Professional Documents
Culture Documents
Z650 Troubleshooting Guide-A
Z650 Troubleshooting Guide-A
Z650 Troubleshooting Guide-A
ZPrinter650
Troubleshooting Guide
Part Number 09915
Revision A
09915ZPrinter650TroubleshootingGuide
Revision History:
Rev A ECN 2590 BWH 10/22/08
09915ZPrinter650TroubleshootingGuide
Preface
TroubleshootingZCorporationslineof3Dprintercansometimesbeafrustrating,complexand
tediousprocessbutitdoesnthavetobethisway.Oftenatechniciangoesintoasituationwithblinders
on,focusingononeproblemandjumpingtoconclusionsthathavefixedothermachines.Every
encounterwithanerrororproblemshouldstartthesameway.Thereareafewsimplestepsand
processesthatcanhelpyoutonarrowdowntheproblemyouarefacingandgetyouthehelpyouneed
quicklyandefficiently.
InthePrefacesectionTroubleshooting101youwillfindalistofstepsthatyoushouldperform
EVERYtimeyouencounteraproblemononeofZCorporationslineof3DprintersandinthePreface
sectionGettingHelpfromZCentral101youwillfindachecklistofitemsthattheZCentralDept.needsin
ordertohelpyoumoreefficientlyandeffectively.RememberthatZCentralistheretobeyoursecond
supportoptionandprovideyouwiththehelpthatyouneedbutcanonlydosowiththeproper
information.
Troubleshooting101:
1. Understandtheproblemathand!(example:PrinterWontBoot=Notvery
descriptive.PrinterWontBoot=Iturntheprinteronanddonotgetanylightsor
readoutonthemonitorpluggedintothemachine)ismuchmoredescriptive.
2. Cleanthemachinethoroughly!Thisincludesallpartsoftheservicestation,axis
rails,pulleyteethandtopdeck.Removeanydebrisbuildupattheendsof
travel,ontheaxisrailandevenonaxisrailsupports.
3. Performaquickinspectionofthemachine,removesidepanelsandcovers,
lubricatethemachineandretensionallbelts.Duringtheinspectionyoushould
belookingforanysignsofleaks,loosescrewsornutsandwornparts.Badly
wornitemsshouldbereplacedduringthisservicevisit,screwsandcoversneed
tobetightenedandleaksshouldbefixedimmediately.
4. Turnthemachineoffandmovethecarriageandfastaxistothemiddleofthe
buildbedandrebootthemachine.Itisveryimportantthatyouwatch,study
andbecomefamiliarwiththebootprocessoftheZCorp3Dprinteryouare
workingon.
Manyproblemscanbeidentifiedandpossiblysolvedbysimplyperformingthese3steps
butsometimesittakesalittlemorework.
5. OncethemachinehasrebootedandcomebackOnlinetakeaquicklook
throughtheprinterslogfileandtakealookattheprintheadreport.Inthelog
filelookfortrendsleadinguptotheerrororproblemyouare
experiencing(example:repeated1006HeadTooHoterrorswithaheadwilllead
3
09915ZPrinter650TroubleshootingGuide
to40800HeadCheckFailedorothererrors).Withthesamepointsinmind,a
clearprintheadwithover1000mlonitoracolorprintheadwithover500mlof
binderthroughitmaystarttoexperience1006HeadTooHoterrorswhichare
normal.
Ifyouhaventfoundtheproblemyouwherelookingforbynowyouareactuallyjustgettingreadyto
startthetroubleshootingprocess.Changeonepartatatime.Wearetryingtofindtherootcauseofan
issuenotonlytohelpthiscustomerbuttomakeourequipmentbetter.Ifthatpartdoesnotfixthe
problemthenitneedstoberemovedandplacedbackintoyourspareskitorsentbacktoZCorp.
GettingHelpfromZCentral101:
HavingthebelowinformationreadyfortheZCentralteamWILLmakeyourinitialinformationinquiry
morefruitfulandhelpyoutogetyourcustomerupandrunningintheleastamountoftime.
1.
2.
3.
4.
5.
6.
7.
8.
9.
SerialNumber
CustomerName
LogFile
.INIFile
.CSVFile(Z450andZ650)
HeadReportInformation
Binder/PowderType
Binder/PowderExpiration
EXACTErrorCode/DescriptionofProblem
a. Understandandbedescriptiveoftheproblemathand.(Remember
example:PrinterWontBoot=Notverydescriptive.PrinterWontBoot=I
turntheprinteronanddonotgetanylightsorreadoutonthemonitor
pluggedintothemachine)
b. Whatschanged?IfyouhaverecentlyreplacedanEbox,FastAxisorany
otherpartandarenowhavingadifferentproblemoreventhesame
problemthenitsbestforyouandfortheZCentralservicestafftohave
andknowthisinformation.
Failuretofollowtheabovestepsandprovidetheaboveinformationcanresultinyourquestionsnot
beingansweredtoyouoryourcustomerssatisfactionanddefinitelyleadtoamoredrawnoutservice
call.
09915ZPrinter650TroubleshootingGuide
Notices
CopyrightandTrademarks
CopyrightZCorporation19952008.Allrightsreserved.Theinformationinthisdocumentmaynotbe
duplicatedortransmittedinanywaywithouttheexpresswrittenconsentofZCorporation.The
informationcontainedhereinisfortheuseofZCorporationcustomers,whoarepermittedtocreate
briefexcerptsforthepurposesoftrainingandreview.Thisinformationmaynotbeincorporatedinany
commercialprograms,books,databases,orinanykindofsoftwarewithouttheconsentofZ
Corporation.
Z,ZCorporation,zp,zb,ZMap,ZPhoto,ZCure,ZPrints,ZPrinter,ZCast,ZScanner,ZScanandtheZCorp.
logoanddesignarepending/registeredtrademarksofZCorporation.
ZPrint7.6SystemSoftwareCopyright(c)19962008ZCorporation.Thissoftwareisbasedinpartonthe
workoftheIndependentJPEGGroup.
PNGlibrarylibpngversion1.2.2Copyright(c)19982002GlennRandersPehrson,(Version0.96
Copyright(c)1996,1997AndreasDilger),(Version0.88Copyright(c)1995,1996GuyEricSchalnat,
Group42,Inc.)
ZLIBgeneralpurposecompressionlibraryversion1.1.4,Copyright(C)19952002JeanloupGaillyand
MarkAdler.
MicrosoftWindowsisatrademarkofMicrosoftCorporation.
ZCorporationacknowledgesthetrademarksofotherorganizationsfortheirrespectiveproductsor
servicesmentionedinthisdocumentation.
ProprietaryInformation
InformationcontainedinthisdocumentistheconfidentialpropertyofZCorporation.Recipientshall
notdisclosesuchInformationtoanythirdparty,andshallnotuseitforanypurposewhatsoeverother
thanwhatisrequiredtoinstallandusetheZPrinter650.
UseofEquipment
ZCorporation'sEquipment,anduseoftheEquipment,maybesubjecttolimitationsimposedunder
patentslicensedtoorownedbyZCorp.,andistobeusedsolelyforthefabricationofappearance
modelsandprototypesusingnewZCorporationsuppliedconsumablesfromZCorporationorits
authorizeddistributorsintheoriginalpackaging.Otherusesmayberestricted;contactZCorporationfor
furtherinformation.ConsulttheUser'sManualbeforeoperationofanyZCorporationEquipment.The
EquipmentmaybecoveredbythefollowingU.S.Patentsand/orU.S.PatentApplications:
5,204,055
6,416,850
6,036,777
7,332,537
11/606,960
5,340,656
6,610,429
6,989,115
11/335,282
60/808,721
5,387,380
6,403,002
7,037,382
11/860,087
11/807,325
6,007,318
5,660,621
7,291,002
60/558,940
11/807,329
5
6,375,874
5,851,465
7,387,359
12/118,899
11/807,175
5,902,441
6,397,922
7,087,109
11/000,100
11/807,237
09915ZPrinter650TroubleshootingGuide
09/706,350
60/879,703
09/835,292
11/952,727
11/453,695
12/035,743.
60/472,221
60/499,220
11/732,490
TheEquipmentisdesignedtobeusedbydesignengineersandotherprofessionalsintheproductionof
earlystage3Dappearancemodelsandprototypes.TheEquipmentisnottobeusedtoproduce,either
directlyorindirectly,medicalorotherproductsthatmayrequireprecisedimensionsortolerancesto
ensurethesafeandeffectiveoperationofsuchproducts.Youagreetoindemnify,defendandholdZ
Corporationanditsofficers,directorsandemployeesharmlessfromandagainstanyandallclaims,
losses,damages,costsandexpensesresultingfromanyuseoftheEquipmentotherthanforthe
productionofearlystageappearancemodelsandprototypes.
Warranty
YourZPrinterisguaranteedtobefreeofdefectsinmaterialsandworkmanship,whenusedfor
productionofearlystageappearancemodelsandprototypesandwithZCorporationconsumables,for
theperioddescribedbelowunderWARRANTYPERIOD.Allconsumablesandmaterialsareguaranteedto
performasdescribedintheirspecificationswhenstoredandusedasdirected,uptotheexpirydate
printedonthelabel.THECOMPANYMAKESNOWARRANTIES,EXPRESSORIMPLIED,ANDDISCLAIMS
ALLWARRANTIESINCLUDING,BUTNOTLIMITEDTO,IMPLIEDWARRANTIESOFMERCHANTABILITYAND
FITNESSFORAPARTICULARPURPOSEANDANYOTHEROBLIGATIONSORLIABILITIESWHETHERIN
CONTRACT,WARRANTY,NEGLIGENCEOROTHERWISE.THECOMPANYISNOTLIABLEFORANYDIRECT,
INDIRECT,SPECIAL,PUNITIVE,CONSEQUENTIALORINCIDENTALDAMAGESINCLUDING,WITHOUT
LIMITATION,DAMAGESFORLOSSOFBUSINESSPROFITSORBUSINESSINTERRUPTIONARISINGOUTOF
THEUSEORINABILITYTOUSEPRODUCTSORSERVICESSOLDHEREUNDER.INNOEVENTWILLTHE
COMPANY'SLIABILITYEXCEEDTHETOTALCHARGEOFTHISZZPRINTER650.
WARRANTYPERIOD:IntheU.S.,warrantyisfor90daysandcoversservice,partsandtrainingmaterial.
IntheEU,warrantyisfor1yearandcoversservice,partsandtrainingmaterial.
Symbols
ThefollowingsymbolsareusedontheZPrinter650andinthismanual.
GeneralCaution:Usershouldusecaretoavoidpossibledamageto
equipment.
HotSurface:Usershouldusecarewhenworkingnearoronthelabeled
item.
HighVoltage:Usershoulduseappropriateelectricalsafetyprecautions.
09915ZPrinter650TroubleshootingGuide
TableofContents
Preface..................................................................................................................................................3
Notices..................................................................................................................................................5
Symbols.................................................................................................................................................6
Print Head and Pogo Issues: Print head, pogo and alignment issues ........................................ 10
1003: I2C read failed for Head x........................................................................................................10
1004: Head x fire voltage failed..........................................................................................................11
1006: Head x temperature too high...................................................................................................12
1007: Head x current too high............................................................................................................13
1009: Head fire voltage stuck.............................................................................................................14
1010: Invalid head temperature.........................................................................................................15
3011: SEQUENCER: error in DPC, flags.........................................................................................16
40006: AUTOALIGN: weak sensor reading.....................................................................................17
40007 AUTOALIGN: alignment 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...................................................................................................22
60520: HP11 COMMANDSPI: timed out..........................................................................................23
10040: POGOSTATUSSPI: timed out..............................................................................................23
Motion Errors: Axis Problems ..................................................................................................... 26
2301(0): MOVER: axis 0 destination out of range...........................................................................26
2303(0): MOVER: axis 0 excessive position error..........................................................................27
2303(1): MOVER: axis 1 excessive position error..........................................................................28
2305(0): MOVER: axis 0 didnt settle................................................................................................29
2305(1): MOVER: axis 1 didnt settle................................................................................................30
2400(0): REZERO: axis 0 can't find end of travel...........................................................................31
09915ZPrinter650TroubleshootingGuide
09915ZPrinter650TroubleshootingGuide
09915ZPrinter650TroubleshootingGuide
Print Head and Pogo Issues: Print head, pogo and alignment
issues
Cause / Problem
Solution
Reference
Documents
Please follow the above listed suggestions and remember that a bad print head can cause the same error so it is always
beneficial to use new print heads while troubleshooting. If the problem remains after trying the above contact the ZCorp
service Dept.
10
09915ZPrinter650TroubleshootingGuide
Cause / Problem
Solution
(Figure 1)
PC104+ Failed
Reference
Documents
Please follow the above listed suggestions and remember that a bad print head can cause the same error so it is always
beneficial to use new print heads while troubleshooting. If the problem remains after trying the above contact the ZCorp
service Dept.
11
09915ZPrinter650TroubleshootingGuide
Reference
Documents
Cause / Problem
Solution
(Figure 3)
Out of ZC6
Add ZC6
See Fluids
See Fluids
(Figure 5)
(Figure 6)
Coming Soon
Coming Soon
The first steps in troubleshooting should always be to check the print head life, verify the flow rate is correct, and try
another print head! Once a print head has thrown an over temp error the print head is usually dead and must be
replaced.
12
09915ZPrinter650TroubleshootingGuide
(Figure 1)
PC104+ Failed
Please follow the above listed suggestions and remember that a bad print head can cause the same error so it is always
beneficial to use new print heads while troubleshooting. If the head current is displayed as 255v then the problem may
be located in the carriage cable, festoon cable or PC104+. If the problem remains after trying the above contact the
ZCorp Service Dept.
13
09915ZPrinter650TroubleshootingGuide
Cause / Problem
Solution
PC104+ Failed
Reference
Documents
Please follow the above listed suggestions and remember that a bad print head can cause the same error so it is always
beneficial to use new print heads while troubleshooting. If the problem remains after trying the above contact the ZCorp
service Dept.
14
09915ZPrinter650TroubleshootingGuide
(Figure 3)
The main cause of this error is fluid getting onto the Pogo and print head contacts. A clean service station is key to
keeping the machine free of this error. This error can usually be troubleshot by cleaning the electrical contacts on the
Pogo PCB and print head or replacing the print head.
15
09915ZPrinter650TroubleshootingGuide
Cause / Problem
Solution
PC104+ Failed
Reference
Documents
Please follow the above listed suggestions and remember that a bad print head can cause the same error so it is always
beneficial to use new print heads while troubleshooting. If the problem remains after trying the above contact the ZCorp
service Dept.
16
09915ZPrinter650TroubleshootingGuide
Reference
Documents
Cause / Problem
Solution
Poor Spread
17
09915ZPrinter650TroubleshootingGuide
Reference
Documents
Cause / Problem
Solution
40010 AUTOALIGN:
alignment of Axis x failed
40007 AUTOALIGN:
alignment of Axis x failed
40008 AUTOALIGN:
alignment of Axis x failed
Poor Spread
40009 AUTOALIGN:
alignment of Axis x failed
Stripy printing
40011 AUTOALIGN:
alignment of Axis x failed
40012 AUTOALIGN:
alignment of Axis x failed
40013 AUTOALIGN:
alignment of Axis x failed
Stripy printing is one of the most common causes of this error. The key to troubleshooting this error is defining the
problem that you are dealing with. You must differentiate weather the problem is caused by stripy printing or an axis
problem. When this error is encountered the machine will do a stripe test over the alignment pattern. If that stripe test
looks good then the problem may be related to a dirty sensor window or movement problems with the indicated axis.
18
09915ZPrinter650TroubleshootingGuide
Cause / Problem
Solution
40008: AUTOALIGN
40008: AUTOALIGN
40008: AUTOALIGN
Poor Spread
40008: AUTOALIGN
Stripy printing
40008: AUTOALIGN
(Figure 7)
40008: AUTOALIGN
40008: AUTOALIGN
40008: AUTOALIGN
PC104+ Failed
Reference
Documents
Stripy printing is one of the most common causes of this error. The key to troubleshooting this error is defining the
problem that you are dealing with. You must differentiate weather the problem is caused by stripy printing or an axis
problem. When this error is encountered the machine will do a stripe test over the alignment pattern. If that stripe test
looks good then the problem may be related to a dirty sensor window or movement problems with the indicated axis.
19
09915ZPrinter650TroubleshootingGuide
Reference
Documents
Cause / Problem
Solution
PC104+ Failed
Please follow the above listed suggestions and remember that a bad print head can cause the same error so it is always
beneficial to use new print heads while troubleshooting. If the problem remains after trying the above contact the ZCorp
service Dept.
20
09915ZPrinter650TroubleshootingGuide
Cause / Problem
Solution
(Figure 1)
PC104+ Failed
Reference
Documents
While print heads may cause this error the most common cause of 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.
21
09915ZPrinter650TroubleshootingGuide
Cause / Problem
Solution
60501: POGOPOWERSPI
60501: POGOPOWERSPI
60501: POGOPOWERSPI
(Figure 1)
60501: POGOPOWERSPI
PC104+ Failed
Reference
Documents
While print heads may cause this error the most common cause of 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.
Cause / Problem
Solution
(Figure 1)
PC104+ Failed
Reference
Documents
While print heads may cause this error the most common cause of 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.
22
09915ZPrinter650TroubleshootingGuide
Reference
Documents
Cause / Problem
Solution
60520: HP11
COMMANDSPI: timed out
60520: HP11
COMMANDSPI: timed out
60520: HP11
COMMANDSPI: timed out
(Figure 1)
60520: HP11
COMMANDSPI: timed out
PC104+ Failed
The most common cause of 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.
Cause / Problem
Solution
70400: POGOSTATUSSPI:
timed out
(Figure 1)
70400: POGOSTATUSSPI:
timed out
70400: POGOSTATUSSPI:
timed out
Reference
Documents
While print heads may cause this error the most common cause of this error 50108 Slow Axis Festoon Cable+. This
error may be diagnosed through the control panel on the machine by going through the PC104+ and Pogo tests.
23
09915ZPrinter650TroubleshootingGuide
Spittoon
Figure 4
24
09915ZPrinter650TroubleshootingGuide
Alignment window
Figure 7
Stripping on an alignment
Figure 8
25
09915ZPrinter650TroubleshootingGuide
Reference
Documents
Cause / Problem
Solution
2301(0)
SKIP_REZERO is set to 1
in the ini file
2301(0)
Gantry is obstructed
Remove obstruction
2301(0)
2301(0)
2301(0)
2301(0)
2301(0)
2301(0)
2301(0)
PC104++ Failed
The main cause of this error is the line item SKIP_REZERO 1 in the ZPrinter's INI file.
26
09915ZPrinter650TroubleshootingGuide
Carriage is obstructed
Remove obstruction
The main cause of this error is the buildup of powder and dirt on the axis rails and poor lubrication.
27
09915ZPrinter650TroubleshootingGuide
Reference
Documents
Cause / Problem
Solution
Carriage is obstructed
Remove obstruction
PC104+ Failed
The main cause of this error is the buildup of powder and dirt on the axis rails and poor lubrication.
28
09915ZPrinter650TroubleshootingGuide
Reference
Documents
Cause / Problem
Solution
Gantry is obstructed
Remove obstruction
PC104+ Failed
The main cause of this error is the buildup of powder and dirt on the axis rails and poor lubrication.
29
09915ZPrinter650TroubleshootingGuide
Reference
Documents
Cause / Problem
Solution
Carriage is obstructed
Remove obstruction
PC104+ Failed
The main cause of this error is the buildup of powder and dirt on the axis rails and poor lubrication.
30
09915ZPrinter650TroubleshootingGuide
Reference
Documents
Cause / Problem
Solution
Gantry is obstructed
Remove obstruction
PC104+ Failed
The main cause of this error is a buildup of dirt and debris on the ends of travel. Cleaning the areas where the slow axis
comes to a hard stop should fix the problem.
(Figure 14)
31
09915ZPrinter650TroubleshootingGuide
Reference
Documents
Cause / Problem
Solution
Carriage is obstructed
Remove obstruction
PC104+ Failed
The main cause of this error is a buildup of dirt and oil on the ends of travel. Cleaning the areas where the fast axis
comes to a hard stop(bumpers) should fix the problem.
(Figure 13)
32
09915ZPrinter650TroubleshootingGuide
Cause / Problem
Solution
3012: SEQUENCER:
spurious interrupt
3012: SEQUENCER:
spurious interrupt
3012: SEQUENCER:
spurious interrupt
3012: SEQUENCER:
spurious interrupt
3012: SEQUENCER:
spurious interrupt
3012: SEQUENCER:
spurious interrupt
3012: SEQUENCER:
spurious interrupt
3012: SEQUENCER:
spurious interrupt
3012: SEQUENCER:
spurious interrupt
PC104+ Failed
33
Reference
Documents
09915ZPrinter650TroubleshootingGuide
Cause / Problem
Solution
Reference
Documents
(Figure 1)
PC104+ Failed
34
09915ZPrinter650TroubleshootingGuide
Carriage is obstructed
Remove obstruction
43000: SEQUENCER:
missed position
43000: SEQUENCER:
missed position
43000: SEQUENCER:
missed position
43000: SEQUENCER:
missed position
43000: SEQUENCER:
missed position
43000: SEQUENCER:
missed position
43000: SEQUENCER:
missed position
43000: SEQUENCER:
missed position
43000: SEQUENCER:
missed position
PC104+ Failed
The main cause of this error is the buildup of powder and dirt on the axis rails and poor lubrication.
35
09915ZPrinter650TroubleshootingGuide
Reference
Documents
Cause / Problem
Solution
Carriage is obstructed
Remove obstruction
PC104+ Failed
Make sure that the rubber bumpers are in place and that the ends of travel are free of dirt and debris.
(Figure 13)
36
09915ZPrinter650TroubleshootingGuide
Reference
Documents
Cause / Problem
Solution
Gantry is obstructed
Remove obstruction
PC104+ Failed
Make sure that the rubber bumpers are in place and that the ends of travel are free of dirt and debris.
(Figure 14)
37
09915ZPrinter650TroubleshootingGuide
Carriage anti-rotate
Figure 10
Worn pulley
Figure 12
38
09915ZPrinter650TroubleshootingGuide
Figure 14
39
09915ZPrinter650TroubleshootingGuide
Part Quality Issues: Finished parts are not coming out well
Geometry/Sizing Issues
Print problems relating to parts size and shape. See Figures 15
Monitor Read-Out or
Secondary
Symptom
Solution
Old Head(s)
Replace Head(s)
(Figure 3)
Incorrect Saturation
Settings
PC is Pausing in between
layers
Check PC Settings/Specs
Expired Binder
Incorrect Binder
Rough Spread
Short Spread
Dirty Pogo
Change
DRY_ENVIRONEMENT
Setting to 1 in the .INI file
40
Reference
Documents
Cause / Problem
09915ZPrinter650TroubleshootingGuide
(Figure 11 and 12 )
The number one cause of inaccuracies in printed parts is not using bleed compensation or dialing in bleed
compensation for that specific machine and environment. Please visit the ZCentral web site for more info.
Bleed Comp Tweak Tool
Weak Parts/De-laminations
Problems relating to a printed part's strength. See Figures 16 and 17
Monitor Read-Out or
Secondary
Symptom
Cause / Problem
Solution
Old Head(s)
Replace Head(s)
(Figure3 )
Incorrect Saturation
Settings
PC is Pausing in between
layers
Check PC Settings/Specs
Expired Binder
Incorrect Binder
Rough Spread
Short Spread
41
Reference
Documents
09915ZPrinter650TroubleshootingGuide
Change
DRY_ENVIRONEMENT
Setting to 1 in the .INI file
Dirty Pogo
(Figure5)
This is usually a seasonal problem but the ZPrinter 650 is designed to operate between 55-75 F (12.7 23.9C) and 20
- 55%, non-condensing humidity. Zp131 powder has been finely tuned to produce maximum green strength quickly after
printing. This is done by elevating the printing environment to 38C. If the ambient environment is close to or out of the
limits, the elevated temperature could cause layers to dry too quickly resulting in layer separation. Ambient environment
could be affected by air conditioned rooms and/or high altitude installations. If these conditions occur, adding the dry
environment variable to the .INI file will lower the temperature set point when zp131 is selected. Maximum green
strength is still achieved quickly as the low humidity environment acts similar to the elevated temperature for zp131.
Cause / Problem
Solution
Old Head(s)
Replace Head(s)
(Figure 3)
Incorrect Saturation
Settings
Realign Heads
Expired Binder
42
Reference
Documents
09915ZPrinter650TroubleshootingGuide
Incorrect Binder
Rough Spread
Short Spread
Dirty Pogo
(Figure 5)
Color problems must be interpreted AFTER the part has been infiltrated. For more information please visit or ZCentral
web site for more info.
Color Quality Best Practices
43
09915ZPrinter650TroubleshootingGuide
Surface Finish
Problems related to the surface finish of a printed part. See Figures 21 and 22.
Monitor Read-Out or
Secondary
Symptom
Cause / Problem
Solution
Old Head(s)
Replace Head(s)
(Figure 3)
Incorrect Saturation
Settings
PC is Pausing in between
layers
Check PC Settings/Specs
Realign Heads
Expired Binder
Incorrect Binder
Rough Spread
Short Spread
Dirty Pogo
Change
DRY_ENVIRONEMENT
Setting to 1 in the .INI file
(Figure 5)
44
Reference
Documents
09915ZPrinter650TroubleshootingGuide
Most 3D printed parts will require a small amount of post processing including sanding or brushing. This can be
especially true for color models. For more information please visit or ZCentral website for more info.
Color Quality Best Practices
45
09915ZPrinter650TroubleshootingGuide
Weak Parts
Figure 16
Delamination
Figure 17
Bad Spread
Figure 18
Streaking/Striping
Figure 19
Color Banding
Figure 20
46
09915ZPrinter650TroubleshootingGuide
Cause / Problem
Solution
Powder is old
Motor is damaged
PC104+ Failed
Reseat/Replace motor
PC104+ Failed
(Figure 22)
47
Reference
Documents
09915ZPrinter650TroubleshootingGuide
48
09915ZPrinter650TroubleshootingGuide
Cause / Problem
Solution
Short Spreading
Re-zero Piston
09912 ZPrinter650
Installation Manual
Short Spreading
Tune Feeder
09912 ZPrinter650
Installation Manual
Short Spreading
Short Spreading
(Figure 22)
Short Spreading
Short Spreading
Short Spreading
Call Z Corp
49
Reference
Documents
Call Z Corp
09915ZPrinter650TroubleshootingGuide
Cause / Problem
Solution
Reference
Documents
09570 ZPrinter650 User
Manual
Cause / Problem
Solution
Powder is Packed
See Appendix A
PC104+ Failed
Reference
Documents
In extreme cases the powder can pack in the feeder very tightly, such as during transport. If this occurs then the covers
must be removed and the powder must be removed manually till you can see the metering wheel.
50
09915ZPrinter650TroubleshootingGuide
Reference
Documents
Cause / Problem
Solution
Piston Position is
Incorrect
Re-zero pistons
(must be done
after installation of
new E-Box)
Replace the
31479 Piston Seal
(Figure 25)
Reconnect piston
motor cables
PC104+ Failed
Excessive Powder
Build up Under
Piston
Retighten screws
(Piston will need
to be re-zeroed)
Vacuum powder
into feeder (Piston
will need to be rezeroed)
Replace 50012
ZPrinter650 E Box
Assy
Replace 30695
Piston Motor
( Figure 24)
Replace the
31479 Piston Seal
The main reason for this error and the piston getting stuck in a position is the triangular plate and guide rods getting a
little twisted. All that is needed to fix the error is to loosen the screws holding the plate and re-tighten. The piston must
be re-zeroed after this procedure.
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09915ZPrinter650TroubleshootingGuide
Short spread
Figure 21
Snowplows on correctly
Figure 22
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09915ZPrinter650TroubleshootingGuide
Solution
Weak Vacuum
Reboot Printer
Bad/Improper cabling
Vacuuming tubing is
twisted or a hose clamp is
caught in the gears
PC104+ Failed
No Vacuum
No Vacuum
Powder is jammed
Powder is jammed
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Reference
Documents
09915ZPrinter650TroubleshootingGuide
Solution
Weak Vacuum
Reboot Printer
Bad/Improper cabling
Automated depowdering is
not working
Automated depowdering is
not working
Vacuuming tubing is
twisted or a hose clamp is
caught in the gears
PC104+ Failed
No Vacuum
No Vacuum
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Reference
Documents
09570 ZPrinter650 User
Manual
09915ZPrinter650TroubleshootingGuide
Cause / Problem
Solution
Hose is split
Hose is Clogged
Latch Cover
Reseat filter
Debris Separator is
clogged
Empty Separator
Weak Vacuum
Reboot Printer
Debris Separator is
full/Feeder is full of powder
See 5001:POWDER: no
more feed
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Reference
Documents
Appendix A
09915ZPrinter650TroubleshootingGuide
Solution
De-powdering Chamber is
full of powder while depowdering
Bad/Improper cabling
Vacuuming tubing is
twisted or a hose clamp is
caught in the gears
Failed PC104+
No Vacuum
No Vacuum
Reference
Documents
Solution
Compressor is on
Replace 06797
Compressor
08859 ZPrinter650
Compressor Removal and
Replacement
Compressor is damaged
Replace 06797
Compressor
8860 ZPrinter650
Compressor Removal and
Replacement
Failed PC104+
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Reference
Documents
09915ZPrinter650TroubleshootingGuide
Solution
57
Reference
Documents
09915ZPrinter650TroubleshootingGuide
Boot Failure and Inverter Issues: Printer will not come online
Reference
Documents
(Figure 1)
PC104+ Failed
Inverter is Damaged
Inverter is Damaged
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09915ZPrinter650TroubleshootingGuide
Inverter is Damaged
Inverter is Damaged
Inverter is Damaged
Reference
Documents
The ZPrinter 650 draws a lot of power. Make sure the printer is the only thing on that electrical circuit, and plug the
printer directly into the outlet. Surge protectors and UPS systems have been known to cause this error.
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09915ZPrinter650TroubleshootingGuide
Cabling
Bad E-Box
Reference
Documents
08860 ZPrinter650 E-Box
Removal and Replacement
Reference
Documents
09570 ZPrinter650 User
Manual
08605 Ethernet Connection
Setup
Plug in to appropriate
voltage (Universal Power
Supply)
E-box Failure
Reference
Documents
The Z Printer 650 requires a dedicated 15AMP circuit and will draw a lot of power. Most UPS(Uninterruptable Power
Supply) and surge protectors will not supply adequate power to the machine.
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09915ZPrinter650TroubleshootingGuide
Cause / Problem
Solution
Lost Connection
Software Manual
Printer or PC is not
properly configured
Replace Cable
Reference
Documents
The main cause of a printer not being found is that it has not been located through the 3D Print Setup window in the
software. If a build file is opened it will contain the settings from the last printer that was used or may be set to Offline.
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09915ZPrinter650TroubleshootingGuide
Cause / Problem
Solution
Power Management Is
Enabled
A temporary increase in
network traffic may have
caused Z Print data to slow
down
Reference
Documents
Cause / Problem
Solution
Reference
Documents
Cause / Problem
Solution
Printer or PC is not
properly configured
62
Reference
Documents
09915ZPrinter650TroubleshootingGuide
Cause / Problem
Solution
Reference
Documents
See Appendix B
Reference
Documents
Cause / Problem
Solution
Reinsert Cartridge
Replace Cartridge
Septum is leaking
Reservoir is leaking
Cause / Problem
Solution
Reference
Documents
Loose fitting
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09915ZPrinter650TroubleshootingGuide
Air in Lines
Air Bubbles have formed inside the printers tubing
Monitor Read-Out or
Secondary
Symptom
Cause / Problem
Solution
Air in Lines
Loose fitting
Air in Lines
Air in Lines
Reference
Documents
Cause / Problem
Solution
Reference
Documents
Out of binder
Out of binder
Check/Replace Cabling
Clog in line
08855 ZPrinter650
Sanitization Procedure
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09915ZPrinter650TroubleshootingGuide
Cause / Problem
Solution
Reference
Documents
Cause / Problem
Solution
Damaged E-Box
65
Reference
Documents
09915ZPrinter650TroubleshootingGuide
Solution
Mechanical Issue
See 2303(1)
66
Reference
Documents
Cause / Problem
09915ZPrinter650TroubleshootingGuide
Appendix:
Appendix A: Cleaning the alignment sensor
If the fast axis is over oiled during maintenance on the ZPrinter 650 the alignment sensor on the
Pogo PCB and alignment 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.
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09915ZPrinter650TroubleshootingGuide
Step 2: Clean the alignment window in the Carriage with alcohol and a cotton swab. Make sure you can
see clearly through the window when done and that no liquid remains.
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09915ZPrinter650TroubleshootingGuide
The ZPrinter650 uses a load cell to measure the weight of the powder. The Load Cell is basically a
scale. The feeder sits on 4 metal slats so that the center of gravity pushes the feeder down against the
load cell. The load cell is located just behind the feeder.
The load cell is extremely sensitive. Simply moving the printer will alter the reading on the load 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 load cell reads in pounds from -40LBS to 330LBS . A load cell with no load reads between 36LBS and -24LBS.
If the printer is throwing an AD7730 ERROR on reboot check that the ribbon cable is connected properly
at the Feeder card and E-Box.
If the printer is not throwing errors but you still suspect a malfunctioning load cell follow these steps. To
read the load cell:
Plug in a keyboard and monitor into the rear of the printer or use the Z Monitor application
Enter the following keyboard commands so that you will be able to view the readings coming from
the Load Cell
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09915ZPrinter650TroubleshootingGuide
2. Now key in the > character (shiftperiod) to proceed to the next screen.
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09915ZPrinter650TroubleshootingGuide
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09915ZPrinter650TroubleshootingGuide
Note that when using Zmonitor the numbers are not always aligned well with the names:
Filt = 5234703
% = 90.34
LBS = 110.75
>5% = 0.
o
o
o
o
Filt: This is the filtered read out from the load cell in ticks. Approximately 37,000 ticks is
1LB.
%: This is the percent the feeder is full. Keep in mind that it will read 0% until about
15LBS of powder is in the feeder. This amount of powder will come just above the feed
wheel.
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 will increase as soon as powder is added.
>5%: This is how many readings have been more than 5% different than the previous
reading. If nothing is agitating the hopper and weight is not being added this should read
0. Adding weight or pushing down on the hopper will cause this number to increase.
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09915ZPrinter650TroubleshootingGuide
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09915ZPrinter650TroubleshootingGuide
5. Read the load cell LBS. The weight should drop by between 3.0 and 3.7 LBS from the reading in
step 4. This is the weight of the filter cleaner.
If the load cell slope is off it is possible that something is interfering 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 feeder.
Loose wires can also cause bad readings. Make sure that all 5 pins from the load cell wire are pushed all
of the way into the connector. Make sure none of the wires look damaged.
If none of those checks fixes the problem then the feeder needs to be replaced.
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