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ZPrinter

650 Hardware Manual

Troubleshooting the ZPrinter 650

zcentral.zcorp.com

10/21/08

7.11 Part Quality Issues - Bad Surface Finish

The problems behind bad surface finish on parts will be different depending on whether the rough surface
is in the vertical plane or the horizontal plane.

7.11.1 Bad Horizontal 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 smooth, flat layer of powder.

Solution

Clean the Spreader Roller. See

Section 6.8, ’Clean The Spreader Roller’

7.11.2 Bad Vertical Surface Finish

Explanation:

A bad surface finish on

vertical

surfaces is usually the result of either or both of these:

•

A problem with the print heads.

•

A motion problem with either the Fast Axis or the Slow Axis.

Содержание ZPrinter 650

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 18: ...ZPrinter 650 Hardware Manual ZPrinter 650 Overview zcentral zcorp com 12 All Rights Reserved 10 21 08 1 9 Service Station Number Component 1 Squeegee 2 Spit Plate 3 Front Overflow...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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