DP3000 error

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stueck9356

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Hey guys. This is my first post so please only make a little fun of me!

Here is our problem. We purchased a DP3000 about 18 months ago from a local reseller. They are only about an hour away so we figured we would get quick tech support if we needed. Well we have used them, and let me tell you close proximity doesn't help one bit in getting a tech out here. Regardless, I am on here and hoping to learn a bit about our printer.

We only print about 50 cases a day, copings, bridges, full contour, the occasional tie fighter or death star, etc. We only use one part every 2 weeks or so.

Currently, I am trying to get a print going. Twice now, it has errors out with

ABORT - HMS WIPE ERROR

Here is a bit of the log

Code:
Wed 04/10/13 14:59:44 TCP      STORE_FILE      0  File:C:\ProJet\Bin\..\work\11676632.ctl
Wed 04/10/13 14:59:48 TCP      SEND_JOB        0 10.0.0.113: scan@scan-pc2-0270
Wed 04/10/13 15:01:14 DEBUG    BTN_PRESSED    1 Online Pressed
Wed 04/10/13 15:01:14 BUILD    WAIT_READY      0
Wed 04/10/13 15:01:14 DEBUG    TEMP_STATE_CHANGE    4 Adapter Build
Wed 04/10/13 15:01:15 DSP      LOCAL_LOG       0 Realtime GO_TO_BUILD
Wed 04/10/13 15:01:15 DSP      LOCAL_LOG       0 Machine Off Time Sets Delay
Wed 04/10/13 15:01:15 DSP      LOCAL_LOG       0 Jetstack Delay = 10 Minutes
Wed 04/10/13 15:01:15 BUILD    PRE_JOB_CHECKS    0
Wed 04/10/13 15:01:17 DEBUG    BTN_PRESSED   11 Yes Pressed
Wed 04/10/13 15:01:19 DEBUG    NOTICE         0 Send Parameters To DSP
Wed 04/10/13 15:01:19 DSP      LOG             0 Servo Enabled by PC
Wed 04/10/13 15:01:19 DSP      LOG             0 Try to servo X at 26.1999
Wed 04/10/13 15:01:19 BUILD    HOME_XY         0
Wed 04/10/13 15:01:20 DSP      LOG             0 Home X
Wed 04/10/13 15:01:20 DSP      LOG             0 Detected X Limit
Wed 04/10/13 15:01:20 DSP      LOG             0 Home Y
Wed 04/10/13 15:01:21 DSP      LOG             0 Detected Y Limit
Wed 04/10/13 15:01:22 BUILD    HOME_Z          0
Wed 04/10/13 15:01:22 DSP      LOG             0 Home Z
Wed 04/10/13 15:02:54 DSP      LOG             0 Z Right Limit Detected
Wed 04/10/13 15:02:54 DSP      LOG             0 Z Left Limit Detected
Wed 04/10/13 15:02:54 DSP      LOG             0 Delta Z set to -0.020000
Wed 04/10/13 15:02:55 BUILD    ONLINE          0
Wed 04/10/13 15:02:55 PREP     CTL_COMBINE_JOBS     0
Wed 04/10/13 15:02:55 PREP     OPEN_FILES        0 Build Style: UHD
Wed 04/10/13 15:02:55 DSP      LOG             0 DSP Comm Reset by PC
Wed 04/10/13 15:02:55 DEBUG    PARAM_CHANGE    0 LoadBuildStyle: UHD COLUMN
Wed 04/10/13 15:02:55 DEBUG    NOTICE         0 Send Parameters To DSP
Wed 04/10/13 15:02:55 DEBUG    NOTICE         0 Read and updated ini parameters.  Cure Passes = 10
Wed 04/10/13 15:02:56 DEBUG    NOTICE         0 Setting resolution mode to (PP) 2
Wed 04/10/13 15:02:56 DEBUG    NOTICE         0 Send Parameters To DSP
Wed 04/10/13 15:02:56 DSP      LOG             0 SetResolutionMode : 2
Wed 04/10/13 15:02:56 PREP     CTL_INITIALIZE    2 Input File: C:\ProJet\Bin\..\work\11676632.ctl, Support Type: ORIGINAL, Minimum Supports: 0.110000
Wed 04/10/13 15:03:54 PREP     CTL_FINISH_SUPPORTS    0
Wed 04/10/13 15:03:54 PREP     CTL_GET_INITIAL_TOKENS    0 MaxX = 2.27 MaxY = 7.07
Wed 04/10/13 15:08:16 DEBUG    TEMP_STATE_CHANGE    6 Jetstack Delay; Delay: 10
Wed 04/10/13 15:18:16 DEBUG    TEMP_STATE_CHANGE    7 Control Build; Delay: 10
Wed 04/10/13 15:18:25 DEBUG    TEMP_STATE_CHANGE    7 Control Build; Delay: 10
Wed 04/10/13 15:18:25 DSP      LOCAL_LOG       0 Realtime READY_TO_BUILD
Wed 04/10/13 15:18:26 BUILD    PRE_BUILD       0
Wed 04/10/13 15:18:26 BUILD    BLD_HEAD_CLEANING    0
Wed 04/10/13 15:18:27 HMS      WIPE_INITIATE    0 Materials Present - Head Cleaning Initiated
Wed 04/10/13 15:18:27 HMS      WIPE_MOVE_Z_TO_PICKUP    0 Beginning Printhead Maintenance
Wed 04/10/13 15:19:14 HMS      WIPE_CYCLE_START_STATE    0
Wed 04/10/13 15:19:17 DSP      LOG             0 X Following Error, Error Value = 0.101376 Encoder = -0.007500
Wed 04/10/13 15:19:17 HMS      WIPE_ERROR_STATE    0 Position error - was -0.006667, expected 22.600000 during state HMS
Wed 04/10/13 15:19:17 HMS      WIPE_ERROR_STATE_2    0 Error 6 During Printhead Maintenance
Wed 04/10/13 15:19:17 DEBUG    NOTICE         0 Exiting HeadCleaning().  Error reported is : 27 Abort is 0
Wed 04/10/13 15:19:17 BUILD    NON_BUILD_ERROR   27 HMS WIPE ERROR.  ABORTING
Wed 04/10/13 15:19:18 PREP     ABORTED           0
Wed 04/10/13 15:19:18 PREP     COMPLETE          0
Wed 04/10/13 15:19:18 PREP     IDLE              0
Wed 04/10/13 15:19:18 BUILD    NON_BUILD_FATAL_ERROR   0
Wed 04/10/13 15:19:18 DEBUG    TEMP_STATE_CHANGE    3 Control Conserve
Wed 04/10/13 15:19:19 DSP      LOCAL_LOG       0 Realtime GO_TO_ERROR
Wed 04/10/13 15:19:19 DSP      LOCAL_LOG       0 Control Conserve Temperature
Wed 04/10/13 16:49:19 DEBUG    TEMP_STATE_CHANGE    9 Control Error
Wed 04/10/13 16:49:19 DSP      LOCAL_LOG       0 Conserve Time Expired
Wed 04/10/13 16:49:19 DSP      LOCAL_LOG       0 Control Cold Temperature
Wed 04/10/13 16:49:19 DSP      LOCAL_LOG       0 Reservoir    = 93.8
Wed 04/10/13 16:49:19 DSP      LOCAL_LOG       0 Adapter      = 46.9
Wed 04/10/13 16:49:19 DSP      LOCAL_LOG       0 Jetstack1    = 45.6
Wed 04/10/13 16:49:19 DSP      LOCAL_LOG       0 Jetstack2    = 46.0
Wed 04/10/13 16:49:19 DSP      LOCAL_LOG       0 Roller       = 46.3
Wed 04/10/13 16:49:19 DSP      LOCAL_LOG       0 Trough       = 45.1
Wed 04/10/13 16:49:20 DSP      LOCAL_LOG       0 Preheat1     = 65.1
Wed 04/10/13 16:49:20 DSP      LOCAL_LOG       0 Preheat2     = 55.1
Wed 04/10/13 16:49:20 DSP      LOCAL_LOG       0 SupFeed     = 65.1
Wed 04/10/13 16:49:20 DSP      LOCAL_LOG       0 PartFeed    = 55.2
Wed 04/10/13 16:49:20 DSP      LOCAL_LOG       0 SupPreheat2  = 35.9
Wed 04/10/13 16:49:20 DSP      LOCAL_LOG       0 PartPreheat2  = 56.0
Wed 04/10/13 16:49:20 DSP      LOCAL_LOG       0 Feedumb1     = 60.2
Wed 04/10/13 16:49:20 DSP      LOCAL_LOG       0 Feedumb2     = 40.0
Wed 04/10/13 16:49:20 DSP      LOCAL_LOG       0 WasteUmb     = 50.2
Wed 04/10/13 16:49:21 DSP      LOCAL_LOG       0 WasteNoz     = 40.5
Wed 04/10/13 16:49:21 DSP      LOCAL_LOG       0 Maintenance  = 40.1
Wed 04/10/13 16:49:21 DSP      LOCAL_LOG       0 Needle1      = 62.5
Wed 04/10/13 16:49:21 DSP      LOCAL_LOG       0 Needle2      = 41.4
Wed 04/10/13 18:00:11 DEBUG    BTN_PRESSED   11 Yes Pressed
Wed 04/10/13 18:00:11 Exiting Application - Log Stopped

And the Restart Log

Code:
Wed 04/10/13 18:00:11
Service ProJet Opened
StopService() failed:
    error code = 109
    message    = The pipe has been ended.
Service start pending.
Service not started.
  Current State: 2
  Exit Code: 0
  Service Specific Exit Code: 0
  Check Point: 4
  Wait Hint: 10000
StartingService() failed:
    error code = 1460
    message    = This operation returned because the timeout period expired.

I am not sure what to do really, our knowledge here really doesn't go past the options on the display. I only got the logs because I'm used to doing it! I was hoping to get it running so we can print overnight, but 3ds and our local company don't offer after hour tech support. So ANY advice is appreciated (though I have already tried kicking the waste bin.. lightly)
 
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DMC

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When the build plate went back to pick-up the HMS, the printer thinks that it did not make it all the way back to couple up with it. Maybe it did, and maybe it didn't? LOL

You either have a physical obstruction, or maybe a dirty X-encoder strip.

Your machine probably has a -0.05 pick up location on the X axis to grab the HMS.

It never got back that far. Maybe missed some encoder counts on the way back, due to dirty strip...... or physical obstruction.

That's the answer!

Want me to run a few x-axis mapping sequences for ya to rule out that? Cleaning the X-axis encoder is kinda Stage II or advanced service stuff? You good with a wrench?

Teamviewer?

Bill Clinton
 
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DMC

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Open HMS....what is your pick-up location? You can Home the X, then command the X-axis into that position and see the reading of actual position (or at least what the printer thinks is the position based on encoder counts). Did it make it? Try it over and over to 2x check.

(I bet you need the X-axis encoder cleaned)

I run my printers with the front door off to keep air flow going and I have never had to clean my strip on current printer for Four years now.
 
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stueck9356

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Can you walk me through this? I can get to work in about 5 minutes if need be, and have teamviewer or join.me.

This is just above my head. I am not sure about the internals of the printer, but would like to know a little more. I took a picture of inside the machine this morning, and it is covered with this crystal dust, and it shows the plate fully rear and what I assume is the HMS strip on top of it.

Honestly though, I don't think the company would like me tearing down their expensive printer, and they will probably just continue to beg for a tech guy to come out. Unless it is something software related or non-invasive, I am not sure I would be able to work on it.

p.s. I have never seen those areas in the software before that you have posted pictures of.
 
DMC

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Yeah.

That Acytal alchohol dust will get on the encoder.

Screws up everything. It is a free fix if you can get it out and wipe it off.

Needs to be done yearly unless you take off the front door. (which is another story)

I am just working and drinking beer at the moment. Let's do it! LOL

804-285-0777

Chewbacca.
 
DMC

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Piece of cake. Be a hero and bring some tools. You will need only the Torx #T-20

a very very clean rag, and some solvent. Denatured alchohol from Home Depot is the best.

Then, ask for a raise in salary in the morning! LOL
 
DMC

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Wanna print with no test strip and save on material costs?

Yo!
 
Labwa

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Scott. You are a freak! I love dental lab network for the help we get from complete strangers. Kudos mate.
 
DMC

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Got his machine into pieces....working it out now.

Encoder strip is out! WOOT.
Cleaning it..........??? (on the phone now...)

Now the easy part, just putting it back together.
 
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Success!

It was a BIG lab in North Carolina....Drake.

Nice guy.
 
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stueck9356

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Dude, I can not thank you enough! You are insane! Literally knew every single screw, tab, zip strip and button to press to make it come apart. Initial testing showed x-axis missing about 105 lines (maybe per inch, maybe total, maybe a % of what it requires to pass? no idea). Post-surgery we were at 5 (again, lines per inch, total lines, %? who knows.. just... 5)

I was half way through re-installing it and I realized I had 5 extra screws.. forgot to put the protective shield over the strip lol. Disassembly, install the cover, reassembly, and I left there about half an hour ago.

Also, increasing the Z-axis cuts only increased print time by about an hour. It is still warming, so I just submitted the job and will start it tomorrow morning. Since we still have a *shudder* service agreement with the company, I will keep the verification strip. They want that in case the printer effs up.

I need to paypal you some beer money. Or, rather, the company needs to paypal us both some. Now I just need to find a cover story so they don't know I gutted their expensive machine!

Seriously, thanks again!!
 
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stueck9356

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Also, if it isn't too much trouble, I think you spoke about some CDs that have the manual or tech write-up or tear down? I'd love to go through them, so I can actually diagnose the error codes and don't think "HMS WIPE ERROR" means my printer has decided to become a boat in her Majesty's navy.. Let me know, I can't find a PM system on the forums.
 
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stueck9356

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Well, we thought we were good, until I saw this in the printer. I aborted the job half way in.

aimg705.imageshack.us_img705_4088_img20130411113233.jpg

aimg560.imageshack.us_img560_2956_img20130411113245.jpg

Just going to drag the tech down here to look at it..
aimg705.imageshack.us_img705_4088_img20130411113233.jpg aimg560.imageshack.us_img560_2956_img20130411113245.jpg
 
DMC

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Yeah, that is also X-encoder issue.

I guess it still has something on it?? Could it be?

We tested before you assembled, maybe accidently got a smudge on it?

The encoder seems to have problem still.

Want to try teamviewer to run a x-axis test again?
 
DMC

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Rails are smooth and have no crap on it? Maybe right under the printhead, sometimes build material ends up hardened on the round rails.


Looks like it (patterns) get shifted by temporary loss of encoder counts, or physical "sticky" situation.

The sled may not have been sliding smoothly, and had a jumpy-jerky movement at some point?

Either One or the other. (Physical crap somewhere or encoder reading error still)

That is a big shift. Maybe a complete loss of encoder counts for a brief second?

Seldom, this could occure from a cable dragging.

It would be under the build plate...On the frame of the moving sled and zip-tied to bottom.

Sometimes it gets moved and then the cable will drag up and down and eventually rubs a hole in wire's insulation.

Look?

I have to eat! Be back soon....
 
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They cleaned the strip again and now printing....

Maybe it is good? The readings beforwe and after this second cleaning showed what the issue was.

Just not picking up as much encouder counts as necessary again? After cleaning we now have a happy repeatable 5-7% deviation which is good as it gets. We'll see?

They haven not called back, so I guess that is a good sign?
 
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stueck9356

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Hey. Sorry for delay. After reassembling everything we found that the wire that connects to the door sensor has a bad connection. Probably from forcing it through that tiny hole 4-5 times now. We have evrrything installed, but since the printer reads the door open we are stuck and can not do anything with the printer.

We called the service techs, they will be out on Monday. Man that's a story within itself. I have never seen someone get so upset from us touching our own, out of warranty machine, telling them the issue, asking for a bill for the parts and install, and continue to bitch that we didn't follow their protocol. Sorry? Next time I plan in the machine breaking down, I'll be sure it's between 8 and 5 est.. I was so close to going off on them, luckily my boss took the phone from me!

Regardless, I think our X axis problem is gone, she might install a new one jic. the door is the only issue and then I think we are in business again.


Side note, they say to clean the strip, you just need to open the door, remove a single cover screw and the strip is exposed. Just run a lint free cloth with alcohol down it and reinstall the cover. Thoughts?
 
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primus

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One screw eh? Well tell Melika that was not what my class was taught when I went to school for this at 3DUniversity.

Believe me, I would love to do it that way, but the cover comes out from the front, as you saw. Once screw is blocked by the top hood.

The top of printer blocks access to removing the encoder cover. The hood, and the material doors needed to come off I am 99.9% sure.

I have tried to keep the top of printer on, and it is close, but impossible to do.

So you got a bad connection on the door Opto-sensor? I guess you looked at the pins in the plug and on the opto itself?

It's just a few wires to connect. Damn, so close! No broken tabs or plugs or ??

How about just making a new jumper wire or something?

You did a great job on the phone! Sooooo close!
 
Slipstream

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I believe the newer machines are more accessable than the early versions
 

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