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ZPrinter

650 Hardware Manual

Troubleshooting the ZPrinter 650

zcentral.zcorp.com

10/21/08

7.4 Alignment Errors

If you have run an alignment pattern and the printer reports that the alignment has failed, follow the trou-
bleshooting flowchart below.

How to do it

If it passes alignment but the print quality is not OK, see

Section 7.3, ’Print Head Errors/ Weak Parts’

Summary of Contents for ZPrinter 650

Page 2: ...Corporation Recipient shall not dis close such Information to any third party and shall not use it for any purpose whatsoever other than what is required to install and use the ZPrinter 650 Use of Equ...

Page 3: ...SS FOR A PARTICULAR PURPOSE AND ANY OTHER OBLIGATIONS OR LIABILITIES WHETHER IN CONTRACT WARRANTY NEGLIGENCE OR OTHERWISE THE COMPANY IS NOT LIA BLE FOR ANY DIRECT INDIRECT SPECIAL PUNITIVE CONSEQUENT...

Page 4: ...1 10 Parking Caps 13 1 11 Carriage Print Heads and Pogo Pins 14 1 11 1 Front View 14 1 11 2 Top Inside View 15 1 12 LCD Menu And Control Knob Control Panel 16 1 12 1 Control Knob Operations 16 1 13 L...

Page 5: ...1 Example Dirty Service Station 42 3 5 2 Example Clean Service Station 43 3 5 3 Cleaning Procedure 43 4 Post Processing With Z Bond 46 4 1 Preparation 46 4 2 Using the Post Processing Unit 47 4 3 Post...

Page 6: ...work Errors Packet Timeout 82 7 9 Part Quality Issues General 82 7 9 1 Part Colors Do Not Match PC Monitor Colors 82 7 9 2 Parts Broken After Automatic Depowdering 82 7 10 Part Quality Issues Streaky...

Page 7: ...unlimited access to this excellent resource 1 1 New Features The ZPrinter 650 is our fastest most capable printer We ve built in the features customers most asked for Larger build volume Higher resolu...

Page 8: ...echnology s patented 3DP Technol ogy 3D Printing The 3D Printing process requires Build Volume 10 x 15 x 8 254 mm x 381 mm x 203 mm 1200 cubic inches build capacity Build Speed 2 4 layers per minute L...

Page 9: ...to the edges of the part creating a strong shell for the part exterior Next an infrastructure that works like strong scaffolding is created for the part walls which are also built with a higher satura...

Page 10: ...t Axis assembly the Vacuum Hose the Heater Vent and the Feeder Carriage Assembly that houses the Print Heads Pogo Pin Connectors and the Alignment Sensor Win dow Consumables Powder Binder Infiltrant p...

Page 11: ...r Wand Printed parts are moved from the Build Bed to the Post Processing Unit for final removal of any powder left on the part and for infiltration Powder Very fine particles that are not bound togeth...

Page 12: ...hts Reserved 10 21 08 1 7 ZPrinter 650 Components The main components of the ZPrinter 650 system are highlighted below 1 7 1 System Exterior Number Component 1 Printer 2 Post Processing Unit PPU 3 Con...

Page 13: ...al zcorp com 7 All Rights Reserved 10 21 08 1 7 2 Printer Interior Number Component 1 Binder Cartridges 2 Debris Separator 3 Heater Vent 4 Vacuum Hose 5 Service Station 6 Deck 7 Fast Axis Assembly 8 B...

Page 14: ...650 Overview zcentral zcorp com 8 All Rights Reserved 10 21 08 1 7 3 Post Processing Unit PPU Interior Number Component 1 Air Wand 2 Air Pressure Control Nut 3 Air Hose 4 Heater Vent 5 Carbon Filter 6...

Page 15: ...ware Manual ZPrinter 650 Overview zcentral zcorp com 9 All Rights Reserved 10 21 08 1 7 4 Printer Storage Number Component 1 Tools and Acessories Storage 2 Cleaning Solution Cartridge 3 Print Head Sto...

Page 16: ...Hardware Manual ZPrinter 650 Overview zcentral zcorp com 10 All Rights Reserved 10 21 08 1 7 5 Post Processing Unit PPU Storage Number Component 1 Tool Basket 2 Parts Trays shown under Dipping Kit 3 A...

Page 17: ...Hardware Manual ZPrinter 650 Overview zcentral zcorp com 11 All Rights Reserved 10 21 08 1 8 ZPrinter 650 Rear View Number Component 1 Power Switch 2 Power Cord 3 Network Cable 4 Electronics Box E Box...

Page 19: ...ZPrinter 650 Hardware Manual ZPrinter 650 Overview zcentral zcorp com 13 All Rights Reserved 10 21 08 1 10 Parking Caps Number Component 1 Parking Caps 5 total 2 Parking Spittoon under Parking Caps...

Page 20: ...erview zcentral zcorp com 14 All Rights Reserved 10 21 08 1 11 Carriage Print Heads and Pogo Pins 1 11 1 Front View Number Component 1 Print Head removed 2 Print Head Contacts 3 Pogo Pins inside 4 Sep...

Page 21: ...650 Hardware Manual ZPrinter 650 Overview zcentral zcorp com 15 All Rights Reserved 10 21 08 1 11 2 Top Inside View Note Carriage cover shown removed Number Component 1 Pogo Pins 5 sets total 2 Septum...

Page 22: ...l Stop a menu function Turn the Control Knob left or right to Highlight a menu item 1 13 LCD Menu Overview Main Menu Vacuum Depowder Prep Build Chamber Status Report Printheads Build Chamber Post Proc...

Page 23: ...at zcentral zcorp com Software User Manuals User Manuals for the ZPrint and ZEdit Software programs are supplied on the Installation CD with the software Additional copies are available on our Web sit...

Page 24: ...ications and printing post processing techniques Post Processing Learn more about the different post processing products that are available to use with your printer on the Materials section of our Use...

Page 25: ...s the X or the slow axis the fast axis direction of travel and in laminated layers along the Z Axis Once a part is infiltrated it uniformly takes on the strength characteristics of the infiltrating pr...

Page 26: ...on during powder removal See Section 2 9 for instructions on how to create a Fixture An example of a part with hollow sides facing down 2 2 2 Parts Containing Overhangs For delicate parts and parts wi...

Page 27: ...am of software develop ers and application engineers as a tool to help those who use HD3DP high definition 3D printing to optimize their color applications This software program works in conjunction w...

Page 28: ...ort and select more files By default ZPrint will position each file in the Build Bed for the fastest print time 2 5 ZPrint Main Window See the ZPrint Software Manual for a complete description of the...

Page 29: ...Type Click the Find button to locate the printer on the network If the printer is connected to the network it will appear on the list Select the printer and click OK 4 The Default Printer Settings dia...

Page 30: ...ect File 3D Print Setup to disable the Bleed Compensation or to change the Layer Thick ness Select Transform Anisotropic Scaling to change the values for Anisotropic Scaling Select Edit Make Fixture t...

Page 31: ...ected part in the specified plane view Select your part left click on the part in ZPrint and select Transform Rotate Select the plane view to rotate the part in and then enter the degree of rotation i...

Page 32: ...uild the smallest Fixture necessary with minimum use of materials Mirror Mirror Mirror Group Mirror a part in the X Y or Z direction Select your part Select Transform Mirror Choose a direction to mirr...

Page 33: ...r will cause it to squash to something less than round if there is no support underneath 2 9 1 Create a Fixture for an entire part 1 Select the part in ZPrint 2 Select Edit Make Fixture ZPrint orients...

Page 34: ...Make Fixture dialog and increase the Accuracy Coefficient value by 1 one Click OK to regenerate the Fixture Run Collision Detection again 2 9 2 Create a Fixture for a portion of a part 1 Select the pa...

Page 35: ...ggled on the ZPrint 3D View menu when you select the Switch Layer View 3D View command or by selecting the 2D icon on the Toolbar When printing single or multiple parts slice viewing allows you to vie...

Page 36: ...uncheck Bleed Compensation to weld together the places in the assembly that are slightly touching Leaving Bleed Compensation checked will tend to create fracture lines between abutted sections 4 Click...

Page 37: ...calculates the materials needed to complete the build The results are reported in the Printer Status dialog for you to check before starting the build The dialog shows OK for each item and the Print b...

Page 38: ...ng a delicate part build a Fixture for the part 3 Check the Printer Status window to see what is currently displayed on the printer LCD menu The printer must be Online before you can start the print j...

Page 39: ...rying cycle is finished Unused powder is automatically removed from the Build Bed when the Empty Build Piston After Printing option is checked in the Printer Status dialog If you unchecked the Empty B...

Page 40: ...by turn ing the brass control nut located at the junction between the Air Wand and its air hose Use light pressure for delicate or thin walled parts If the air pressure is too strong you run the risk...

Page 41: ...ew min utes and clean the printer Regular cleaning and maintenance is the simplest best way to ensure your parts look their best and to keep your printer running trouble free See Section 3 Routine Cle...

Page 42: ...Excess Powder After every build vacuum up all loose powder in the Build Chamber including the Build Bed Deck and Fast Axis including the Rails and Carriage To vacuum 1 Select VACUUM on the LCD panel...

Page 43: ...eeps those pieces from being recycled into the feeder To empty the Debris Separator follow the steps below 1 Pull the Debris Separator out of its holder on the printer 2 Empty the contents into a tras...

Page 44: ...precise accuracy during printing The Parking Caps are located on the right end of the Fast Axis Before you begin Get several dry paper towels Get the squirt bottle included in your Accessories Kit Fil...

Page 45: ...Wipe up any water on the Build Bed Fast Axis or Deck 7 Remove the paper towels from the front overflow and dry it thoroughly 8 Vacuum the Build Bed and Deck remove any powder dislodged from the Rails...

Page 47: ...Axis toward you 2 Using a paper towel dampened with distilled water wipe the top and bottom Rails to remove any pow der Move the Carriage back and forth as needed to clean the entire length of both ra...

Page 48: ...ery build to remove residue buildup and to ensure the printer runs optimally for your next print job Before you begin Get several dry paper towels and a cotton swab Get the squirt bottle filled with d...

Page 49: ...rvice Station 3 5 3 Cleaning Procedure 1 Place paper towels around the Service Station and between the Service Station and the Build Bed 2 Cover the front overflow with paper towels Number Description...

Page 50: ...n the squirt bottle close to the station and squirt water on and around the squeegee 4 Use the cotton swabs or a paper towel and wipe the front and back of the squeegee Use the Pick to scrape excess p...

Page 51: ...Wash Holes Thoroughly wipe the Service Station clean 7 Install a needle onto the small syringe Gently push the tip of the needle through each of the six Wash Holes to clear them 8 Wipe up any water t...

Page 52: ...instructions Wear a dust mask when sanding finished parts Z Bond reacts with water and ambient moisture Once a bottle has been opened it is recom mended that the product be used within 30 days Avoid...

Page 53: ...CAUTION The Post Processing Unit is for use with Z Bond only Do not use with any other Infiltrant Do not use with spray paint of any kind or with any flammable spray Check the Materials section of our...

Page 54: ...d then remove it from the liquid 4 If you see bubbles rising wait until the bubbles stop and then remove the part 5 Keep the part moving in your hands so it does not stick to your gloves Note The part...

Page 55: ...ily reach 4 Reposition the part and repeat this process until the entire part is infiltrated 5 Quickly and thoroughly wipe any excess liquid off the part with the paper towels and place the part on th...

Page 56: ...re the printer before printing Important Do not add powder or binder to the printer or change a print head unless you see a mes sage telling you to in the Printer Status dialog Section 5 1 The Printer...

Page 57: ...ed surface is smooth service the print heads run an auto alignment if a print head was replaced after the previous build 5 1 2 Not Ready to Print If there are not enough materials to complete the job...

Page 58: ...Knob until the build bed is about 6 below the top 2 On the printer s LCD menu select PRINT HEADS then CHANGE PRINT HEADS The fast axis moves to the service position 3 Wet a paper towel with distilled...

Page 59: ...ut of their slots and properly recycle or dispose of any empty car tridge s 7 Get an alcohol swab included with your Startup Kit Snap it to break the glass inside and squeeze the tube to saturate the...

Page 60: ...op of the printhead at the same side as the pogo pins to securely fit a printhead into its slot 11 Close the carriage cover by pressing down until you hear it click shut Be sure both latches are engag...

Page 61: ...eps below 1 Pull the empty binder cartridge out of its housing on the printer 2 Get a new binder cartridge Check the expiration date and check the cartridge label for the correct color and orientation...

Page 62: ...r turn it upside down and shake to loosen the powder inside 2 Check the expiration date on the canister 3 Open both top covers and place the powder canister in the Post Processing Unit 4 Remove the gr...

Page 63: ...g solution cartridge Check the expiration date and check the cartridge label for the correct orientation 4 Insert the cartridge into its housing Ensure the cartridge is pushed all the way in You shoul...

Page 64: ...for the printer to fill the bed and spread a layer of powder before starting a print job If you see the message RAISE BUILD in the Printer Status dialog go to the printer and select PREP BUILD CHAMBE...

Page 65: ...Section 6 9 Printer Storage Preparation The Maintenance dialog found on the ZPrint Service menu keeps a record of when the Fast Axis bear ing the Slow Axis bearing and the Piston Screw require lubric...

Page 66: ...ies Kit place 5 drops of oil into the small reservoir Do not over fill Close the cap 11 Slide the Carriage back and forth to distribute the oil evenly over the Rails 12 Reset the Maintenance Counter i...

Page 67: ...he left end of the printer in between the Waste Tray and the pocket for the Cleaning Solution Cartridge and locate the piston screw 6 Reach into the left end of the printer and wipe the Piston Screw c...

Page 68: ...PLATFORM and BUILD CHAMBER LOWER PLATFORM Don t forget to hold down the Control Knob to raise or lower the platform 10 Wipe off any grease that may collect at the bottom of the screw with a paper towe...

Page 69: ...the grease gun over the grease fitting Push down to snap the gun into place on the fit ting 7 Squeeze the trigger 2 3 times or until you feel the tension change and then STOP Do not over grease 8 Unsn...

Page 70: ...head or remove a print head to clean the contacts and pogo pins 1 On the Control Panel select BUILD CHAMBER then LOWER PLATFORM Continue holding in the Control Knob until the build bed is about 6 bel...

Page 71: ...end of the fast axis and care fully remove any debris or powder from the teeth of the pulley Slide the printhead carriage back and forth to rotate the pulley and expose all the teeth 3 Repeat this fo...

Page 72: ...Maintenance zcentral zcorp com 66 All Rights Reserved 10 21 08 2 Unsnap the top deck from the chassis by pulling up at the front edge 3 Lift up the front edge of the deck and slide the deck out toward...

Page 73: ...vacuum on Thoroughly vacuum the area around the slow axis rails 5 Using a paper towel dampened with distilled water clean the slow axis rails on both sides Carefully clean any debris from the ends of...

Page 74: ...il and carefully remove any debris or powder from the teeth of the pulley Slide the fast axis assembly forward and back to rotate the pul ley and expose all the teeth Also clean any buildup or debris...

Page 75: ...rp com 69 All Rights Reserved 10 21 08 9 Slide the deck back into position Line up the cutout in the deck with the Service Station 10 Press down on the front middle and rear of the deck as shown to sn...

Page 76: ...hly by reaching up from underneath 5 Dry the roller thoroughly with a clean dry paper towel 6 In ZPrint select Service then Toggle Roller On Off to turn the Spreader Roller off 7 Make sure the roller...

Page 77: ...s Section 7 2 Problems Powering Up Motion Errors Section 7 3 Print Head Errors Weak Parts Section 7 4 Alignment Errors Section 7 5 Motion Errors Fast Axis Section 7 6 Motion Errors Slow Axis Network E...

Page 78: ...pins If the printhead is old dirty or has reported an error through ZPrint replace the printhead with a new one Section 5 2 Change Print Head s 2 Perform any needed maintenance Check the Printer Statu...

Page 79: ...rinter 650 Hardware Manual Troubleshooting the ZPrinter 650 zcentral zcorp com 73 All Rights Reserved 10 21 08 7 2 Problems Powering Up If your printer does not power up normally use the flowchart bel...

Page 80: ...ower Fail Error 40802 x Use Only HP11 Error 60700 Head X temperature calibration failed Error 60701 Head X invalid serial number Error 60702 Head X temperature too high Error 10040 Pogo Comm Error For...

Page 82: ...hts Reserved 10 21 08 7 4 Alignment Errors If you have run an alignment pattern and the printer reports that the alignment has failed follow the trou bleshooting flowchart below How to do it If it pas...

Page 83: ...Motors Not Rezeroed Error 2303 1x Axis Pos Error Error 2305 1x Axis Settle Error 2400 1x Axis Seek Error Error 3011 System Error Error 3013 Sequencer Timeout Error 43000 Sequencer Timeout For more de...

Page 85: ...ion Error 2301 0 Motors Not Rezeroed Error 2303 0 x Axis Pos Error Error 2305 0 x Axis Settle Error Error 2400 0 x Axis Seek Error Error 3011 System Error Error 3013 Sequencer Timeout Error 43000 Sequ...

Page 87: ...ubleshooting the ZPrinter 650 zcentral zcorp com 81 All Rights Reserved 10 21 08 7 7 Network Errors Cannot Connect to Printer If you have trouble connecting to your printer over the network follow the...

Page 88: ...be lost Printer s network cable may be unplugged or damaged Server is not responding Network is too busy 7 9 Part Quality Issues General There can be many causes to part quality issues Refer to the se...

Page 89: ...uild chamber cycle In the screen shown below the red area is the fixture and bumpers generated by ZPrint Also try these Check the saturation levels for your powder type If you load a zbd file it will...

Page 90: ...ure the printer has cleaning solution Realign the print heads to ensure proper alignment Clean the Fast Axis Rails of any debris and reboot the printer See Section 3 4 Clean The Fast Axis Rails and Ca...

Page 91: ...Surface Finish Explanation A bad surface finish on horizontal surfaces is usually the result of debris buildup on the Spreader Roller The debris sticks to the Roller and prevents it from spreading a s...

Page 92: ...7 12 Miscellaneous Problems 7 12 1 Vacuum Has Low No Suction Explanation This is usually an indication that the Debris Separator needs to be emptied and cleaned Solution Remove the Debris Separator an...

Page 93: ...ged binder cartridge or a failure in the binder cartridge pocket Solution Remove and reseat the binder cartridge Check the following Be sure it s the correct cartridge for that pocket Check the label...

Page 94: ...g a print head be sure to clean the pogo pins at the same time Failure to clean the pogo pins may result in poor contact to the print head causing the system to report an error and prevent ing operati...

Page 95: ...the axis If the error is 2303 1 it means that there is excessive friction on the fast axis rails or something is obstructing the travel path of the axis Solution First ensure there is nothing blocking...

Page 96: ...Software Service Menu INI File Obtainable through the ZPrint Software Service Menu SPREAD CSV File Z450 and Z650 Obtainable through the ZPrint Software Service Menu Receive File option Head Report Inf...

Page 97: ...es 29 Collision Detection Fixtures 29 Components ZPrinter Z450 6 Consumables Definition 4 Control Knob Operations 16 Cover Close 58 CSA CE Approval 2 Cylindrical features 20 Cylindrical Features Parts...

Page 98: ...g ZPrint 59 Maintenance Printer 59 Make Bumper Fixtures 27 Make Fixture General Preferences 27 Materials 2 89 Mirror Toolbar Shortcut 26 Monochrome Print option 32 N Network Connectivity 1 New Feature...

Page 99: ...ion 2 Resolution Printer 2 Rotate Toolbar Shortcut 25 Routine Cleaning 36 S Scale Toolbar Shortcut 25 Select Printer 30 Service 89 Service Station Diagram 12 Service Station Clean 42 Service Station D...

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Summary of Contents for ZPrinter 650

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