Head Life Issues: Printer is not completing or Starting ...

09913 ZPrinter 450 Troubleshooting Guide.doc

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ZPrinter® 450

Troubleshooting Guide Part Number 09913

Revision H

Information contained in this document is the confidential property of Z Corporation. Recipient shall not disclose such Information to any third party, and shall not use it for any purpose whatsoever other than to price or provide services to Z Corporation. © Z Corporation 1995-2008. All rights reserved. Z, Z Corporation, zp, zb, ZMap, ZPhoto, Z-Cure, Z Prints, ZPrinter, ZCast, ZScanner, ZScan and the Z Corp. logo are pending/registered trademarks of Z Corporation.


Revision History: Rev B Changes: Inserted Doc numbers in Reference Column Inserted Part numbers in Solution Column Corrections to Table Of Contents Additional Descriptions 0f 61302 error Additional Descriptions 0f 2400(1) error Additional Descriptions 0f 2303(1) error Additional Comments for Weak User Hose Additional Comments for Overflow not emptying Included Wrong Vacuum Voltage on Boot Phenomenon Reworded Snowplow Failures Insertion of "Build Bed Not emptying" error Insertion of 60402 error Insertion of 61308 error Insertion of 1006 error Insertion of 60300 error Insertion of 60301 error Insertion of "Air in Lines" error Insertion of 40008 error Removed option to change Load Cell as a standalone spare part. Removed 60400 from Boot Failures and placed in Head errors (reference still present in Boot Failures Rev C Changes: Broke out part quality issues into separate items Insertion of 61300 and 61301 error Added troubleshooting steps caused by un-level fast axis under Short Spreading, uneven spread and added steps to check for uneven slot cover Added 2305 error Added 3012 error Changed Inverter Fuse Part Number Insertion of Fill Bed Issues under Spread issues Insertion of Appendix E: Leveling the fast axis Rev D Changes: Corrected Typos Adjusted order of short spread troubleshooting steps Adjusted Order of 1006, 4006, 40007, 40008 errors Adjusted troubleshooting wording for all motion errors Exchanged Piston issues for 40204 error Inserted Vent Part number Corrected Part Quality title change



Rev E Changes: Added 1011 Error Added 61305 Error Added Troubleshooting Steps For Dry Environment Added Troubleshooting steps for RECOVER BY LAYER option Added Reasons why the heater would not come up to temperature Rev F Changes: Added 60520 Error Corrected inconsistent naming of the PC104 to Head Card Power Wiring Harness Rev G Changes: Changed recommended spare from Ribbon Cable Assembly (06756) and Igus Power Cable Assembly (06757) to Igus Chain Assembly (06632) Added E-box to 60502 troubleshooting list Rev H Changes: Edited Appendix A for new firmware options and load cell outputs Corrected formatting on page 31



Table of Contents: Errors by category Revision History: .......................................................................................................... 2 Table of Contents: Errors by category .......................................................................... 4 Head Life Issues: Printer is not completing or Starting print jobs/purge or Alignment6

1003: I2C read failed for Head 0 ................................................................................ 6 1004: Print head Power Fail........................................................................................ 6 1006: Head Temp Too High ....................................................................................... 7 1007: Head Current Too high ..................................................................................... 7 1009: Head %d fire voltage stuck............................................................................... 8 1010: Invalid Head Temperature ................................................................................ 8 40006: Weak Sensor Reading..................................................................................... 9 40007: Auto alignment failed ..................................................................................... 9 40008: AUTOALIGN: can't pick reference head ..................................................... 10 40800: Head Check Failed........................................................................................ 10 60400: comm error on pogo card.............................................................................. 11 60402 FPGA: load failed on pogo, flags = 0x%x..................................................... 11 60501: Pogo power SPI ............................................................................................ 11 60502:POGO POWER: read error............................................................................ 12 60520: HP11 Command SPI Timeout ...................................................................... 12

Boot Failure: Printer will not come ONLINE............................................................. 13 Blank Illuminated LCD............................................................................................. 13 Net Init Failed ........................................................................................................... 13 No Power .................................................................................................................. 13 2400(0):REZERO: axis 0 can't find end of travel..................................................... 14 2400(1):REZERO: axis 1 can't find end of travel..................................................... 14 40901: TEMPCONTROL: Sensor error, %d degrees............................................... 14 60300: REZERO: fast axis length out of tolerance: %.2f......................................... 14 60301 REZERO: slow axis length out of tolerance: %.2f ........................................ 14 60400:comm error on pogo card............................................................................... 15 60402 FPGA: load failed on pogo, flags = 0x%x..................................................... 15

Spread Issues: Problems with spreading powder efficiently ...................................... 16 Spread not Smooth.................................................................................................... 16 Feeder is not dispensing enough powder (Short Spreading) .................................... 17 5001: POWDER: no more feed ................................................................................ 18 60100: feeder timeout ............................................................................................... 18

Motion Errors: Errors Involving Axis movement....................................................... 19 2303(0): MOVER: axis 0 excessive position error.................................................. 19 2303(1):MOVER: axis 1 excessive position error.................................................... 20 2305(0): MOVER: axis 0 didn’t settle..................................................................... 20 2305(1):MOVER: axis 1 didn’t settle....................................................................... 21 2400(0): REZERO: axis 0 can't find end of travel.................................................... 22 2400(1):REZERO: axis 1 can't find end of travel..................................................... 22 3012: SEQUENCER: spurious interrupt, flags = %x ............................................... 23



3013:SEQUENCER: timed out finishing swath, flags = %x.................................... 23 60300 REZERO: fast axis length out of tolerance: %.2f.......................................... 24 60301 REZERO: Slow axis length out of tolerance: %.2f ....................................... 24 40204: TI: Build piston driver overload ................................................................... 25

Part Quality Issues: Finished parts are not coming out well....................................... 26 Geometry/Sizing Issues ............................................................................................ 26 Weak Parts/De-laminations ...................................................................................... 27 Color Issues............................................................................................................... 28 Surface Finish ........................................................................................................... 29

Fluids: Fluid leaks within the printer .......................................................................... 30 Service station is full of fluid.................................................................................... 30 Binder on Top deck................................................................................................... 30 Binder leaking from bottom of printer...................................................................... 30 Air in Lines ............................................................................................................... 31 Software says the binder Reservoir is empty............................................................ 31 1011: Out of Binder .................................................................................................. 32

Communication Errors: Errors that are caused by a communication problem........... 33 Packet timeout: Printer not found: Before Printing .................................................. 33 Packet timeout: Printer not Found: While Printing................................................... 33 1905: LAYERS: layer is too big, %dK bytes ........................................................... 34 3900: SOCKETS: can't initialize WinSock interface ............................................... 34

Powder Handling: Issues with Empowering, Auto Gross De-powdering, Vacuum... 35 Front/Rear Overflow is full or not emptying ............................................................ 35 Build Bed will not empty.......................................................................................... 36 No/Light Suction on User Hose................................................................................ 37 De-powdering Chamber is full of powder while de-powdering ............................... 38 No Compressed Air or not enough Compressed Air. ............................................... 38 Powder is seeping out of printer ............................................................................... 39

Sensors and Switches: Errors that are related to the Z Printer's Sensors and switches..................................................................................................................................... 40 Top Cover Open........................................................................................................ 40 1008: Head Cover Open............................................................................................ 40 61300: INVERTER: bad version number: 0x%x ..................................................... 40 61301: timeout waiting for SPI bus .......................................................................... 41 61302: Inverter: Comm. Error .................................................................................. 41 61305: INVERTER: Heater driver over temp. status:0x%x..................................... 41 61308:INVERTER: Line under voltage. Status:0x%x ............................................. 42 Heater is not coming up to Temperature................................................................... 42

Miscellaneous Errors: Errors that do not fall into any other category........................ 43 3202: monitor Thread took too long ......................................................................... 43 40901: TEMPCONTROL: Sensor error, %d degrees............................................... 43 Appendix A: Understanding and troubleshooting the ZPrinter 450 Load Cell. ....... 44 Appendix B: Cleaning the service Station ................................................................ 46 Appendix C: Pogo Card Alignment......................................................................... 47 Appendix D: Fast Axis Bumper Location ................................................................ 48 Appendix E: Squareness of the Fast Axis................................................................. 49



Head Life Issues: Printer is not completing or Starting print jobs/purge or Alignment

1003: I2C read failed for Head 0 1003 is HP 11 Specific. This error is caused by the printer not being able to read the data off of the HP11 print head's smart chip Monitor Read-

Out or Secondary Symptom Cause / Problem Solution Reference Documents

1003: I2C read failed for Head 0

Print head not seated properly / contacts dirty

Clean print head contacts and Pogo Pins; Reinsert print heads 09570 ZPrinter 450 User Manual

1003: I2C read failed for Head 0 Bad/Old HP11 Print Head Replace HP11 Print Head 09570 ZPrinter 450 User Manual

1003: I2C read failed for Head o Bad Carriage Component Replace 06582 Carriage 08858 Carriage Removal and

Replacement

1003: I2C read failed for Head o Bad Head Card Replace 06631 Head Card

1004: Print head Power Fail The power going to the print head is either bad or misread. 1004 is specific to Head 0 Monitor Read-


1004: Print head Power Fail



1004: Print head Power Fail Bad/Old HP11 Print Head ReplaceHP11 Print Head 09570 ZPrinter 450 User Manual

1004: Print head Power Fail Bad Carriage Component Replace 06582 Carriage 08858 Carriage Removal and

Replacement

1004: Print head Power Fail Bad Head Card Replace 06631 Head Card

1004: Print head Power Fail

Bad PC104 to Head Card Power Wiring Harness Replace 06632 Igus Chain Assembly 08899 ZPrinter 450 Igus Chain

Assy Removal and Replacement

1004: Print head Power Fail PC104 Failed Replace 06624 E-Box 08860 ZPrinter 450 E-Box

Removal and Replacement



1006: Head Temp Too High This error is caused by a print head overheating due to low binder flow or failed electrical circuit including the print head Monitor Read-


1006: Head Temp Too High



Heads are getting powder on them

Service Station is not clean or station is damaged Clean Service Station 9571 ZPrinter 450 User Manual


Parking Station is not clean or is damaged Clean Parking Station 9572 ZPrinter 450 User Manual

Heads are getting powder on them Out of ZC10 Add ZC10 09570 ZPrinter 450 User Manual


Service Station Wiper is Worn Replace Service Station

1006: Head Temp Too High Bad/Old Print Head Replace Print head 09570 ZPrinter 450 User Manual

1006: Head Temp Too High Binder is past expiration Sanitize System: DO NOT USE

BLEACH: Use 06965 Sanitation Kit 08855 ZPrinter 450 Sanitization

Procedure

1006: Head Temp Too High Air in Fluid System See Fluids

1006: Head Temp Too High Binder system is leaking See Fluids


Air Vent is clogged (May happen during transport) Replace Air Vent


Out of binder and float switch is failed

Troubleshoot float switch and add binder


Lines are contaminated or Clogged

Sanitize System: DO NOT USE BLEACH: Use06965 Sanitation Kit

08855 ZPrinter 450 Sanitization Procedure

1007: Head Current Too high This error is caused by the current for the print heads being locked on. In the Z Printer 450, this voltage comes from the PC104 card. Monitor Read-


1007: Head Current too high



1007: Head Current too high Bad/Old Print Head Replace Print Head 09570 ZPrinter 450 User Manual

1007: Head Current too high Bad Carriage Component Replace 06582 Carriage 08858 Carriage Removal and

Replacement

1007: Head Current too high Bad Head Card Replace 06631 Head Card

1007: Head Current too high PC104 Failed Replace 06624 E-Box 08860 ZPrinter 450 E-Box




1009: Head %d fire voltage stuck This error is caused by the fire voltage for the print heads being locked on. In the Z Printer 450, this voltage comes from the PC104 card. Monitor Read-


1009: Fire Voltage Stuck



1009: Fire Voltage Stuck Bad/Old Print Head Replace Print Head 09570 ZPrinter 450 User Manual

1009: Fire Voltage Stuck PC104 Failed Replace 06624 E-Box 08860 ZPrinter 450 E-Box


1009: Fire Voltage Stuck Bad Carriage Component Replace 06582 Carriage 08858 Carriage Removal and

Replacement

1010: Invalid Head Temperature This error is caused by a bad reading of the print head temperature Monitor Read-


1010: Invalid Head Temperature



1010: Invalid Head Temperature Bad/Old Print Head Replace Print head 09570 ZPrinter 450 User Manual

1010: Invalid Head Temperature Bad Carriage Component Replace 06582 Carriage 08858 Carriage Removal and

Replacement

1010: Invalid Head Temperature Bad Head Card Replace 06631 Head Card



40006: Weak Sensor Reading This error is caused by the sensors lack of ability to properly align the heads. Monitor Read-


40006:Weak Sensor Reading Dirty sensor Window Clean Window and Retry 09570 ZPrinter 450 User Manual

40006:Weak Sensor Reading Build bed is not Flat Perform Fill Bed 09570 ZPrinter 450 User Manual

40006:Weak Sensor Reading Poor Spread "See Spread Issues" "See Spread Issues"

40006:Weak Sensor Reading Dirty Sensor on Pogo Clean sensor on Pogo and clean

inside the carriage and Retry

40006:Weak Sensor Reading

Pogo Card is crooked or sensor is not snapped in Realign the pogo card See Appendix C

40006:Weak Sensor Reading Bad Carriage Component Replace 06582 Carriage 08858 Carriage Removal and

Replacement

40006:Weak Sensor Reading PC104 Failed Replace 06624 E-Box 08860 ZPrinter 450 E-Box


40007: Auto alignment failed This error is caused by the sensors lack of ability to properly align the heads. Monitor Read-

Out or Secondary Symptom Cause / Problem Solution Reference Documents 40007: Auto

alignment failed Build bed is not Flat Perform Fill Bed 09570 ZPrinter 450 User Manual

40007: Auto alignment failed Poor Spread "See Spread Issues" "See Spread Issues"

40007: Auto alignment failed Stripy printing "See Part Quality Troubleshooting" "See Part Quality

Troubleshooting"

40007: Auto alignment failed Dirty sensor Window Clean Window and Retry 09570 ZPrinter 450 User Manual

40007: Auto alignment failed Dirty Sensor on Pogo Clean sensor on Pogo and clean


40007: Auto alignment failed


40007: Auto alignment failed Bad Carriage Component Replace 06582 Carriage 08858 Carriage Removal and

Replacement

40007: Auto alignment failed PC104 Failed Replace 06624 E-Box 08860 ZPrinter 450 E-Box




40008: AUTOALIGN: can't pick reference head This error is caused by the sensors lack of ability to read the yellow ink just before the alignment pattern is printed Monitor Read-


40008 AUTOALIGN: can't pick reference

head Build bed is not Flat Perform Fill Bed 09570 ZPrinter 450 User Manual


head Poor Spread "See Spread Issues" "See Spread Issues"


head Stripy printing "See Part Quality Troubleshooting" "See Part Quality

Troubleshooting"


head Dirty sensor Window Clean Window and Retry 09570 ZPrinter 450 User Manual


head Dirty Sensor on Pogo Clean sensor on Pogo and clean



head



head Bad Carriage Component Replace 06582 Carriage 08858 Carriage Removal and

Replacement


head PC104 Failed Replace 06624 E-Box 08860 ZPrinter 450 E-Box


40800: Head Check Failed 40800 is HP 11 Specific. The Printer cannot find the HP 11 Print HEAD Monitor Read-


40800: Head Check Failed



40800: Head Check Failed Bad/Old HP11 Print Head ReplaceHP11 Print Head 09570 ZPrinter 450 User Manual

40800: Head Check Failed Bad Carriage Component Replace 06582 Carriage 08858 Carriage Removal and

Replacement

40800: Head Check Failed Bad Head Card Replace 06631 Head Card



60400: comm error on pogo card The PC104 card cannot read the pogo card Monitor Read-


60400:comm error on pogo card




Bad/Old Print Head Replace Print Head 09570 ZPrinter 450 User Manual


Bad Carriage Component Replace 06582 Carriage 08858 Carriage Removal and Replacement


Bad Head Card Replace 06631 Head Card

60402 FPGA: load failed on pogo, flags = 0x%x The PC104 card cannot load the FPGA onto the pogo card at boot Monitor Read-


60402 FPGA: load failed on pogo, flags

= 0x%x




= 0x%x Bad/Old Print Head Replace Print head 09570 ZPrinter 450 User Manual


= 0x%x Bad Carriage Component Replace 06582 Carriage 08858 Carriage Removal and

Replacement


= 0x%x Bad Head Card Replace 06631 Head Card

60501: Pogo power SPI This error is caused by a fluctuation in the pogo card power Monitor Read-

Out or Secondary Symptom Cause / Problem Solution Reference Documents 60501:Pogo powerSPI



60501:Pogo powerSPI Bad/Old Print Head Replace Print Head 09570 ZPrinter 450 User Manual

60501:Pogo powerSPI Bad Carriage Component Replace 06582 Carriage 08858 Carriage Removal and

Replacement 60501:Pogo powerSPI Bad Head Card Replace 06631 Head Card




60502:POGO POWER: read error The PC104 card cannot read the pogo card Monitor Read-

Out or Secondary Symptom Cause / Problem Solution Reference Documents 60502:POGO

POWER: read error Print head not seated

properly / contacts dirty Clean print head contacts and Pogo

Pins; Reinsert print heads 09570 ZPrinter 450 User Manual

60502:POGO POWER: read error Bad/Old Print Head Replace Print Head(s) 09570 ZPrinter 450 User Manual

60502:POGO POWER: read error

Bad PC104 to Head Card Power Wiring Harness Replace 06632 Igus Chain Assembly 08899 ZPrinter 450 Igus Chain


60502:POGO POWER: read error Bad Carriage Component Replace 06582 Carriage 08858 Carriage Removal and

Replacement

60502:POGO POWER: read error Bad Head Card Replace 06631 Head Card

60502:POGO POWER: read error Bad PCI Card Replace 06624 E-Box 08860 ZPrinter 450 E-Box


60520: HP11 Command SPI Timeout The PC104 card cannot read the pogo card Monitor Read-

Out or Secondary Symptom Cause / Problem Solution Reference Documents 60520:HP 11

Command SPI Timeout



60520:HP 11 Command SPI

Timeout Bad/Old Print Head Replace Print Head(s) 09570 ZPrinter 450 User Manual


Timeout Bad Carriage Component Replace 06582 Carriage 08858 Carriage Removal and

Replacement


Timeout Bad Head Card Replace 06631 Head Card


Boot Failure: Printer will not come ONLINE

Blank Illuminated LCD The LCD is powered on, but blank. LEDs are on. No movement Monitor Read-


Disk Boot Failure Failed Flash Drive Replace 06624 E-Box 08860 ZPrinter 450 E-Box Removal and Replacement

Ready for Debugger Commands Cabling Check all Cables for missed

connections

Ready for Debugger Commands Bad E-Box Replace 06624 E-Box 08860 ZPrinter 450 E-Box


Net Init Failed The printer has not found an IP address form the network Monitor Read-


Net Init Failed Network Initialization failed Press Control Panel Button: Printer will enter Setup Mode

09570 ZPrinter 450 User Manual 08605 Ethernet Connection

Setup

No Power The printer has no power at all. No LED's, control panel power or movement Monitor Read-


LCD Panel has no Power Power 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 E-box Failure Replace 06624 E-Box 08860 ZPrinter 450 E-Box




2400(0):REZERO: axis 0 can't find end of travel This error is caused by the printer not being able to reach it's desired slow axis location (front to back) Monitor Read-


2400(0) See Motion ERRORS See Motion Errors

2400(1):REZERO: axis 1 can't find end of travel This error is caused by the printer not being able to reach it's desired fast axis location (left to right) Monitor Read-


2400(1) See Motion ERRORS See Motion Errors

40901: TEMPCONTROL: Sensor error, %d degrees This error is failure of the circuit that reads the heater temperature Monitor Read-


40901 See Miscellaneous Errors See Miscellaneous Errors

60300: REZERO: fast axis length out of tolerance: %.2f This error is caused by the fast axis length being out of tolerance while rebooting Monitor Read-


60300 See Motion ERRORS See Motion Errors

60301 REZERO: slow axis length out of tolerance: %.2f This error is caused by the slow axis length being out of tolerance while rebooting Monitor Read-


60301 See Motion ERRORS See Motion Errors




60400:comm error on pogo card The PC104 card cannot read the pogo card Monitor Read-


60400:comm error on pogo card See Head Errors See Head Errors

60402 FPGA: load failed on pogo, flags = 0x%x The PC104 card cannot load the FPGA onto the pogo card at boot Monitor Read-


See Head Errors See Head Errors USER


Spread Issues: Problems with spreading powder efficiently

Spread not Smooth The Printer is not laying down powder in a consistent manner. Monitor Read-


Spread not Smooth Powder is old Replace powder or add fresh powder to old powder 09570 ZPrinter 450 User Manual

Spread not Smooth Snowplows are damaged or not sitting properly

Reseat/Replace 06839 Left Snowplow and 06840 Right Snowplow

Spread not Smooth Scraper is worn Replace 30578 Scraper 08865 ZPrinter 450 Scraper Blade Replacement Procedure

Spread not Smooth Roller is Dirty Clean roller and replace 30857 Scraper

Roller is not moving Roller belt is stripped Replaced 15375 Roller Belt

Roller is not moving Bad Roller Bearing (remove belt and move roller by hand) Replace 06566 Fast Axis Assembly

08861 ZPrinter 450 Fast Axis Removal and Replacement

Procedure

Roller is not moving Pulley is loose or worn Replace Roller Motor Roller is not moving Motor is damaged Replace Roller Motor

Roller is not moving PC104 Failed Replace 06624 E-Box 08860 ZPrinter 450 E-Box Removal and Replacement

Roller is moving in the wrong direction. (top of roller moves

away from the front of the printer)

Roller motor is keyed wrong or misfired Reseat/Replace motor

Roller is moving in the wrong direction. (top of roller moves

away from the front of the printer)

PC104 Failed Replace 06624 E-Box 08860 ZPrinter 450 E-Box Removal and Replacement

Fast Axis is not sitting flat Fast Axis is not sitting flat Remove fast axis, level and replace See Appendix E for more

information

Fast axis "jumping". If hard error occurs, see hard error )

Slow Axis motor shaft is loose. (shaft should have

zero vertical play) Replace 31174 Slow axis motor



Feeder is not dispensing enough powder (Short Spreading) This error occurs may be due to many things but is noticeable by the build box not being full while printing. Monitor Read-


Short Spreading Build box was not smooth when print started Stop job, fill bed and restart the job 09570 ZPrinter 450 User Manual

Short spreading during fill bed Piston is not re-zeroed Re-zero Piston 08860 ZPrinter 450 E-Box


Short spreading during fill bed

Piston is a tiny amount too low when at Peak Position

Adjust FILL BED SPREAD setting in INI

09912 ZPrinter 450 Installation Manual

Short Spreading Tune feeder is required Tune Feeder

Short Spreading Fast Axis not seated Properly Reseat 06566 Fast Axis Assembly 08861 ZPrinter 450 Fast Axis Removal and Replacement

Procedure

Short Spreading Calibration values are not properly set in .INI file Change INI settings 08862 ZPrinter 450 Feeder


Short Spreading Debris Separator is full Empty, and clean the separator 09570 ZPrinter 450 User Manual

Short Spreading Snowplows are damaged or not sitting properly

Reseat/Replace 06839 Left Snowplow and 06840 Right Snowplow

Fast Axis is not sitting flat Fast Axis is not sitting flat Remove fast axis, level and replace See Appendix E for more

information

Short Spreading Load Cell is reading improperly Replace 06544 Feeder

See Appendix A and 08862 ZPrinter 450 Feeder Removal

and Replacement

Short Spreading Load Cell is not registering Properly Replace 06624 E-Box 08860 ZPrinter 450 E-Box


Short Spreading Load Cell bearing is damaged Replace load cell bearing

Short Spreading Feeder Mounting Bearings are damaged Replace 06544 Feeder


and Replacement Fast axis "jumping". If

hard error occurs, see hard error )

Slow Axis motor shaft is loose. (shaft should have

zero vertical play) Replace 31174 Slow axis motor

Fast axis is not perpendicular to build

box

Fast axis is not perpendicular to build box Call Z Corp Call Z Corp




5001: POWDER: no more feed This error occurs when the feeder runs out of powder or it thinks it is out of powder. Monitor Read-


5001: No More Feed Feeder is out of powder Check Powder Level 09570 ZPrinter 450 User Manual

User hose has weak suction

See "No/Little suction on User Hose" See "No/Little suction on User Hose"

5001: No More Feed The Overflows are over packed

Remove powder and check hoses for leaks

5001: No More Feed Feeder slot cover is bent or broken Replace 06827 feed slot cover

5001: No More Feed Load cell damaged Replace 06544 Feeder See Appendix A and 08862

ZPrinter 450 Feeder Removal and Replacement

5001: No More Feed Load Cell Bearing damaged Replace load cell bearing

5001: No More Feed Load Cell is not registering Properly Replace 06624 E-Box

Appendix A and 08860 ZPrinter 450 E-Box Removal and

Replacement

5001: No More Feed Feeder mounting bearings failed Replace 06544 Feeder


and Replacement

60100: feeder timeout This error occurs when the Feeder drive motor is not responding Monitor Read-


60100: feeder timeout Powder is Packed Update Firmware to latest firmware. Newer versions of software will auto-

unpack.

60100: feeder timeout Metering motor is damaged Replace 06544 Feeder 08862 ZPrinter 450 Feeder Removal and Replacement

60100: feeder timeout Metering bearings failed Replace 06544 Feeder 08862 ZPrinter 450 Feeder Removal and Replacement

60100: feeder timeout PC104 Failed Replace 06624 E-Box 08860 ZPrinter 450 E-Box Removal and Replacement


Motion Errors: Errors Involving Axis movement

2303(0): MOVER: axis 0 excessive position error This error is caused by the presence of or the appearance of excessive friction on the slow axis rail (front to back). Monitor Read-


2303(0) Gantry is obstructed Remove obstruction 2303(0) Rails are dirty Clean rails 09570 ZPrinter 450 User Manual

2303(0) Slow Axis bearing needs grease

Grease Slow Axis bearing (reset the Maintenance in the software) 09570 ZPrinter 450 User Manual

2303(0) Service station is dirty and carriage is jammed

Clean the service station and reassemble if necessary

2303(0) Slow axis motor pulley is dirty Clean Pulleys with a dental Pick

2303(0) Slow Axis idler pulley is dirty/worn

Clean Pulley with a dental Pick. If worn, replace slow axis idler pulley

06564

2303(0) Slow axis belt is loose/worn Re-tension the slow axis belt or Replace the belt

2303(0) Slow axis bearing is damaged

Replace 06927 Slow Axis Bearing and Fitting

08867 ZPrinter 450 Slow Axis Bearing Removal and

Replacement Procedure

2303(0) Slow axis motor is damaged/ Pulley is worn Replace 31174 Slow axis motor

2303(0) PC104 Failed Replace 06624 E-Box 08860 ZPrinter 450 E-Box Removal and Replacement



2303(1):MOVER: axis 1 excessive position error This error is caused by the presence of or the appearance of excessive friction on the fast axis rails left to right). Monitor Read-


2303(1) Carriage is obstructed Remove obstruction 2303(1) Rails are dirty Clean rails 09570 ZPrinter 450 User Manual

2303(1) Fast Axis bearing needs grease

Grease Fast Axis bearing (reset the Maintenance in the software) 09570 ZPrinter 450 User Manual

2303(1) Fast axis motor pulley is dirty Clean Pulley with a dental Pick

2303(1) Fast Axis idler pulley is dirty/worn

Clean Pulley with a dental Pick. If worn, replace fast Axis idler pulley

06920

2303(1) Fast axis belt is loose/worn Replace 06566 Fast Axis or 06746 Fast axis belt


Procedure

2303(1) Fast Axis Bearing or motor failure Replace 06566 Fast Axis Assembly


Procedure


2305(0): MOVER: axis 0 didn’t settle This error is caused by the presence of or the appearance of excessive friction on the slow axis rail (front to back). Monitor Read-








06564










2305(1):MOVER: axis 1 didn’t settle 2305(1):MOVER: axis didn’t settle Monitor Read-








06920



Procedure



Procedure




2400(0): REZERO: axis 0 can't find end of travel This error is caused by the printer not being able to reach it's desired slow axis location (front to back) Monitor Read-








06564








2400(1):REZERO: axis 1 can't find end of travel This error is caused by the printer not being able to reach it's desired fast axis location (left to right) Monitor Read-








06920



Procedure



Procedure




3012: SEQUENCER: spurious interrupt, flags = %x This error is caused by the fast axis drive not keeping up with the printer's location requests Monitor Read-

Out or Secondary Symptom Cause / Problem Solution Reference Documents 3012: 3012:

SEQUENCER: spurious interrupt,

flags = %x

Rails are dirty Clean rails (do not grease) 09570 ZPrinter 450 User Manual

3012: 3012: SEQUENCER:

spurious interrupt, flags = %x

Fast axis belt is loose/worn Replace 06566 Fast Axis Assembly or 06746 Fast Axis Belt


Procedure

30123012: SEQUENCER: spurious interrupt, flags = %x

Bearings need grease Grease bearings 09570 ZPrinter 450 User Manual

3012: 3012: SEQUENCER: spurious interrupt, flags = %x

Fast axis bearing is damaged Replace 06582 Carriage 08858 Carriage Removal and Replacement


Fast Axis Motor is damaged Replace 30809 Fast Axis Motor



3013:SEQUENCER: timed out finishing swath, flags = %x This error is caused by the fast axis drive not keeping up with the printer's location requests Monitor Read-


3013: SEQUENCER: timed out finishing swath, flags = %x

Rails are dirty Clean rails (do not grease) 09570 ZPrinter 450 User Manual

3013: SEQUENCER: timed out finishing swath

Fast axis belt is loose/worn Replace 06566 Fast Axis Assembly or 06746 Fast Axis Belt


Procedure 3013: SEQUENCER: timed out finishing swath

Bearings need grease Grease bearings 09570 ZPrinter 450 User Manual


Fast axis bearing is damaged Replace 06582 Carriage 08858 Carriage Removal and Replacement


Fast Axis Motor is damaged Replace 30809 Fast Axis Motor





60300 REZERO: fast axis length out of tolerance: %.2f This error is caused by the fast axis length being out of tolerance while rebooting Monitor Read-


60300 Carriage is obstructed Remove obstruction 60300 Rails are dirty Clean rails 09570 ZPrinter 450 User Manual

60300 Fast Axis bearing needs grease


60300 Fast axis motor pulley is dirty Clean Pulley with a dental Pick

60300 Fast Axis idler pulley is dirty/worn


06920

60300 Fast axis belt is loose/worn Replace 06566 Fast Axis or 06746 Fast axis belt


Procedure

60300 Fast Axis Bearing or motor failure Replace 06566 Fast Axis Assembly


Procedure

60300 PC104 Failed Replace 06624 E-Box 08860 ZPrinter 450 E-Box Removal and Replacement

60301 REZERO: Slow axis length out of tolerance: %.2f This error is caused by the slow axis length being out of tolerance while rebooting Monitor Read-


60301 Gantry is obstructed Remove obstruction 60301 Rails are dirty Clean rails 09570 ZPrinter 450 User Manual

60301 Slow Axis bearing needs grease


60301 Slow axis motor pulley is dirty Clean Pulleys with a dental Pick

60301 Slow Axis idler pulley is dirty/worn


06564

60301 Slow axis belt is loose/worn Re-tension the slow axis belt or Replace the belt

60301 Slow axis bearing is damaged




60301 Slow axis motor is damaged/ Pulley is worn Replace 31174 Slow axis motor

60301 PC104 Failed Replace 06624 E-Box 08860 ZPrinter 450 E-Box Removal and Replacement




40204: TI: Build piston driver overload This error is caused by a failed piston drive. Monitor Read-


Piston Position is Incorrect Piston position incorrect Re-zero pistons (must be done after

installation of new E-Box)

08857 ZPrinter 450 Piston Drive / Vibration Motor Removal and

Replacement

Piston is not moving Piston motor cables disconnected Reconnect piston motor cables


Replacement

Piston is not moving Powder is over packed in the piston

Vacuum powder into feeder (Piston will need to be re-zeroed)


Replacement


Piston is not moving Piston seal is sticking to feeder wall Replace 30623 Piston Seal


Replacement

Piston is not moving Shaft screws came loose Retighten screws (Piston will need to be re-zeroed)


Replacement

Piston is not moving Piston Motor Failed Replace 30695 Piston Motor 08857 ZPrinter 450 Piston Drive / Vibration Motor Removal and

Replacement

Excessive Powder Build up Under Piston Piston Seal is failed Replace 30623 Piston Seal


Replacement



Part Quality Issues: Finished parts are not coming out well

Geometry/Sizing Issues Errors relating to a printed parts size and shape Monitor Read-


Bad Part Quality Old Heads Replace Head(s))) 09570 ZPrinter 450 User Manual Bad Part Quality Service Station dirty Clean Service Station 09570 ZPrinter 450 User Manual Bad Part Quality Parking Cap Dirty Clean Parking Cap 09570 ZPrinter 450 User Manual Bad Part Quality Incorrect Saturation Settings Check and correct Saturation settings 09570 ZPrinter 450 User Manual

Bad Part Quality PC is Pausing in between layers Check PC Settings/Specs 09570 ZPrinter 450 User Manual

Bad Part Quality Part is not dry yet Allow extra dry time 09570 ZPrinter 450 User Manual Bad Part Quality Out of Wash Fluid Add Wash Fluid 09570 ZPrinter 450 User Manual

Bad Part Quality Incorrect Wash Fluid Remove Wash fluid, replace wick, install new Wash Fluid 09570 ZPrinter 450 User Manual

Bad Part Quality Wick is worn Replace 06571 Service Station Bad Part Quality Squeegee is worn Replace 06571 Service Station Bad Part Quality Parking Cap Damaged Replace/Repair 06611Parking Cap Bad Part Quality Expired Binder Clean binder system, Replace binder 09570 ZPrinter 450 User Manual Bad Part Quality Incorrect Binder Drain and Replace binder 09570 ZPrinter 450 User Manual Bad Part Quality Rough Spread See "Spread Issues" See “Spread Issues" Bad Part Quality Short Spread See Short Spread See Short Spread Bad Part Quality Dirty Pogo Clean Pogo Contacts 09570 ZPrinter 450 User Manual Bad Part Quality Dirty Pogo cable connector Remove Pogo and Clean Connectors

Bad Part Quality Environment is too dry Change DRY_ENVIRONEMENT Setting to 1 in the .INI file

SB61 09861 Dry Environment Option

Bad Part Quality Failed POGO Replace 06582 Carriage 08858 Carriage Removal and Replacement

Bad Part Quality Failed Pogo Cable Replace 06582 Carriage 08858 Carriage Removal and Replacement

Bad Part Quality Hose Vent is Clogged Replace Vent filter 15936 Bad Part Quality Rails are dirty Clean rails

Bad Part Quality Heater is not Heating the Chamber See Heater Problems See Heater Problems



Weak Parts/De-laminations Errors relating to a printed parts strength Monitor Read-


Bad Part Quality Old Heads Replace Head(s) 09570 ZPrinter 450 User Manual Bad Part Quality Service Station dirty Clean Service Station 09570 ZPrinter 450 User Manual Bad Part Quality Parking Cap Dirty Clean Parking Cap 09570 ZPrinter 450 User Manual Bad Part Quality Incorrect Saturation Settings Check and correct Saturation settings 09570 ZPrinter 450 User Manual


Bad Part Quality Part is not dry yet Allow extra dry time 09570 ZPrinter 450 User Manual Bad Part Quality Out of Wash Fluid Add Wash Fluid 09570 ZPrinter 450 User Manual


Bad Part Quality Wick is worn Replace 06571 Service Station Bad Part Quality Squeegee is worn Replace 06571 Service Station Bad Part Quality Parking Cap Damaged Replace/Repair 06611Parking Cap Bad Part Quality Expired Binder Clean binder system, Replace binder 09570 ZPrinter 450 User Manual Bad Part Quality Incorrect Binder Drain and Replace binder 09570 ZPrinter 450 User Manual Bad Part Quality Rough Spread See "Spread Issues" See “Spread Issues" Bad Part Quality Short Spread See Short Spread See Short Spread



Bad Part Quality Dirty Pogo Clean Pogo Contacts 09570 ZPrinter 450 User Manual Bad Part Quality Dirty Pogo cable connector Remove Pogo and Clean Connectors



Bad Part Quality Hose Vent is Clogged Replace Vent filter 15936 Bad Part Quality Rails are dirty Clean rails

Bad Part Quality Heater is not Heating the Chamber See Heater Problems See Heater Problems



Color Issues Errors relating to a printed color Monitor Read-


Bad Part Quality Old Heads Replace Head(s))) 09570 ZPrinter 450 User Manual Bad Part Quality Service Station dirty Clean Service Station 09570 ZPrinter 450 User Manual Bad Part Quality Parking Cap Dirty Clean Parking Cap 09570 ZPrinter 450 User Manual Bad Part Quality Incorrect Saturation Settings Check and correct Saturation settings 09570 ZPrinter 450 User Manual Bad Part Quality Heads are not aligned Realign Heads 09570 ZPrinter 450 User Manual Bad Part Quality Out of Wash Fluid Add Wash Fluid 09570 ZPrinter 450 User Manual





Bad Part Quality Hose Vent is Clogged Replace Vent filter Bad Part Quality Rails are dirty Clean rails 09570 ZPrinter 450 User Manual

Bad Part Quality Fast Axis bearing needs grease


Bad Part Quality Fast axis motor pulley is dirty/worn Clean Pulley with a dental Pick

Bad Part Quality Fast Axis idler pulley is Dirty/worn Clean Pulley with a dental Pick

Bad Part Quality Fast axis belt is loose/worn Replace 06566 Fast Axis or 06746 Fast axis belt

Bad Part Quality Rails are dirty Clean rails

Bad Part Quality Slow Axis bearing needs grease


Bad Part Quality Slow axis motor pulley is dirty/worn Clean Pulleys with a dental Pick

Bad Part Quality Slow Axis idler pulley is Dirty/worn Clean Pulley with a dental Pick

Bad Part Quality Slow axis belt is loose/worn Re-tension the slow axis belt or Replace the belt

Bad Part Quality Slow axis bearing is damaged




Surface Finish Errors relating to a printed color

Monitor Read-Out or

Secondary Symptom

Cause / Problem Solution Reference Documents

Bad Part Quality Old Heads Replace Head(s))) 09570 ZPrinter 450 User Manual Bad Part Quality Service Station dirty Clean Service Station 09570 ZPrinter 450 User Manual Bad Part Quality Parking Cap Dirty Clean Parking Cap 09570 ZPrinter 450 User Manual Bad Part Quality Incorrect Saturation Settings Check and correct Saturation settings 09570 ZPrinter 450 User Manual


Bad Part Quality Heads are not aligned Realign Heads 09570 ZPrinter 450 User Manual Bad Part Quality Out of Wash Fluid Add Wash Fluid 09570 ZPrinter 450 User Manual







Bad Part Quality Hose Vent is Clogged Replace Vent filter Bad Part Quality Rails are dirty Clean rails 09570 ZPrinter 450 User Manual

Bad Part Quality Fast Axis bearing needs grease


Bad Part Quality Fast axis motor pulley is dirty/worn Clean Pulley with a dental Pick

Bad Part Quality Fast Axis idler pulley is Dirty/worn Clean Pulley with a dental Pick

Bad Part Quality Fast axis belt is loose/worn Replace 06566 Fast Axis or 06746 Fast axis belt

Bad Part Quality Rails are dirty Clean rails

Bad Part Quality Slow Axis bearing needs grease


Bad Part Quality Slow axis motor pulley is dirty/worn Clean Pulleys with a dental Pick

Bad Part Quality Slow Axis idler pulley is Dirty/worn Clean Pulley with a dental Pick

Bad Part Quality Slow axis belt is loose/worn Re-tension the slow axis belt or Replace the belt

Bad Part Quality Slow axis bearing is damaged




Fluids: Fluid leaks within the printer

Service station is full of fluid Service Station drain has backed up Monitor Read-


Service station is full of fluid

Service Station Drain is Clogged Clean drain area

Service station is full of fluid Waste line is clogged Use a syringe to back wash the

system from the waste container up. See Appendix B

Binder on Top deck Binder has leaked onto the top deck Monitor Read-


Binder on top deck Binder cartridge not plugged in Reinsert Cartridge 09570 ZPrinter 450 User Manual

Binder on top deck Binder Cartridge Leaking Replace Cartridge 09570 ZPrinter 450 User Manual Binder on top deck Binder Intake Valve Leaking Replace 06595 Binder Intake Valve

Binder on top deck Septum is leaking Replace 06419 Septum Clean; POGO CARD

Binder on top deck Reservoir is leaking Tighten float switch nut

Binder leaking from bottom of printer Binder is leaking and building up under the printer Monitor Read-


Binder leaking form bottom of printer

Solid Waste Container is overflowing Replace 15933 Solid waste container 09570 ZPrinter 450 User Manual

Binder leaking form bottom of printer Loose fitting Remove panels and check binder

fittings for potential leak



Air in Lines Air Bubbles have formed inside the printers tubing. Monitor Read-

Out or Secondary Symptom Cause / Problem Solution Reference Documents Air in Lines Loose fitting Tighten Fittings: Bleed Air out of

System.

Air in Lines Out of binder and float switch is failed

Troubleshoot float switch and add binder

Air in Lines Air Vent is clogged Replace Air Vent

Software says the binder Reservoir is empty Reservoir thinks it is empty (or actually is). This will come up just before a job Monitor Read-

Out or Secondary Symptom Cause / Problem Solution Reference Documents Out of binder Out of binder Add binder only if existing Cartridge is

empty 09570 ZPrinter 450 User Manual

Binder Reservoir is Empty, but the Binder

Cartridge is Full

Binder Cartridge not inserted properly Reseat Binder Cartridge 09570 ZPrinter 450 User Manual


Cartridge is Full

Binder Cartridge Damaged or valve not working Try a new Binder Bottle 09570 ZPrinter 450 User Manual


Cartridge is Full

Binder Intake Valve not functioning Replace 06595 Binder intake valve


Cartridge is Full Clog in line Sanitize System: DO NOT USE

BLEACH: Use06965 Sanitation Kit 08855 ZPrinter 450 Sanitization

Procedure

Binder Reservoir is Full

Float switch in reservoir not reading properly, due to foam

in reservoir Let the bottle settle for a while


Float switch in reservoir stuck in the down position

Remove switch and rinse with distilled water


Float switch in reservoir not reading properly. (To Bypass,

circuit should be closed to read a full bottle)

Replace 06609 Binder Reservoir

Binder Reservoir is full

Float switch in reservoir not reading properly, but bypass

does not work Check/Replace Cabling



does not work Replace 06624 E-Box 08860 ZPrinter 450 E-Box




1011: Out of Binder Reservoir thinks it is empty (or actually is). This will come up if doing a purge or an alignment form the control panel. Monitor Read-

Out or Secondary Symptom Cause / Problem Solution Reference Documents Out of binder Out of binder Add binder only if existing Cartridge is

empty 09570 ZPrinter 450 User Manual


Cartridge is Full

Binder Cartridge not inserted properly Reseat Binder Cartridge 09570 ZPrinter 450 User Manual


Cartridge is Full

Binder Cartridge Damaged or valve not working Try a new Binder Bottle 09570 ZPrinter 450 User Manual


Cartridge is Full

Binder Intake Valve not functioning Replace 06595 Binder intake valve


Cartridge is Full Clog in line Sanitize System: DO NOT USE

BLEACH: Use06965 Sanitation Kit 08855 ZPrinter 450 Sanitization

Procedure


Float switch in reservoir not reading properly, due to foam

in reservoir Let the bottle settle for a while


Float switch in reservoir stuck in the down position

Remove switch and rinse with distilled water


Float switch in reservoir not reading properly. (To Bypass,

circuit should be closed to read a full bottle)

Replace 06609 Binder Reservoir



does not work Check/Replace Cabling



does not work Replace 06624 E-Box 08860 ZPrinter 450 E-Box



Communication Errors: Errors that are caused by a communication problem

Packet timeout: Printer not found: Before Printing The printer is not being found before printing. If there is an error code on the printer, troubleshoot that error code first. Monitor Read-


Printer is not ONLINE Printer is not ONLINE Put printer ONLINE or troubleshoot accordingly

Normal: May be sleeping or ONLINE Lost Connection Go to "3D Print Setup" under 'File' and

refresh the connection Software Manual

Normal: May be sleeping or ONLINE

Printer or PC is not properly configured Configure Printer and PC

09570 ZPrinter 450 User Manual and 08605 Ethernet Setup

Procedure


Bad/Wrong Type Ethernet Cable Replace Cable


Procedure


See your MIS Manager: Note that Windows firewall,

wireless networking, and other security features may

prevent the printer from connecting to the PC

See your MIS Manager

Packet timeout: Printer not Found: While Printing If error code is on Control Panel, check respective troubleshooting section as this is not a communication problem Monitor Read-



Power Management Is Enabled Disable all power management


Ethernet Cable was interrupted or is bad

Reseat Cable and try again or replace Ethernet cable


PC does not meet required specs

Upgrade System to proper Specifications 09570 ZPrinter 450 User Manual


Printer is not keeping up with Z Print Demands

PC may be over tasked. Z Print requires a dedicated PC

Normal: May be sleeping or ONLINE Excessive network traffic

A temporary increase in network traffic may have caused Z Print data

to slow down




1905: LAYERS: layer is too big, %dK bytes This error occurs when the layer being sent is too large for the buffer. Monitor Read-


1905 Layer is too large for printer's buffer Reduce file size

3900: SOCKETS: can't initialize WinSock interface The printer has lost communication with the PC Monitor Read-


3900 Ethernet Cable was interrupted or is bad

Reseat Cable and try again or replace Ethernet cable

3900 Printer or PC is not properly configured Configure Printer and PC


Procedure

3900 See you MIS Manager See you MIS Manager


Powder Handling: Issues with Empowering, Auto Gross De-powdering, Vacuum

Front/Rear Overflow is full or not emptying The overflows have not emptied after a print job Monitor Read-


Front/Rear Overflow is full or not emptying

Air Valve is not in proper position Re-zero Air Valve

Weak Vacuum Printer chose incorrect voltage on Boot Reboot Printer

Air Valve is not Moving Bad/Improper cabling Check Air Valve Cabling

User Hose has Light suction

See "No/Light Suction on User Hose" See "No/Light Suction on User Hose"

Air Valve is not Moving Bad Motor or Gear work Replace 06597 Vacuum Valve

Assembly

08864 ZPrinter 450 Vacuum Valve Removal and


Air Valve is not Moving PC104 Failed Replace 06624 E-Box 08860 ZPrinter 450 E-Box


Front/Rear Overflow is full or not emptying Vacuum hose has a leak Check hose for leaks

No Vacuum Vacuum Motor is not working Replace 06802 Vacuum motor

No Vacuum Failed PC104 or Inverter Card Replace 06624 E-Box 08860 ZPrinter 450 E-Box


Powder is jammed Powder is jammed As a last resort, edit the RECOVER BY LAYERS Variable in the .INI file

09876 SB76 ZPrinter 450 Firmware Update



Build Bed will not empty The build bed is not emptying after a print job Monitor Read-


Build Bed will not Empty well

Software setting is set to not empty the bed Change setting as desired 09570 ZPrinter 450 User Manual

Build Bed will not Empty well

Air Valve is not in proper position Re-zero Air Valve or Re-Boot


User Hose has Light suction

See "No/Light Suction on User Hose" See "No/Light Suction on User Hose"


Vibrator Is not coming on or is faint Bad Vibrator Motor Replace 06812 Piston Vibrator Motor


Replacement

Vibrator Is not coming on or is faint Bad PCI104 Card Replace 06624 E-Box 08860 ZPrinter 450 E-Box



Assembly



Air Valve is not Moving PC104 Failed Replace 06624 E-Box 08860 ZPrinter 450 E-Box








No/Light Suction on User Hose The user hose has light suction, which when plugged in, the other vacuum functions may not work well. Monitor Read-


No Suction on User Hose Hose is split Replace 30861 User Hose

No Suction on User Hose Hose is Clogged Unclog hose

No Suction on User Hose Feeder Cover is unlatched Latch Cover

No Suction on User Hose

Feeder filter is not seated properly Reseat filter

Debris Separator is full Debris Separator is clogged Empty Separator

No Suction on User Hose Tighten Hose Clamps Tighten Hose Clamps


Debris Separator is full/Feeder is full of

powder

Load Cell Registering improperly See 5001:POWDER: no more feed Appendix A

Vacuum not running Vacuum Motor is not working Replace 06802 Vacuum motor

Vacuum not running Failed PC104 or Inverter Card Replace 06624 E-Box 08860 ZPrinter 450 E-Box


Feeder Filter motor isn't rotating

Filter Cleaner motor is failed or jammed causing filter to

clog Replace 06828 Feeder Cover



De-powdering Chamber is full of powder while de-powdering Powder is not emptying the depowdering chamber Monitor Read-

Out or Secondary Symptom Cause / Problem Solution Reference Documents De-powdering

Chamber is full of powder while de-

powdering

Air Valve is not in proper position Re-zero Air Valve



Assembly



Air Valve is not Moving Failed PC104 Replace 06624 E-Box 08860 ZPrinter 450 E-Box






No Compressed Air or not enough Compressed Air. The compressor is not kicking on. Monitor Read-


Compressor is on Compressor is not working (there are no adjustments) Replace 06797 Compressor 08859 ZPrinter 450 Compressor


Compressor is Off. Voltage is present Compressor is damaged Replace 06797 Compressor 8860 ZPrinter 450 Compressor


Compressor is Off. Voltage is not present Failed PC104 Replace 06624 E-Box 08860 ZPrinter 450 E-Box





Powder is seeping out of printer Powder is coming from various spots on the printer Monitor Read-


Powder blowing out back Panel

Feeder Filter is not seated correctly

Clean Filter, reseat filter and replace 06802 Vacuum Motor

Powder coming from feeder Feeder Filter is torn Replace 30502 Filter, 06828 Feeder

Cover and 06802 Vacuum Motor

Powder coming from feeder metering

bearings

Metering bearing seals are worn Replace 06544 Feeder 08862 ZPrinter 450 Feeder


Powder blowing out back Panel

Feeder filter installed upside-down

Install a new filter correctly. Replace vacuum motor.


Sensors and Switches: Errors that are related to the Z Printer's Sensors and switches

Top Cover Open The top cover is open or the printer thinks it is Monitor Read-


Top Cover Open Top Cover is Open Close Top Cover

Top Cover Open Cover Switch is damaged Replace 31383Top Cover (Interlock) Switch

1008: Head Cover Open There is no cover sensor over the heads. This cover is caused by the top cover having been opened Monitor Read-


1008:Head Cover Open Top Cover Open Close Top cover

1008:Head Cover Open Top Cover witch damaged Replace 31383Top Cover (Interlock)

Switch

61300: INVERTER: bad version number: 0x%x This error indicates a bad version or unreadable version of code in the inverter card. Monitor Read-


61300:Inverter Comm. Error

Inverter misread power intake

Unplug the printer for 5 minutes and try again

61300:Inverter Comm. Error Inverter fuse is Blown Replace 16336 Inverter Fuse

61300:Inverter Comm. Error Inverter is Damaged Replace 06624 E-Box 08860 ZPrinter 450 E-Box




61301: timeout waiting for SPI bus This error is Caused by the printer’s inability to communicate with the Inverter PCB in the E-Box Monitor Read-








61302: Inverter: Comm. Error This error is Caused by the printer’s inability to communicate with the Inverter PCB in the E-Box Monitor Read-








61305: INVERTER: Heater driver over temp. status:0x%x This error is Caused by a failure in the Inverter card causing the driver to over temp. Monitor Read-











61308:INVERTER: Line under voltage. Status:0x%x This error is usually caused by a bad reading on the inverter's line voltage. Monitor Read-








Heater is not coming up to Temperature The heater is not turning on or not coming up to temperature Monitor Read-


Heater not reaching temperature Top cover open Close top cover

Heater not reaching temperature

Panels are missing or removed Install or tighten panels

Input Voltage is good Heater Module is damaged Replace 06718 Heater Module (universal Voltage)

08863 ZPrinter 450 Heater Removal and Replacement

Procedure

Input Voltage is bad Damaged E-Box Replace 06624 E-Box 08860 ZPrinter 450 E-Box Removal and Replacement


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

3202: monitor Thread took too long This error is not head specific. This error is caused by data not transmitting between the E box and The fast axis Monitor Read-


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 Bad Ribbon Cable Replace 06632 Igus Chain Assembly 08899 ZPrinter 450 Igus Chain


3202 Monitor Thread took Too Long

Motherboard Fan is not working Properly Replace 06624 E-Box 08860 ZPrinter 450 E-Box


3202 Monitor Thread took Too Long Other issue in E-Box Replace 06624 E-Box 08860 ZPrinter 450 E-Box


40901: TEMPCONTROL: Sensor error, %d degrees This error is failure of the circuit that reads the heater temperature Monitor Read-


40901: TEMPCONTROL: Sensor error, %d degrees

Sensor miss-Read Reboot


Failed Carriage Cable or Pogo Replace 06582 Carriage Replace 06582 Carriage


Failed Head Card Replace 06631 Head Card



Appendix A: Understanding and troubleshooting the ZPrinter 450 Load Cell. The ZPrinter 450 uses a load cell to measure the weight of the powder in the feeder. The load cell is basically a scale. The feeder sits on two bearings so that the center of gravity pushes the feeder against the load cell. The load cell is located just behind the feeder. A bearing is the only contact point between the load cell and the feeder to prevent friction from altering the weight reading. The load cell is extremely sensitive. Simply moving the printer will alter the reading on the cell, but the printer takes many readings (20 per second) and averages them to improve the result. The load cell is also somewhat delicate, and it can be damaged by rough handling or by moving the printer over rough surfaces, particularly when there is powder in the feeder. The feeder should always be emptied of powder and the feeder should be restrained when shipping or moving the machine over any rough surface (i.e. door threshold, parking lot, etc.) See 08873 ZPrinter 450 Transportation Manual for more information. The load cell measures in ticks from 0 to 4095. A load cell with no load reads between 0 and 50 ticks. A load cell will not read above 4095 no matter how much weight is on it. To read the load cell:

• On the control knob, enable the SIRVICE MENU by scrolling to STATUS and holding the knob down until SERVICE MENU ENABLED is displayed

• In the service menu, scroll down until READ FEEDER is highlighted




The feeder assembly is calibrated at the factory. The Ebox circuit that reads the load cell is calibrated at the factory independently. These can not be recalibrated in the field, but the net system calibration can be checked to ensure it’s within expected limits and the load cell has not been damaged.

• First, verify that the calibration settings in the .INI file match those on the sticker on the back of the feeder.

• No load condition:

o Push the feeder away from the load cell so that the bearing no longer contacts the load cell.

o “READ FEEDER” from the service menu on the control panel. Raw counts should be between 0 and 50.

Push Feeder Away from the load cell

Push this direction

Load Cell

• No powder condition: o Empty the feeder of ALL powder. o Replace the filter, diffuser and top cover o “READ FEEDER” from the service menu on the control panel. Raw counts

should be 150 +/- 50. NOTE: The feeder must be empty for the weight to be accurate.

Cover

Hose Diffuser

Filter

• If these two readings are accurate, then the load cell and PC104 card are working correctly. Inaccurate readings point to a damaged load cell or PC104 card, or failure to enter the feeder calibrations correctly in the INI file.



Appendix B: Cleaning the service Station In the event of a clog in the service station, it will have to be unclogged.

1. Clean the top deck of powder 2. Shut the printer off and unplug the power and network connections 3. Remove the rear panel 4. Remove the service station 5. Disconnect the tube. 6. Plug in a syringe full of DI Water and force the water up the line until it comes out of the

service station drain onto the top deck 7. Clean up water 8. Reinsert hose at bottom, panel, service station, and power/network connections

Remove this tube and force distilled Water will come out here. Place a towel water up to the top of the printer on top of the hole to collect the water



Appendix C: Pogo Card Alignment The alignment sensor on the Pogo Card must be clean and properly aligned. The bottom of the window should be cleaned regularly as instructed in the user manual. Powder may build up on the inside of the window as well. While cleaning the inside of the window, be sure to properly insert the pogo card in the slot. Also ensure that the alignment sensor lens is properly snapped in as shown in the photos below.

Pogo placement in the carriage Clean here

Retainer is out of alignment Properly aligned retainer



Appendix D: Fast Axis Bumper Location The Fast axis will measure the distance in between the two bumpers while re-zeroing. If the distance is incorrect, a 2400 error will occur. The bumpers may be missing or damaged. Below are photos of the location of the bumpers.



Appendix E: Squareness of the Fast Axis To check the squareness of the fast axis, remove the fast axis from the printer.

1. Follow the instructions in 08861 Fast Axis Remove and Replace Procedure 2. Place the Fast Axis Module on a flat surface. A granite surface plate is ideal. 3. Check that the end plates sit flat against the surface.

End Plates

4. If either plate is raised more than .01” then the plates should be adjusted until

they are flat. To adjust the plates, loosen the screws that secure the support brackets to the end plates.

Loosen screws

5. Adjust the plates until they are flat and tighten all screws. Once tight, double

check that they are flat.