Maintenance
Like all equipment, the AO Backpack needs regular maintenance to remain in good working condition.
Adjusting, removing, reconfiguring, or otherwise tampering with any components that are not explicitly flagged here for user maintenance is strongly discouraged, as it can lead to hardware damage and prolonged and costly periods of machine downtime.
If you have any questions about what is and is not off-limits, please contact Carbon Support.
The sections below are organized by the frequency of the maintenance tasks.
- Inspect the resin hose for leaks or damage.
- Pay particular attention to the section of hose that runs through the pump.
Check the inline filter for excessive debris or particulate matter that could obstruct resin flow.
1. Open the resin cabinet.
2. Remove the cover from the top of the resin cabinet and place it to the side.
3. Disconnect the quick disconnect from the resin tank.
4. Pull the quick disconnect end of the hose through the top of the resin cabinet.
5. Lift the in-line filter out of the clips that hold it in place.
6. Place the in-line filter on a tray lined with a blue towel to catch resin. Rest the tray on top of the resin cabinet.
7. Carefully unscrew the filter cap and set on the tray. The filter chamber is full of resin so resin will spill out.
8. Remove and inspect the cylindrical metal screen. Remove solid debris or particles, using blue towels if necessary.
Do not use any solvents as this will contaminate the resin and may affect part quality.
9. Empty out the resin from inside the filter, remove any solid debris or particles, using blue towels if necessary.
Do not use any solvents as this will contaminate the resin and may affect part quality.
10. Place the metal screen back in the filter housing.
11. Screw the cover back on the inline filter.
12. Make sure that the exterior of the filter is free of resin residue. Use blue towels and IPA if necessary.
13. Pull the quick disconnect connector end of the resin hose back through the front opening of the resin cabinet
14. Place the filter back in the retaining clips at the top of the resin cabinet.
15. Connect the quick disconnect to the resin tank.
16. Replace the resin cabinet cover.
The blade is sharp and can cause severe injury. Use extreme caution when cleaning the blade.
- Confirm the blade is free of solid debris like part supports.
- Check for any visible damage to the blade, such as dents, bends, wear, or cracks, to ensure it remains in optimal condition.
- Check that the bin is intact and free of resin smears or build up, paying special attention to the top lip on either side of the bin.
- If needed, clean the bin with blue towels and IPA.
- Verify that the basket sits properly in the bin. Be sure it is free of damage and that any deformation or damage does not interfere with proper seating in the bin.
- If the basket does not sit properly in the bin, it may cause damage to printed parts or to the AO Backpack.
- Inspect the handles to ensure they are not bent.
- Check the walls and floor of the basket to verify that they are free of dents or warping.
- Make sure the basket screen surfaces are not covered or blocked with resin.
- If needed, clean the basket with IPA and/or acetone and blue towels.
- Remove the drip tray and Inspect the interior floor of the AO Backpack.
- If needed, clean with blue towels and IPA.
- Replace the drip tray.
- Inspect the platform for excessive dents, gouges, or damage which could damage the cassette window or affect part removal.
Any damage that projects above the normal printing surface of the platform can damage the cassette window and the blade.
- If significant damage is present, remove the platform from production.
- Inspect the two horizontal bars that hold the platform for any damage or excess resin buildup.
- Pay particular attention to the mechanism at the back of each rail.
- Clean with IPA and blue towels if necessary.
- The platform gates secure the platform during part removal.
- Check the gates, especially the back-facing surfaces, to confirm they are free of resin and debris that could impede their function. Clean with IPA and blue towels if necessary.
- Inspect the quick release connector and nozzle.
- Wipe excess resin with a blue towel. IPA may be used on external surfaces only.
Do not use IPA to clean the quick connector nozzle as this can contaminate the resin and affect part quality.
- Check the resin spout opening to ensure it is clear of cured resin or debris that could hinder resin flow or introduce particulates into the resin cassette.
- Disconnect the quick release connector from the resin tank.
- Remove the resin tank from the resin cabinet and set aside.
- Clean any residual resin from the shelf with blue towels and IPA.
Do not apply excessive force to the resin shelf (no more than the weight of a full resin container) as excessive weight may damage the scale mechanism housed within it.
- Check horizontal surfaces for damage, resin debris or resin buildup.
- Clean with IPA and blue towels if necessary.
When the resin tank is almost empty, it will need to be replaced with a full tank. Follow the instructions below to swap an empty tank for a full one.
Equipment
- Full resin tank
- Shop towels
- IPA
Workflow
1. Approach the open resin cabinet.
- If the resin cabinet is not already open, grasp the back corner of the resin cabinet and pull. The resin cabinet will swing out towards the front of the printer.
- Continue until the cabinet is flush with the side of the printer and catches on the foot latch.
2. Push the lock button on the quick release connector and pull the hose off.
- Be aware that the button mechanism extends out of the opposite side of the clamp. You may need to move your fingers to allow for free movement of the button mechanism.
3. Push the quick release connector into the clip mounted on the back wall of the resin cabinet to keep it out of your way. 4. Remove the empty resin tank from the resin cabinet and place near the full resin tank. 5. Unscrew the cap from the full resin tank.
- Do not grasp the filter as this will damage the assembly.
6. Remove the straw assembly and transfer it to the full tank.
- Use caution as resin will drip from the straw.
- A tray covered with a blue towel can be useful to transport the straw between the tanks.
7. Screw the cap onto the resin tank.
8. Clean any drips or smears from the tanks using shop towels and IPA.
9. Move the full tank into the resin cabinet and carefully place it on the shelf.
- Use caution as the full tank will be quite heavy.
10. Push the quick release connector onto the quick release nozzle.
11. Carbon recommends leaving the resin cabinet open for easy access to the resin tank. However, if you wish to close it, follow the instructions below.
- Press down on the foot latch with the tip of your foot. Then push the cabinet back until it clicks into place at the back of the AO Backpack.
There are two options for refilling an empty resin tank:
- Use resin from 55 gallon drum of DPR 10 equipped with the DPR 10 Drum Pump
- Use resin from multiple plastic containers
Go to DPR 10 Drum Pump for resin dispensing information.
The resin tank can be refilled directly at the Drum Pump.
Carbon recommends placing the resin tank on a stable surface during dispensing as the tank will become quite heavy as it fills.
Chemical resistant plastic containers can also be used to fill the resin tank. These can be 3.2 L bottles of new DPR 10 resin purchased directly from Carbon or bottles that are filled at the DPR 10 Drum Pump and then poured into the resin tank.
Filling the resin tank requires approximately six 3.2 L bottles of resin and 10 minutes.
Residual resin may gather on the resin cabinet.
- Disconnect the resin tank from the resin hose and remove from the resin cabinet.
- Clean any residual resin from cabinet surfaces with blue towels and IPA.
- Use care when cleaning the resin tank shelf to avoid damaging the scale mechanism housed within it.
Do not use acetone as this will damage painted surfaces.
Over time, residual resin will gather on the resin tanks.
- Disconnect the quick release connector from the resin tank.
- Remove the resin tank from the resin cabinet.
- Clean any residual resin from the outside of the tank with blue towels and IPA.
- Unscrew the straw assembly cap.
- Lift the straw assembly to expose the screw threads on the resin tank.
- Clean the screw threads with blue towels only.
- Do not use any solvents as this may contaminate the resin and may affect part quality.
- Screw the straw assembly cap back onto the resin tank.
- Place the resin tank back onto the shelf in the resin cabinet.
- Reconnect the quick release connector to the quick release nozzle.
The resin hose is typically replaced replaced by a Carbon FSE every 18 months. If the hose requires replacement before then, contact Carbon Support before following the instructions below.
- 2.5 mm hex wrench
- Nitrile glove
1. Swing the resin cabinet out to its open position.
2. Push the lock button on the quick release connector and pull the hose off.
- Be aware that the button mechanism extends out of the opposite side of the clamp. You may need to move your fingers to allow for free movement of the button mechanism.
3. Locate the two black plastic hose clamps that hold the resin hose in place at the back of the AO Backpack.
4. Unlock each hose clamp: a. push down on the outer band with your thumb to release the tab and b. pull the tab forward with your forefinger to unlock the hose clamp. 5. Free the resin hose from each hose clamp.
6. Remove the cover from the top of the resin cabinet to expose the resin pump.
7. Pull the in-line resin filter out of the clips that hold it in place.
8. Flip the pump clamp lever.
9. Undo the yellow straps that secure the resin hose in the pump.
10. Lift the hose out of the ridged brackets on both sides of the pump and let it hang loosely.
11. Move to the front of the printer, open the printer door and flip the resin spout up.
12. Use a 2.5 mm hex wrench to unscrew the spout screw. The spout screw is locked in the resin spout so it will not fall out.
13. Lift the resin spout out of its bracket and place a nitrile glove over the spout. Make sure the open end of the spout fits into one of the fingers or thumb of the glove. This will prevent leaks while moving the hose.
14. Reach behind the AO Backpack and pull the resin hose out through the slot.
- It will help to have a second person at the front of the printer to help guide the hose through the hole.
15. Dispose of the old hose according to local regulations.
This video shows steps 1 - 7 below. Use it as a reference.
1. Take the new resin hose and position the in-line resin filter between the filter clips and push down to secure it.
2. Push the resin spout end of the hose through the back of the resin cabinet.
3. Push the quick release connector end of the hose through the front opening.
4. Push the first direct joint (white plastic ring) into the ridged bracket closest to the front of the resin cabinet. The channel that runs around the circumference of the direct joint fits into the ridge on the bracket.
- Make sure the crimps on the crimp clamps are pointing up.
- Push down firmly so that the hose is secure.
5. Thread the loose end of the hose through the curved channel of the pump and push the second direct joint into the ridge on the far bracket. The hose should have a bit of tension on it through the curved channel.
- Make sure the crimps on the crimp clamps are pointing up.
- Push down firmly so that the hose is secure.
6. Secure the yellow straps that secure the resin hose in the pump.
7. Turn the pump clamp lever to lock the resin hose.
8. Push spout end of the hose through the slot in the back of the AO Backpack. You may need to rotate the end to successfully maneuver it through the slot and into the interior of the printer.
9. At the front of the printer, grab the resin spout and push it onto mounting pins on the resin spout bracket.
10. Use a 2.5 mm hex wrench to turn the resin spout screw and secure the resin spout. The screw only requires hand tightening.
11. Push the resin hose into the hose clamps at the back of the AO Backpack. Lock the hose clamps to secure the hose.
- If the resin hose is not locked in the hose clamps, the hose can be pinched when closing the resin cabinet.
12. Replace the cover on the top of the resin cabinet.
13. Close the resin cabinet if desired.