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Z Corporation ZPrinter 650 Troubleshooting Manual Download Page 60

 

09915

 

ZPrinter

 

650

 

Troubleshooting

 

Guide

 

 

Miscellaneous Errors: Errors that do not fall into any other 
category 

  

  

  

  

3202: Monitor thread took too long 

This error is caused by data not transmitting between the E box and The fast axis 

Monitor Read-Out or 

Secondary 

Symptom 

Cause / Problem 

Solution 

Reference 

Documents 

3202 Monitor Thread took 

Too Long 

Mechanical Issue 

Treat initially like a 2303(1): 

See 2303(1) 

See 2303(1) 

3202 Monitor Thread took 

Too Long 

Motherboard Fan is not 

working Properly 

Replace 15725 

Motherboard PCB 

85070 ZPrinter 650 E-Box 

Field Repair Procedure 

After performing the above steps try performing a service print head and alignment. If the machine performs both tasks 

then proceed with a test print. 

3202 Monitor Thread took 

Too Long 

Other issue in E-Box 

Replace 50012 ZPrinter650 

E Box Ass’y 

08860 ZPrinter650 E-Box 

Removal and Replacement 

  

  

  

  

 

 

 

 

60

 

 

Summary of Contents for ZPrinter 650

Page 1: ...09915 ZPrinter 650 Troubleshooting Guide ZPrinter 650 Troubleshooting Guide Part Number 09915 Revision B 1...

Page 2: ...09915 ZPrinter 650 Troubleshooting Guide Revision History Rev A ECN 2590 BWH 10 22 08 Rev B ECN 3209 RAB 11 23 11 2...

Page 3: ...on and do not get any lights or readout on the monitor plugged into the machine is much more descriptive 2 Check to make sure that the customer is following proper storage procedures for consumables...

Page 4: ...iry more fruitful and help you to get your customer up and running in the least amount of time 1 Serial Number 2 Customer Name 3 Log File Service Menu View Printer Log Save As 4 INI File Service Menu...

Page 5: ...for their respective products or services mentioned in this documentation Proprietary Information Information contained in this document is the confidential property of Z Corporation Recipient shall n...

Page 6: ...HER IN CONTRACT WARRANTY NEGLIGENCE OR OTHERWISE THE COMPANY IS NOT LIABLE FOR ANY DIRECT INDIRECT SPECIAL PUNITIVE CONSEQUENTIAL OR INCIDENTAL DAMAGES INCLUDING WITHOUT LIMITATION DAMAGES FOR LOSS OF...

Page 7: ...nment of Axis x failed 18 40008 AUTOALIGN can t pick reference head 19 40800 Head x check failed 20 60400 FPGA comm error on pogo card 21 60501 POGOPOWERSPI timed out 22 60502 POGO POWER read error 23...

Page 8: ...not empty 47 No Light Suction on User Hose 48 De powdering Chamber is full of powder while de powdering 49 No Compressed Air or not enough Compressed Air 49 Powder is seeping out of printer 50 Boot Fa...

Page 9: ...voir is empty 58 Sensors and Switches Errors that are related to the ZPrinter s Sensors and switches 59 Top Cover Open 59 1008 Head Cover Open 59 Heater is not coming up to Temperature 59 Miscellaneou...

Page 10: ...Print Head 09577 ZPrinter650 User Manual After performing the above step try performing a service print head and alignment If the machine performs both tasks the problem should be solved 1003 I2C read...

Page 11: ...voltage failed Bad Carriage Cable Replace 50080 Pogo Flex Cable 85026 ZPrinter 650 Carriage Cable Removal and Replacement After performing the above step try performing a service print head and alignm...

Page 12: ...h Low flow rate of binder to the print head Check and verify the flow rates according to the reference document 85052 ZPrinter 650 Flow Rate Test Heads are getting powder on them Service station is di...

Page 13: ...olved 1007 Head x current too high Bad Carriage Cable Replace 50080 Pogo Flex Cable 85026 ZPrinter 650 Carriage Cable Removal and Replacement After performing the above step try performing a service p...

Page 14: ...he problem should be solved 1009 Head fire voltage stuck Bad Carriage Cable Replace 50080 Pogo Flex Cable 85026 ZPrinter 650 Carriage Cable Removal and Replacement After performing the above step try...

Page 15: ...nd Pogo Pins Reinsert print heads 09577 ZPrinter650 User Manual 1010 Invalid head temperature Bad Old Print Head Replace Print head 09577 ZPrinter650 User Manual After performing the above step try pe...

Page 16: ...the above step try performing a service print head and alignment If the machine performs both tasks the problem should be solved 3011 Sequencer error in DPC flags Bad Pogo PCB Replace 50019 Pogo PCB 8...

Page 17: ...6 AUTOALIGN weak sensor reading Pogo Card is crooked or sensor is not snapped in Realign the pogo card 85022 ZPrinter 650 Pogo PCB Removal and Replacement figure 9 and 9 1 After performing the above s...

Page 18: ...performing a service print head and an alignment Watch the alignment pattern for print quality If the machine performs both tasks the problem should be solved 40007 AUTOALIGN alignment of Axis x faile...

Page 19: ...Pogo or oil has leaked in the carriage Clean sensor on Pogo with alcohol and clean inside the carriage then retry Figure 7 40008 AUTOALIGN Pogo Card is crooked or sensor is not snapped in Realign the...

Page 20: ...age Cable Replace 50080 Pogo Flex Cable 85026 ZPrinter 650 Carriage Cable Removal and Replacement After performing the above step try performing a service print head and alignment If the machine perfo...

Page 21: ...the machine performs both tasks the problem should be solved 60400 FPGA comm error on pogo card Bad Carriage Cable Replace 50080 Pogo Flex Cable 85026 ZPrinter 650 Carriage Cable Removal and Replacem...

Page 22: ...nd alignment If the machine performs both tasks the problem should be solved 60501 POGOPOWERSPI Bad Pogo PCB Replace 50019 Pogo PCB 85022 ZPrinter 650 Pogo PCB Removal and Replacement After performing...

Page 23: ...machine performs both tasks the problem should be solved 60502 POGO POWER read error Bad Pogo PCB Replace 50019 Pogo PCB 85022 ZPrinter 650 Pogo PCB Removal and Replacement After performing the above...

Page 24: ...f this error is a cable disconnect bad cable or a bad pogo This error can be diagnosed through the control panel on the machine by going through the PC104 and Pogo tests 10040 POGOSTATUSSPI timed out...

Page 25: ...ssembly Figure 1 Service station squirter holes Figure 2 Service station diagram squeegee in red Figure 3 Spittoon Figure 4 Binder air vent Figure 5 Binder bottle float switch and connector Figure 6 A...

Page 26: ...09915 ZPrinter 650 Troubleshooting Guide Bad pogo card sensor Figure 9 Good pogo card sensor Figure 9 1 26...

Page 27: ...ngs reset the Maintenance in the software 09577 ZPrinter650 User Manual 2301 0 Slow Axis idler pulley is dirty worn Clean Pulley with a dental Pick If worn replace slow axis idler pulley 06564 Figure...

Page 28: ...slow axis idler pulley 06564 Figure 11 and 12 2303 0 MOVER axis 0 excessive position error Slow axis motor pulley is dirty worn Clean Pulleys with a dental Pick If worn replace 31174 Pittman Motor 142...

Page 29: ...worn Clean Pulley with a dental Pick If worn replace the 50038 Tiamat Fast Axis Idler Tensioner Ass y Figure 11 and 12 2303 1 MOVER axis 1 excessive position error Fast axis motor pulley is dirty wor...

Page 30: ...ce slow axis idler pulley 06564 Figure 11 and 12 2303 0 MOVER axis 0 excessive position error Slow axis motor pulley is dirty worn Clean Pulleys with a dental Pick If worn replace 31174 Pittman Motor...

Page 31: ...with a dental Pick If worn replace the 50038 Tiamat Fast Axis Idler Tensioner Ass y Figure 11 and 12 2305 1 MOVER axis 1 didn t settle Fast axis motor pulley is dirty worn Clean Pulley with a dental...

Page 32: ...12 2400 0 REZERO axis 0 can t find end of travel Slow axis motor pulley is dirty worn Clean Pulleys with a dental Pick If worn replace 31174 Pittman Motor 14205 24V Modified Figure 11 and 12 After pe...

Page 33: ...ttman Motor 9234 19 1V Modified RoHS Figure 11 and 12 2400 1 REZERO axis 1 can t find end of travel Fast Axis idler pulley is dirty worn Clean Pulley with a dental Pick If worn replace the 50038 Tiama...

Page 34: ...low Axis idler pulley is dirty worn Clean Pulley with a dental Pick If worn replace slow axis idler pulley 06564 Figure 11 and 12 3012 SEQUENCER spurious interrupt Slow axis motor pulley is dirty worn...

Page 35: ...oval and Replacement Procedure 3013 SEQUENCER timed out finishing swath Fast axis motor pulley is dirty worn Clean Pulley with a dental Pick If worn replace the 31175 Pittman Motor 9234 19 1V Modified...

Page 36: ...Axis idler pulley is dirty worn Clean Pulley with a dental Pick If worn replace slow axis idler pulley 06564 Figure 11 and 12 43000 SEQUENCER missed position Slow axis motor pulley is dirty worn Clea...

Page 37: ...worn replace the 31175 Pittman Motor 9234 19 1V Modified RoHS Figure 11 and 12 60300 REZERO fast axis length out of tolerance Fast axis belt is loose worn Retension the fast axis belt or Re tension t...

Page 38: ...a dental Pick If worn replace 31174 Pittman Motor 14205 24V Modified Figure 11 and 12 60301 REZERO Slow axis length out of tolerance Slow axis belt is loose worn Re tension the slow axis belt or Repl...

Page 39: ...5 ZPrinter 650 Troubleshooting Guide Carriage anti rotate Figure 10 Dirty idler pulley Figure 11 Worn pulley Figure 12 Fast axis ends of travel bumpers Figure 13 Slow axis end of travel stop Figure 14...

Page 40: ...irection top of roller moves away from the front of the printer Roller motor is keyed wrong or miss wired Reseat Replace 30834 Roller Motor After performing the above steps try performing a service pr...

Page 41: ...ual Short Spreading Snowplows are damaged or not sitting properly Reseat Replace 06839 Left Snowplow and 06840 Right Snowplow Figure 22 After performing the above steps try performing a service print...

Page 42: ...mbly After performing the above steps try performing a service print head and alignment If the machine performs both tasks then proceed with a test print 5001 No More Feed Metering bearings failed Rep...

Page 43: ...alignment If the machine performs both tasks then proceed with a test print 60100 feeder timeout Metering motor is damaged Replace 50011 Feeder 08862 ZPrinter650 Feeder Removal and Replacement 60100...

Page 44: ...rforming a service print head and alignment If the machine performs both tasks then proceed with a test print Piston is not moving Piston seal is sticking to build chamber wall Replace the 31479 Pisto...

Page 45: ...09915 ZPrinter 650 Troubleshooting Guide Short spread Figure 21 Snowplows on correctly Figure 22 Feeder slot cover Figure 23 Build piston support plate Figure 25 Build piston assy Figure 25 45...

Page 46: ...ow is full or not emptying Vacuum hose has a leak Check hose for leaks Air Valve is not Moving Vacuuming tubing is twisted or a hose clamp is caught in the gears Un twist the tubing or rotate the hose...

Page 47: ...or leaks User Hose has Light suction See No Light Suction on User Hose See No Light Suction on User Hose Air Valve is not Moving Vacuuming tubing is twisted or a hose clamp is caught in the gears Un t...

Page 48: ...Separator No Suction on User Hose Tighten Hose Clamps Tighten Hose Clamps After performing the above steps try performing a service print head and alignment If the machine performs both tasks then pr...

Page 49: ...tor or Gear work Replace 06597 Vacuum Valve Assembly After performing the above steps try performing a service print head and alignment If the machine performs both tasks then proceed with a test prin...

Page 50: ...eeder Slot Cover Powder blowing out back Panel Feeder Filter is not seated correctly Clean Filter reseat filter and replace 06802 Vacuum Motor Powder blowing out back Panel Feeder filter installed ups...

Page 51: ...PCB 85022 ZPrinter 650 Pogo PCB Removal and Replacement After performing the above steps try performing a service print head and alignment If the machine performs both tasks then proceed with a test...

Page 52: ...unicate with the Inverter PCB in the E Box Monitor Read Out or Secondary Symptom Cause Problem Solution Reference Documents 61302 Inverter Comm Error Inverter misread power intake Unplug the printer f...

Page 53: ...ectly into the outlet Surge protectors and UPS systems have been known to cause this error Blank Illuminated LCD The LCD is powered on but blank LED s are on No movement Monitor Read Out or Secondary...

Page 54: ...r not connected Plug in to appropriate voltage Universal Power Supply LCD Panel has no Power Loose Cabling inside E Box Check cabling inside E Box LCD Panel has no Power Failed PC104 Replace 50016 PC1...

Page 55: ...connection Software Manual Normal May be sleeping or ONLINE Printer or PC is not properly configured Configure Printer and PC 09577 ZPrinter650 User Manual and 08605 Ethernet Setup Procedure Normal Ma...

Page 56: ...rary increase in network traffic may have caused Z Print data to slow down 1905 LAYERS layer is too big This error occurs when the layer being sent is too large for the buffer Monitor Read Out or Seco...

Page 57: ...plugged in Reinsert Cartridge 09577 ZPrinter650 User Manual Binder on top deck Binder Cartridge Leaking Replace Cartridge 09577 ZPrinter650 User Manual Binder on top deck Binder Intake Valve Leaking...

Page 58: ...y but the Binder Cartridge is Full Binder Cartridge Damaged or valve not working Try a new Binder Bottle 09577 ZPrinter650 User Manual Binder Reservoir is Empty but the Binder Cartridge is Full Binder...

Page 59: ...condary Symptom Cause Problem Solution Reference Documents 1008 Head Cover Open Top Cover Open Close Top cover 1008 Head Cover Open Top Cover witch damaged Replace 31383Top Cover Interlock Switch Heat...

Page 60: ...took Too Long Mechanical Issue Treat initially like a 2303 1 See 2303 1 See 2303 1 3202 Monitor Thread took Too Long Motherboard Fan is not working Properly Replace 15725 Motherboard PCB 85070 ZPrinte...

Page 61: ...nt window on the carriage may become coated with oil Below are the steps you may need to take in order to correct the error 40006 AUTOALIGN weak sensor reading Step 1 Remove the Pogo PCB 85022 ZPrinte...

Page 62: ...alignment sensor cont Step 3 To clean the alignment sensor on the Pogo PCB you can submerge that side of the Pogo in a cup of alcohol Shake the Pogo dry once you are done and all it to air dry to 15 m...

Page 63: ...cell When dealing with the load cell absolute precision is a must The problem that this presents is that every load cell is different and deciding if one is reading correctly becomes difficult The loa...

Page 64: ...Press the x key to bring up the TIAMAT_RESEARCH menu 2 Now key in the character shift period to proceed to the next screen 3 Now key in an uppercase P to proceed to the Powder Handling menu 4 Now key...

Page 65: ...09915 ZPrinter 650 Troubleshooting Guide 65...

Page 66: ...s in the feeder This amount of powder will come just above the feed wheel o LBS This is the weight of powder in the hopper A reading of 0 would be an empty hopper Unlike the reading the LBS reading wi...

Page 67: ...S and 1LBS If the offset is outside of the limits than the load cell was most likely damaged during shipping and needs to be replaced To check the slope 1 Disconnect the vacuum hose from the filter cl...

Page 68: ...with the feeder Make sure the gantry is not touching the feeder Check that no tools or screws have somehow fallen between the feeder and the structure Check that the flexures are not contacting the f...

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