material lifter, and remove both material lifters.
19. Vacuum both material lifters with a soft-brush nozzle.
20. Clean the material lifter duct with a hand-held low-scratch tube brush. 21. Locate the material lid and remove the two Torx 20 screws from it.
a. 62 Chapter 7 Load material into the build unit

b. 22. Loosen the six flat screws.
Empty the material from the build unit 63

23. Remove the lid. 24. Using a soft-brush nozzle, vacuum the material inside the build unit from top to bottom.
a. Vacuum the perimeter below the platform.
64 Chapter 7 Load material into the build unit

b. Vacuum the column gasket.
c. Vacuum the mesh point by point. You cannot slide the nozzle over the mesh, but must vacuum one point and then lift the nozzle and put it down in another point.
25. Using a narrow nozzle, vacuum first around the mesh and then the material-lifter inlets.
Empty the material from the build unit 65

Check and clean the interior of the build unit
Make sure that no material is left in the build unit.
IMPORTANT: All build units to be used with the new material must be clean before starting: see Empty the material from the build unit on page 58.
Prepare for cleaning
1. Ensure that you have an explosion-protected vacuum cleaner with soft-brush nozzle, an absorbent all-purpose cloth, a flat screwdriver, a Torx 20 screwdriver, and deionized water (these things are not provided by HP).
2. You are recommended to wear gloves, goggles, and mask.
Check and clean the interior of the build unit

1. At the front panel, tap the Settings icon

, then Maintenance > Utilities > Set build unit as clean.

2. Locate the material lid and remove the two Torx 20 screws from it.

a.

b. 66 Chapter 7 Load material into the build unit

3. Loosen the six flat screws. 4. Remove the lid.
Check and clean the interior of the build unit 67

5. Check the interior of the build unit and use the explosion-protected vacuum cleaner with soft-brush nozzle, if needed, to remove the remaining material.
Finish cleaning
1. Tighten the four captive flat screws. 2. Put back and tighten the two Torx 20 screws. 3. Vacuum the area below the cap of the build unit’s loading inlet.
68 Chapter 7 Load material into the build unit

8 Print
How to print a job
Job list app
The Jobs icon on the printer’s front panel displays the status of all jobs. Possible statuses are: Waiting to process Processing Processed: The job is ready to be sent for printing. Either it has never been printed, or it is ready for
reprinting. Sent to print: The job has started printing.
Send a job to be printed
Before sending a print job, make sure that the printer is ready for it. Make sure that you have done at least the required daily maintenance tasks. See Hardware maintenance for HP Jet Fusion 5420W 3D Printer on page 317. Make sure you have the build unit filled with the correct material and in the printer. See Load material into the build unit on page 47. Then use the HP SmartStream 3D Build Manager to send the job to the printer. See the HP SmartStream 3D Build Manager User Guide.
Select a job to be printed
Select the job and start printing.
Print 69

1. At the printer’s front panel, tap the Jobs icon

on the home screen.

2. If the build unit has not been inserted, open the door and insert the build unit by pushing the handles.
3. Select the processed job and tap Print. 4. The printer checks that all subsystems and supplies are ready to complete the build. If one of
them is not ready, the printer notifies and advises you: a notification appears in the job details with an accessible summary of any issues. If necessary, correct the issue(s) and resend the job for printing. 5. The printer starts the printing process. Wait until the printer tells you that the process is complete, then remove the build unit.
Add job while printing
If you have available space in the build unit and enough material, you can add a job to be printed while the previous job is still being printed. To do so, select the job to be printed and tap Add. The printer checks whether it can be added, and adds it if feasible. On the Jobs page, the FINISH line shows the total time to finish the currently printing job and the following jobs in the queue. It is updated whenever a job is added or removed.
70 Chapter 8 Print

NOTE: When adding a job to the queue, the button at the bottom of the page becomes Remove, allowing you to remove the job from the queue and return it to its initial location. When you add a job while printing, sacrifice layers are added between jobs; see diagram below.
A job can be added only if there is enough height available for it. Take into account that the height required is the printed height plus the sacrifice layers between jobs. You cannot add a job while the current job is annealing. NOTE: Adding a complex job during printing may slow down the processing of the current job, which could cause printing problems.
Cancel a job
You can cancel a job while it is printing.
Cancel a job 71

If you need to cancel the job while printing, tap Cancel and confirm it in the build status app on the printer’s home screen. The printer will cancel the job.
IMPORTANT: When printing with TPU material, if you cancel during the annealing process, your parts may have major print-quality issues. HP does not recommend canceling.
IMPORTANT: Wait until the printer tells you it is safe to remove the build unit.
Proceed with the cooling process and unpacking if relevant. If no parts have been printed, the build unit should be cleaned and loaded before using it again.

Check status on the front panel
You can monitor the status of the current job from the front panel.

At the printer’s front panel, the Build status icon

on the home screen shows you the status of the

build currently being printed.

Status of the job: A progress bar shows the phase completed. The phases are warming, printing, and annealing (if selected when the job was sent to print).

Estimated finishing time

Job name

Layers printed and layers in total

Parts printed and parts in total

Height printed and total height

Material type

You can select an isometric or section view of the current layer, and you can navigate through layers. 72 Chapter 8 Print

When printing with TPU, after the job has been printed successfully, the build unit will be maintained at optimal temperature for manual unpacking for 4 hours. This process is canceled by removing the build unit from the printer, after which it cannot be resumed. After disconnecting the build unit from the printer, manual unpacking must be finished in the time indicated on the front panel (2 hours for a full build chamber).
Check status remotely
You can check the job status from the Command Center. See HP SmartStream 3D Command Center on page 29
Possible errors while printing
If one of these errors occurs, the printer cancels the job immediately. Out of agent Out of cleaning roll Printhead error Broken lamp Crash during printing Power cut IMPORTANT: Wait until the printer tells you it is safe to remove the build unit. Proceed with the cooling process and unpacking if relevant. If no parts have been printed, the build unit should be cleaned and loaded before using it again.
Print modes
In the HP SmartStream 3D Build Manager, you can choose the balanced or the fast print mode from the print profile drop-down menu. Balanced mode delivers balanced properties. Fast mode maximizes speed for any job.
Check status remotely 73

9 Unpack the build
After printing, the build must be extracted from the build unit.
General advice and precautions
As the build is at a high temperature while printing, you must wait about 30 minutes before extracting the build unit from the printer. Then some further cooling time is required in order to preserve part quality.
Tips Wear personal protective equipment: see Personal protective equipment on page 12. Unpack calmly. There are physical buttons with which you can raise or lower the printing platform to make the
unpacking process more convenient. The sides and corners of the build chamber are colder than the center. If the parts are large, or the material around the parts seems very hot, leave them aside to cool
down. If you notice that the vacuum speed slows down, try to unpack material from cooler locations or
from cooled parts. Unpacking can be done from the build unit or from the natural cooling unit. To handle the natural
cooling unit, a forklift with particular characteristics is required. For this purpose, HP strongly recommends the Hovmand Forklift 5200. ­ The Hovmand Forklift 5200 is specifically designed to support loading and unloading the natural
cooling unit. ­ The presence of at least one Hovmand Forklift 5200 per facility is strongly recommended. ­ For more information on the product and to order the Hovmand Forklift 5200, consult your local
HP 3D printing specialist. ­ Please be aware that HP’s Limited Warranty does not cover any problems that may arise from
the use of non-approved third-party lifting devices. ­ For more detailed information about the use of the Hovmand Forklift 5200, including an
explanation of the position stops, see the user guide provided by Hovmand.
74 Chapter 9 Unpack the build

If the forklift does not fit
In some cases, the forklift may not fit into the processing-station guides. To solve this problem, some parts from the processing-station structure should be replaced by parts from the the sheet-metal parts service kit (3FW27-67150).
Sheet-metal installation process
How to install the sheet-metal parts.
Installation process, left side
1. Remove the six screws highlighted below.
If the forklift does not fit 75

2. Remove the metal tube. The tube is needed when transporting the processing station, so HP recommends keeping it in case of need.
3. Assemble the new metal piece and one sheet-metal part with one screw in the front position. Do not tighten the screw, as you may need to add more sheet-metal parts after calibration.
76 Chapter 9 Unpack the build

Installation process, right side
1. If on the right side you see two metal tubes as shown below, continue with the rest of this procedure. If, instead, you see the flat sheet-metal parts already installed, you can skip the rest of this procedure.
2. Remove two screws from the tubes.
3. Remove both tubes. Keep the one with a U shape. The other one is not needed, unless you decide to reinstall it in the future.
Installation process, right side 77

4. Attach the new sheet metal parts and the U-shaped tube with the two screws that you just removed. Do not tighten the screws until the calibration process has finished.
Calibration process
Position the forklift in front of the processing station and check how it aligns with the processing-station guide on the right.
Horizontal adjustment (if needed)
Move the U-shaped tube to left or right until the forklift foot is aligned with the processing-station guide. 78 Chapter 9 Unpack the build

Figure 9-1 To move to the left: Figure 9-2 To move to the right:
Vertical adjustment (if needed)
Use the sheet-metal parts to make the vertical adjustment.
Vertical adjustment (if needed) 79

1. Take four sheet-metal parts from the left side and place them on top of the forklift foot.
2. Compare the sheet-metal parts on top of the processing-station guide and the ones on top of the forklift foot, and count how many overlap.
3. If the forklift is too high, remove sheet-metal parts from the processing- station guide until there is no overlap. If the forklift is too low, continue adding sheet-metal parts to the processing-station guide as long as there is no overlap.
80 Chapter 9 Unpack the build

4. The final position of the forklift foot should be as shown below.
5. Now you can tighten the screws attaching the U-shaped tube. 6. Count the number of sheet-metal parts you have used on the right, make sure you have used the
same number of parts on the left, and tighten the screw on the left. 7. Check that the natural cooling unit can be moved over the build unit.
Extracting the build to the natural cooling unit
Extracting the build from the build unit frees the build unit to be used for another job. NOTE: The natural cooling unit is an accessory. See Accessories on page 23. 1. Remove the build unit from the printer. 2. Use an explosion- protected vacuum cleaner to remove any material from the overflow trays. 3. Insert the build unit in the processing station, go to the processing station’s front panel, and tap
Build unit > Cooling unit.
Extracting the build to the natural cooling unit 81

4. Open the processing-station door, put the natural cooling unit on the build unit, and ensure that it is properly attached.
Check that: The build unit overflows are empty. The natural cooling unit is correctly attached to the build unit, with the latches closed. You cannot pull up the natural cooling unit without opening the latches. CAUTION: HP recommends leaving the build unit in the processing station while attaching the natural cooling unit. If you first remove the build unit from the processing station, it is your responsibility to use the recommended personal protective equipment (see Personal protective equipment on page 12) and to avoid the risk of explosion. NOTE: The processing station should automatically detect and identify the natural cooling unit. If it does not, check that the unit is correctly positioned and attached. If necessary, contact your service representative.
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5. Remove the slicing blade from the natural cooling unit. Make sure the front flap (slicing blade flap) remains closed.
WARNING! Hazardous substances could be released during the natural cooling process. Ensure that the room is ventilated as recommended in the site preparation guide, and do not open the natural cooling cover before the recommended time. 6. Connect the reusable material collector to the natural cooling unit aspiration connector.
Extracting the build to the natural cooling unit 83

7. Once the print job has been lifted into the natural cooling unit, put the slicing blade back in place. Make sure the front flap and the slicing blade are in the correct positions.
CAUTION: Ensure that the slicing blade is fully inserted, and that the slicing-blade flap is closed. 8. Remove the natural cooling unit from the processing station, using a forklift.
CAUTION: If any material spillage is detected, make sure the slicing blade is closed, and clean up the material with an explosion-protected vacuum cleaner. NOTE: HP recommends transporting the natural cooling unit in the lowest position of the forklift, to avoid it falling. 9. After cleaning, the build unit will be ready for a new print job. 84 Chapter 9 Unpack the build

Unpacking with the natural cooling unit
Insert the natural cooling unit into the processing station for unpacking. NOTE: The natural cooling unit is an accessory. See Accessories on page 23. 1. If there is a build unit in the processing station, remove it. 2. Put the natural cooling unit inside the processing station, in place of the build unit, using a forklift.
3. Wait for the natural cooling unit to be detected by the processing station. 4. Make sure the natural cooling unit is in the unpacking position. 5. Open the natural cooling unit and put the unpacking cover in place.
6. Proceed to unpack, following the instructions on the front panel. 7. After unpacking, clean the natural cooling unit. 8. Remove the unpacking cover and take out the natural cooling unit.
Unpacking without the natural cooling unit
Without the natural cooling unit, you can choose one of two cooling processes.

1. When the printer tells you to proceed, open the door, extract the build unit, and place the safety lid
   over it.
   Unpacking with the natural cooling unit 85

2. Put on heat-resistant gloves and vacuum the top surface of the build unit with an external explosion-protected vacuum cleaner.
3. At this point you can choose to follow the natural cooling process: a. Move the build unit aside to cool down further. CAUTION: You are recommended to lock the wheels of the build unit while it is outside the printer.
b. Wait. The cooling time depends on the size of the build. c. Insert the build unit into the processing station.
4. Alternatively, you can follow the fast cooling process: a. The build unit must be left to cool naturally for 3 or 4 hours before fast cooling can start. It does not need to be inside the processing station during this time. b. When you have inserted the build unit into the processing station, go to the processing station’s front panel and tap Build unit > Fast cooling.
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c. Fast cooling starts. You can tap the Cancel icon at any time to cancel fast cooling. To resume the process, ensure that the build unit is inserted, and tap Fast cooling.

Table 9-1 Default fast cooling times for PA11 and PA12 material

Description

PA11

PA12

Half-full build chamber (190 mm)

7.4 h

6 h

Full build chamber (380 mm)

16 h

11 h

Before starting the fast cooling process, you can modify the timing by tapping Modify.
TIP: Modify can be locked so that only administrators can modify the timing.
The timing is changed based on a cooling factor, which is related to speed; it is used to calculate the fast cooling time for different job heights. Modifying this value may compromise part quality.
NOTE: The use of fast cooling may cause less uniformity in part cooling rates, and parts may finish at higher temperatures than with natural cooling.
d. Connect the reusable material collector to the safety lid, and tap Start on the front panel, which will tell you the remaining time.

Unpacking without the natural cooling unit 87

5. When cooling is complete, remove the safety lid and park it on the front of the build unit.
6. Use the build unit app on the processing station’s front panel to check that the build is ready for unpacking.
7. At the processing station’s front panel, tap Build unit > Unpack > Start to start the unpacking process. IMPORTANT: The vacuum is activated when you tap Start, and the dust extractor is activated to keep the process clean. CAUTION: Wear heat-resistant gloves. TIP: Close the hood to improve the performance of the dust extractor.
8. Redeploy the reusable material collector. You can use one of the following nozzles: Crevice nozzle, for cleaning the feed tray and narrow areas Fine mesh nozzle, with a 2 mm mesh, for unpacking very small parts
88 Chapter 9 Unpack the build

Wide nozzle, for cleaning the working area rapidly CAUTION: Do not use the wide nozzle to clean the mesh shaker (on the feed trays of the build unit), as you could damage the accessory and leave residues inside.
9. Vacuum the external perimeter of the platform (this step is unnecessary if you have used fast cooling).
Unpacking without the natural cooling unit 89

10. Raise the platform by pressing the button.
11. Vacuum the build to reveal the parts.
12. Clean each part separately to avoid having big clumps of material covering the part. You don’t need to clean every surface thoroughly because: The material that is closest to the part or attached to it may reduce the overall quality of reused material. That material will be removed anyway during sandblasting and postprocessing. The example below shows a part that is ready for the bead blast.
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Continue until all parts are extracted from the build chamber. Use the physical buttons to lift the platform to reach all parts. 13. After checking that all parts are unpacked, put them in a box and take them to the postprocessing section.
14. Ensure that the printing platform is at its highest position.
Unpacking without the natural cooling unit 91

15. Vacuum the empty printing platform and feed tray.
16. Tap Finish on the front panel. 17. Clean the surface of the build unit. See Clean the surface of the build unit on page 300. 18. Vacuum the platform control buttons to prevent loose material from blocking them.
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10 Part cleaning and postprocessing
Once parts have been unpacked from the build in the processing station, they should be cleaned. There are different processes that can be followed, depending on your needs. In general, you will need equipment not provided by HP. The main process recommended by HP is a combination of bead blasting (first) and air blasting (second). Bead blasting consists of applying compressed air mixed with an abrasive to the part in order to
remove the attached material. This is a generally appropriate solution; however, you may want to select different abrasives or pressures for specific purposes. Air blasting consists of applying compressed air to the part in order to remove any material remaining after bead blasting. Depending on your specific needs, other postprocessing methods may be suitable for you. The following options are available to improve surface finishing: Tumbling: The part is immersed in a vibro-tumbler full of abrasives, to smooth any surface roughness. Hand sanding: The surfaces of the part are smoothed by abrasion with sandpaper. The following options are available for color-related finishing: Bead blasting with other additives consists of applying compressed air mixed with an abrasive and a colored additive to the part in order to achieve homogeneous surface color. Dyeing consists of immersing the part in a controlled dyeing bath. All details and cavities of the part can be reached. Painting the part with spray can, spray gun, or brush. For specific color finishing, HP recommends applying a primer before painting the part. Repeat the process several times for optimal results. Other industry-standard postprocessing methods may be used: Gluing, bonding, sealing Drilling, tapping Plating Coatings for wear resistance, conductivity, temperature resistance, strength, watertightness, resistance to chemicals, gloss properties, UV protection, and so on Contact your HP support representative to discuss solutions for your specific needs.
Part cleaning and postprocessing 93

Consult your usual EHS specialist for advice on the appropriate measures for your location depending on the post-processing method you use. Consult your local authorities to determine the correct manner in which to dispose of wastes.
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11 Hardware maintenance for HP Jet Fusion 5200 Series 3D Printing Solution
Hardware maintenance is needed from time to time, to keep your products in good working order. WARNING! Hardware maintenance may be performed by trained personnel only. During printer installation, the designated personnel receive training for safe operation and maintenance of the printer. No-one should use the printer without this training.
Safety precautions
Read and follow the safety precautions in this guide to make sure you use the equipment safely. See Safety precautions on page 5. You are expected to have the appropriate technical training and experience necessary to be aware of hazards to which you may be exposed in performing a task, and to take appropriate measures to minimize the risks to yourself and to others.
General cleaning instructions
For general cleaning, a lint-free cloth dampened with distilled water is recommended. After cleaning, let the cleaned part dry or use a cloth to dry it completely. Do not spray fluids directly onto the product. Spray the fluid onto the cloth used for cleaning. To remove stubborn dirt or stains, moisten a soft cloth with water and a neutral detergent, or a generalpurpose industrial cleaner (such as the Simple Green industrial cleaner). Remove any remaining soap foam with a dry cloth. For glass surfaces, use a soft, lint-free cloth lightly moistened with a non-abrasive glass cleaner or with a general-purpose glass cleaner (such as the Simple Green glass cleaner). Remove any remaining soap foam with a lint-free cloth dampened with distilled water, and dry it with a dry cloth to prevent spotting. WARNING! Make sure to use adequate personal protective equipment. See Personal protective equipment on page 12 and Warning labels on page 13. CAUTION: Do not use abrasives, acetone, benzene, sodium hydroxide, or carbon tetrachloride on the glass: they can damage it. Do not place or spray liquid directly on the glass, the liquid might seep under the glass and damage the device.
Hardware maintenance for HP Jet Fusion 5200 Series 3D Printing Solution 95

You can use a canister of compressed air to remove dust from electronic/electrical parts.
CAUTION: Do not use water-based cleaners for parts with electrical contacts: such cleaners may damage electrical circuits.
CAUTION: Do not use wax, alcohol, benzene, thinner, ammonia-based cleaners, or other chemical detergents, to prevent damage to the product or the environment.
NOTE: In some locations the use of cleaner products is regulated. Ensure that your cleaner follows federal, state, and local regulations.

Maintenance resources
Supplies and tools that you may need for maintenance operations.

Maintenance kits

These maintenance kits are available from HP.

Table 11-1 Maintenance kits

Name

Purpose

How to order

Printer initial maintenance kit (3FW25A)

For periodic maintenance operations that require the Through the replacement of printer parts; lasts for about 100 full usual channel jobs

Printer initial maintenance kit (3FW25B)

For periodic maintenance operations that require the Through the replacement of printer parts; lasts for about 100 full usual channel jobs

Processing-station maintenance kit

For periodic maintenance operations that require the Through the

replacement of processing-station parts

usual channel

Part number 8VJ71A
348C4A
8VJ72A

Kit contents and recommended tools
These are the expected contents of each kit in detail. NOTE: The contents may vary in future.

Printer initial maintenance kit contents (8VJ71A)
The maintenance kit contains spare components that you may need to replace from time to time.

NOTE: This kit is for 3FW25A model printers.

Table 11-2 Printer initial maintenance kit contents (8VJ71A)

Part Description

SKU

Quantity of Quantity of Purpose

items inside SKUs in Initial

each SKU kit for 5200A

(8VJ71A)

HP Jet Fusion 5200 Series 3D 1X9A5A Printer Top Enclosure Right Filters

2

2

Replace the top-enclosure left and right fan filters on page 221

96 Chapter 11 Hardware maintenance for HP Jet Fusion 5200 Series 3D Printing Solution

Table 11-2 Printer initial maintenance kit contents (8VJ71A) (continued)

Part Description

SKU

Quantity of Quantity of Purpose

items inside SKUs in Initial

each SKU kit for 5200A

(8VJ71A)

HP Jet Fusion 5200 Series 3D Printer Top Enclosure Left Filters

1X9A4A

1

2

Replace the top-enclosure left and right fan filters on page 221

HP Jet Fusion 5200/4200 Series 3D Printer Heating Lamps

8VJ63A

2

1

Replace a heating lamp on page 258

HP Jet Fusion 5200 Series 3D 8VJ73A Printer Fusing Lamps

1

1

Replace the fusing lamps on page 124

HP Jet Fusion 5200 Series 3D 8VJ74A Printer Intermediate Tank

2

2

Replace an intermediate tank on page 263

HP Jet Fusion 5200/4200 Series 3D Printer Top Heat Lamps Filter

8VJ67A

1

1

Replace the heating-lamp filter on page 208

HP Jet Fusion 5200/4200

8VJ64A

Series 3D Printhead Cleaning

Roll Rubber

1

2

Replace the printhead cleaning roll’s rubber blade on page 237

HP Jet Fusion 5200/4200 Series 3D Printer Print-zone Filter

8VJ65A

1

1

Replace the print-zone filter on page 219

Cleaning kit (protective

–

eyewear and mask)

2

General maintenance processes

Kit includes:

– Protective glasses (qty: 1)

– Protective mask (qty: 2)

Printer & Build Unit PowerBox Filters for 3FW25A model printers

8VJ66A

1

Replace the power-box fan filters on page 213

Kit includes:

– Power Box 1 filter (for 4200 and 5200A) (qty: 1)

– Power Box 2 filter (qty: 1)

– E-cabinet filter (qty: 1)

– Build-unit material-chamber filters (for 3 build units) (qty: 6)

PowerBox 3 Filter for 3FW25A 2E7N3A model printers

1

1

Replace the power-box 3 filter (2E7N3A) on page 216

Each SKU can be ordered separately if needed.
Printer initial maintenance kit contents (348C4A)
The maintenance kit contains spare components that you may need to replace from time to time.

Printer initial maintenance kit contents (348C4A) 97

NOTE: This kit is for 3FW25B model printers.

Table 11-3 Printer initial maintenance kit contents (348C4A)

Part Description

SKU

Quantity of Quantity of Purpose

items inside SKUs in Initial

each SKU kit for 5200A

(8VJ71A)

HP Jet Fusion 5200 Series 3D 1X9A5A Printer Top Enclosure Right Filters

2

2

Replace the top-enclosure left and right fan filters on page 221

HP Jet Fusion 5200 Series 3D Printer Top Enclosure Left Filters

1X9A4A

1

2

Replace the top-enclosure left and right fan filters on page 221

HP Jet Fusion 5200/4200 Series 3D Printer Heating Lamps

8VJ63A

2

1

Replace a heating lamp on page 258

HP Jet Fusion 5200 Series 3D 8VJ73A Printer Fusing Lamps

1

1

Replace the fusing lamps on page 124

HP Jet Fusion 5200 Series 3D 8VJ74A Printer Intermediate Tank

2

2

Replace an intermediate tank on page 263

HP Jet Fusion 5200/4200 Series 3D Printer Top Heat Lamps Filter

8VJ67A

1

1

Replace the heating-lamp filter on page 208

HP Jet Fusion 5200/4200

8VJ64A

Series 3D Printhead Cleaning

Roll Rubber

1

2

Replace the printhead cleaning roll’s rubber blade on page 237

HP Jet Fusion 5200/4200 Series 3D Printer Print-zone Filter

8VJ65A

1

1

Replace the print-zone filter on page 219

Cleaning kit (protective

–

eyewear and mask)

2

General maintenance processes

Kit includes:

– Protective glasses (qty: 1)

– Protective mask (qty: 2)

Printer & Build Unit Powerbox Filters Kit for 3FW25B model printers

348C5A

1

Replace the power-box fan filter (348C5A) on

page 218

Kit includes:

– Power box filter for 5200B (qty: 1)

– E-cabinet filter (qty: 1)

– Build-unit material-chamber filters (for 3 build units) (qty: 6)

Each SKU can be ordered separately if needed.

98 Chapter 11 Hardware maintenance for HP Jet Fusion 5200 Series 3D Printing Solution

Processing-station maintenance kit contents (8VJ72A)
The maintenance kit contains spare components that you may need to replace from time to time.

Table 11-4 Processing-station maintenance kit contents (8VJ72A)

Part Description

SKU

Quantity of Quantity of Purpose

items inside SKUs in initial

each SKU kit for

Processing

Station

(8VJ72A)

HP Jet Fusion 5200/4200 Processing Station E cabinet filters

8VJ79A

4

1

Replace an e-cabinet fan filter on page 286

HP Jet Fusion 5200/4200 Processing Station Dust Extractor Filter

8VJ69A

2

2

Replace the dust extractor filters on page 290

HP Jet Fusion 5200/4200 Processing Station Vacuum Pump Filter

8VJ68A

1

2

Replace the vacuum-pump filter on page 292

Each SKU can be ordered separately if needed.
Maintenance tools recommended but not provided
These common tools may be needed but are not provided by HP. Spiral scourer, for some cleaning operations
Use a scourer that does not scratch glass; test it on a corner if in doubt. Razor scraper

Absorbent all-purpose cloth, for cleaning covers and general cleaning Processing-station maintenance kit contents (8VJ72A) 99

Lint-free cloth or all-cotton cloth, for cleaning covers and general cleaning
General-purpose industrial cleaner (such as Simple Green industrial cleaner), for general cleaning Deionized water, for general cleaning
Explosion-protected vacuum cleaner, with nozzle accessories for general cleaning (crevice and soft brush nozzles highly recommended)
100 Chapter 11 Hardware maintenance for HP Jet Fusion 5200 Series 3D Printing Solution

NOTE: Inside and outside the equipment should be cleaned regularly with an explosion-protected vacuum cleaner to prevent dust and condensation from accumulating. Do not sweep the dust or try to remove it with a compressed-air gun.
An explosion-protected vacuum cleaner certified for collection of combustible dust is required for cleaning. Take measures to mitigate material spillage and avoid potential ignition sources such as ESD (ElectroStatic Discharges), flames, and sparks. Do not smoke nearby.
Flashlight, for general use

Folding steps, for general use

Flat screwdriver

Maintenance tools recommended but not provided 101

Torx screwdriver
Preventive maintenance
The purpose of scheduled preventive maintenance is to perform regular maintenance operations as required, in order to prevent possible failures from occurring and ensure good performance throughout the life of the product. For each scheduled preventive maintenance action, there is an internal life counter in the firmware that counts a variable related to the life of the component. When the internal life counter reaches the limit for a preventive maintenance action (set according to testing and development), an alert is displayed in the notification center on the front panel.
Preventive maintenance alerts and actions
An alert tells you that some maintenance action is required. There are two types of preventive maintenance alerts: Alerts that require a service engineer to complete the action (contact your support representative)
There are three such alerts, corresponding to the three maintenance kits described below. Alerts that require you to complete the action
Service preventive maintenance alerts
Service alerts require action by a service engineer. When a preventive maintenance number is displayed, before dispatching the part, a check is required in case there are other preventive maintenance alerts almost due; in which case, they can be done together.
102 Chapter 11 Hardware maintenance for HP Jet Fusion 5200 Series 3D Printing Solution

Table 11-5 Service preventive maintenance alerts

Alert

Description

Printer maintenance kit #1 required

Replace the scan-axis motor and front bar SRV

Printer maintenance kit #2 required

Replace the recoating unit carriage and sax chain assy SRV

Printer maintenance kit #3 required

Replace the carriage

Build unit maintenance kit #1 required Replace platform nut and column gasket

NOTE: The Notification Center displays alerts only for the build unit that is inserted at that time.

Operator preventive maintenance alerts
Operator alerts require action by you.

The notification center displays alerts whenever a maintenance action is required.

Table 11-6 Operator preventive maintenance alerts

Alert

Action required

Replace fusing agents intermediate tanks
Replace detailing agents intermediate tanks

Replace an intermediate tank on page 263 Replace an intermediate tank on page 263

Replace rubber blade

Replace the printhead cleaning roll’s rubber blade on page 237

Check for alerts through the front panel status center
Any alert concerning the printer and the build unit is displayed at the top of the front panel in the status center, which can be expanded by swiping down from the top.

Operator preventive maintenance alerts 103

NOTE: The status center displays alerts only for the build unit that is inserted at that time.
Check preventive maintenance usage level on the front panel
You can check the preventive maintenance usage levels, which are automatically converted to a percentage according to the life counter values, on the front panel.

To do so, tap the Settings icon instructions.

, then Utilities > Maintenance > Show PMK status and follow the

The front panel displays the current status of all user and service preventive maintenances. It also displays the maintenances required for the build unit currently inserted, if any.
104 Chapter 11 Hardware maintenance for HP Jet Fusion 5200 Series 3D Printing Solution

NOTE: Only the usage levels for the build unit that is inserted at that time are displayed. NOTE: The percentages given are estimates only.
Consumables
Consumables need to be replaced periodically as a matter of routine.
Printer
The printer consumables include agents, printheads, printhead cleaning rolls, and fusing lamps.
Agents
There are two kinds of agents: fusing and detailing agents. The printer accepts agent cartridges with a capacity of 3 or 5 liters.
Please note: This is a dynamic secur

References

• Laptop Computers, Desktops, Printers, Ink & Toner | HP® Official Site
• hp.com/go/jetfusion3D5200/manuals
• hp.com/go/jetfusion3D5200/software
• hp.com/go/jetfusion3D5200/support
• hp.com/go/jetfusion3D5210/manuals
• hp.com/go/jetfusion3D5210/software
• hp.com/go/jetfusion3D5210/support
• hp.com/go/jetfusion3D5210pro/manuals
• hp.com/go/jetfusion3D5210pro/software
• hp.com/go/jetfusion3D5210pro/support
• hp.com/go/jetfusion3D5420W/support
• hp.com/go/jetfusion3Dprocessingstation/software
• hp.com/go/jetfusion3Dprocessingstation/support
• HP
• HP Privacy Central | HP® Official Site
• hp.com/go/selfrepair/

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