Zcorporation ZPrinter 650 User manual

09915ZPrinter650TroubleshootingGuide
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ZPrinter®650
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TroubleshootingGuide
Part Number 09915
Revision B
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1
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09915ZPrinter650TroubleshootingGuide
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Revision History:
Rev A ECN 2590 BWH 10/22/08
Rev B ECN 3209 RAB 11/23/11
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09915ZPrinter650TroubleshootingGuide
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Preface
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TroubleshootingZCorporation‘slineof3Dprintercansometimesbeafrustrating,complexand
tediousprocessbutitdoesn’thavetobethisway.Oftenatechniciangoesintoasituationwithblinders
on,focusingononeproblemandjumpingtoconclusionsthathavefixedothermachines.Every
encounterwithanerrororproblemshouldstartthesameway.Thereareafewsimplestepsand
processesthatcanhelpyoutonarrowdowntheproblemyouarefacingandgetyouthehelpyouneed
quicklyandefficiently.
InthePrefacesectionTroubleshooting101youwillfindalistofstepsthatyoushouldperform
EVERYtimeyouencounteraproblemononeofZCorporationslineof3DprintersandinthePreface
sectionGettingHelpfromZCentral101youwillfindachecklistofitemsthattheZCentralDept.needsin
ordertohelpyoumoreefficientlyandeffectively.RememberthatZCentralistheretobeyoursecond
supportoptionandprovideyouwiththehelpthatyouneedbutcanonlydosowiththeproper
information.
Troubleshooting101:
1. Understandtheproblemathand!(example:PrinterWon’tBoot=Notvery
descriptive.PrinterWon’tBoot=Iturntheprinteronanddonotgetanylightsor
readoutonthemonitorpluggedintothemachine)ismuchmoredescriptive.
2. Checktomakesurethatthecustomerisfollowingproperstorageprocedures
forconsumablesandthattheirproductsarenotexpired.
3. Cleanthemachinethoroughly!Thisincludesallpartsoftheservicestation,axis
rails,pulleyteethandtopdeck.Removeanydebrisbuildupattheendsof
travel,ontheaxisrailandevenonaxisrailsupports.
4. Performaquickinspectionofthemachine,removesidepanelsandcovers,
lubricatethemachineandre‐tensionallbelts.Duringtheinspectionyoushould
belookingforanysignsofleaks,loosescrewsornutsandwornparts.Badly
wornitemsshouldbereplacedduringthisservicevisit,screwsandcoversneed
tobetightenedandleaksshouldbefixedimmediately.
5. Turnthemachineoffandmovethecarriageandfastaxistothemiddleofthe
buildbedandre‐bootthemachine.Itisveryimportantthatyouwatch,study
andbecomefamiliarwiththebootprocessoftheZCorp3Dprinteryouare
workingon.
Manyproblemscanbeidentifiedandpossiblysolvedbysimplyperformingthese5steps
butsometimesittakesalittlemorework.
6. Oncethemachinehasrebootedandcomeback“Online”takeaquicklook
throughtheprinterslogfileandtakealookattheprintheadreport.Inthelog
filelookfortrendsleadinguptotheerrororproblemyouare
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09915ZPrinter650TroubleshootingGuide
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experiencing(example:repeated1006HeadTooHoterrorswithaheadwilllead
to40800HeadCheckFailedorothererrors).Withthesamepointsinmind,a
clearprintheadwithover1000mlonitoracolorprintheadwithover500mlof
binderthroughitmaystarttoexperience1006HeadTooHoterrorswhichare
normal.
Ifyouhaven’tfoundtheproblemyouwerelookingforbynowyouareactuallyjustgettingreadytostart
thetroubleshootingprocess.Changeonepartatatime.Wearetryingtofindtherootcauseofanissue
notonlytohelpthiscustomerbuttomakeourequipmentbetter.Ifthatpartdoesnotfixtheproblem
thenitneedstoberemovedandplacedbackintoyourspareskitorsentbacktoZCorp.
GettingHelpfromZCentral101:
HavingthebelowinformationreadyfortheZCentralteamWILLmakeyourinitialinformationinquiry
morefruitfulandhelpyoutogetyourcustomerupandrunningintheleastamountoftime.
1. SerialNumber
2. CustomerName
3. LogFile(ServiceMenu>ViewPrinterLog:SaveAs)
4. .INIFile(ServiceMenu>Edit.INIFile:SaveAs)
5. .CSVFile(Z450andZ650:ServiceMenu>ReceiveFile:Typespread.csv)
6. HeadReportInformation
7. Binder/PowderType
8. Binder/PowderExpiration
9. EXACTErrorCode/DescriptionofProblem
a. Understandandbedescriptiveoftheproblemathand.(Remember
example:PrinterWon’tBoot=Notverydescriptive.PrinterWon’tBoot=I
turntheprinteronanddonotgetanylightsorreadoutonthemonitor
pluggedintothemachine)
b. What’schanged?IfyouhaverecentlyreplacedanEBox,FastAxisorany
otherpartandarenowhavingadifferentproblemoreventhesame
problemthenit’sbestforyouandfortheZCentralservicestafftohave
andknowthisinformation.
Failuretofollowtheabovestepsandprovidetheaboveinformationcanresultinyourquestionsnot
beingansweredtoyouoryourcustomers’satisfactionanddefinitelyleadtoamoredrawnoutservice
call.
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09915ZPrinter650TroubleshootingGuide
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Notices
CopyrightandTrademarks
Copyright©ZCorporation1995‐2011.Allrightsreserved.Theinformationinthisdocumentmaynotbe
duplicatedortransmittedinanywaywithouttheexpresswrittenconsentofZCorporation.The
informationcontainedhereinisfortheuseofZCorporationcustomers,whoarepermittedtocreate
briefexcerptsforthepurposesoftrainingandreview.Thisinformationmaynotbeincorporatedinany
commercialprograms,books,databases,orinanykindofsoftwarewithouttheconsentofZ
Corporation.
Z,ZCorporation,zp,zb,ZMap,ZPhoto,Z‐Cure,ZPrints,ZPrinter,ZCast,ZScanner,ZBuilder,CreateMore,
ZScanandtheZCorp.logoanddesignarepending/registeredtrademarksofZCorporation.
ZPrint®7.12SystemSoftwareCopyright(c)1996‐2011ZCorporation.Thissoftwareisbasedinparton
theworkoftheIndependentJPEGGroup.
PNGlibrarylibpngversion1.2.2Copyright(c)1998‐2002GlennRanders‐Pehrson,(Version0.96
Copyright(c)1996,1997AndreasDilger),(Version0.88Copyright(c)1995,1996GuyEricSchalnat,
Group42,Inc.)
ZLIBgeneralpurposecompressionlibraryversion1.1.4,Copyright(C)1995‐2002Jean‐loupGaillyand
MarkAdler.
MicrosoftWindowsisatrademarkofMicrosoftCorporation.
ZCorporationacknowledgesthetrademarksofotherorganizationsfortheirrespectiveproductsor
servicesmentionedinthisdocumentation.
ProprietaryInformation
InformationcontainedinthisdocumentistheconfidentialpropertyofZCorporation.Recipientshall
notdisclosesuchInformationtoanythirdparty,andshallnotuseitforanypurposewhatsoeverother
thanwhatisrequiredtoinstallandusetheZPrinter650.
UseofEquipment
ZCorporation'sEquipment,anduseoftheEquipment,maybesubjecttolimitationsimposedunder
patentslicensedtoorownedbyZCorp.,andistobeusedsolelyforthefabricationofappearance
modelsandprototypesusingnewZCorporation‐suppliedconsumablesfromZCorporationorits
authorizeddistributorsintheoriginalpackaging.Otherusesmayberestricted;contactZCorporationfor
furtherinformation.ConsulttheUser'sManualbeforeoperationofanyZCorporationEquipment.
TheEquipmentisdesignedtobeusedbydesignengineersandotherprofessionalsintheproductionof
early‐stage3Dappearancemodelsandprototypes.TheEquipmentisnottobeusedtoproduce,either
directlyorindirectly,medicalorotherproductsthatmayrequireprecisedimensionsortolerancesto
ensurethesafeandeffectiveoperationofsuchproducts.Youagreetoindemnify,defendandholdZ
Corporationanditsofficers,directorsandemployeesharmlessfromandagainstanyandallclaims,
losses,damages,costsandexpensesresultingfromanyuseoftheEquipmentotherthanforthe
productionofearly‐stageappearancemodelsandprototypes.
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09915ZPrinter650TroubleshootingGuide
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Warranty
YourZPrinterisguaranteedtobefreeofdefectsinmaterialsandworkmanship,whenusedfor
productionofearly‐stageappearancemodelsandprototypesandwithZCorporationconsumables,for
theperioddescribedbelowunderWARRANTYPERIOD.Allconsumablesandmaterialsareguaranteedto
performasdescribedintheirspecificationswhenstoredandusedasdirected,uptotheexpirydate
printedonthelabel.THECOMPANYMAKESNOWARRANTIES,EXPRESSORIMPLIED,ANDDISCLAIMS
ALLWARRANTIESINCLUDING,BUTNOTLIMITEDTO,IMPLIEDWARRANTIESOFMERCHANTABILITYAND
FITNESSFORAPARTICULARPURPOSEANDANYOTHEROBLIGATIONSORLIABILITIESWHETHERIN
CONTRACT,WARRANTY,NEGLIGENCEOROTHERWISE.THECOMPANYISNOTLIABLEFORANYDIRECT,
INDIRECT,SPECIAL,PUNITIVE,CONSEQUENTIALORINCIDENTALDAMAGESINCLUDING,WITHOUT
LIMITATION,DAMAGESFORLOSSOFBUSINESSPROFITSORBUSINESSINTERRUPTIONARISINGOUTOF
THEUSEORINABILITYTOUSEPRODUCTSORSERVICESSOLDHEREUNDER.INNOEVENTWILLTHE
COMPANY'SLIABILITYEXCEEDTHETOTALCHARGEOFTHISZZPRINTER650.
WARRANTYPERIOD:IntheU.S.,warrantyisfor90daysandcoversservice,partsandtrainingmaterial.
IntheEU,warrantyisfor1yearandcoversservice,partsandtrainingmaterial.
Symbols
ThefollowingsymbolsareusedontheZPrinter650andinthismanual.

GeneralCaution:Usershouldusecaretoavoidpossibledamageto
equipment.


HotSurface:Usershouldusecarewhenworkingnearoronthelabeled
item.


HighVoltage:Usershoulduseappropriateelectricalsafetyprecautions.
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09915ZPrinter650TroubleshootingGuide
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TableofContents
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...................................................................................................23
60520: HP11 COMMANDSPI: timed out..........................................................................................24
10040: POGOSTATUSSPI: timed out..............................................................................................24
Motion Errors: Axis Problems .....................................................................................................27
2301(0): MOVER: axis 0 destination out of range...........................................................................27
2303(0): MOVER: axis 0 excessive position error..........................................................................28
2303(1): MOVER: axis 1 excessive position error..........................................................................29
2305(0): MOVER: axis 0 didn’t settle................................................................................................30
2305(1): MOVER: axis 1 didn’t settle................................................................................................31
2400(0): REZERO: axis 0 can't find end of travel...........................................................................32
2400(1): REZERO: axis 1 can't find end of travel...........................................................................33
3012: SEQUENCER: spurious interrupt...........................................................................................34
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09915ZPrinter650TroubleshootingGuide
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3013: SEQUENCER: timed out finishing swath..............................................................................35
43000: SEQUENCER: missed position............................................................................................36
60300: REZERO: fast axis length out of tolerance.........................................................................37
60301: REZERO: Slow axis length out of tolerance.......................................................................38
Spread Issues: Problems with spreading powder efficiently.......................................................40
Spread not Smooth..............................................................................................................................40
Feeder is not dispensing enough powder (Short Spreading Figure 21)......................................41
5001: POWDER: no more feed..........................................................................................................42
60100: Feeder timeout........................................................................................................................43
40204: TI: Build piston driver overload.............................................................................................44
Powder Handling: Issues with Depowering, Auto Gross De-powdering, Vacuum......................46
Front/Rear Overflow is full or not emptying......................................................................................46
Build Bed will not empty......................................................................................................................47
No/Light Suction on User Hose..........................................................................................................48
De-powdering Chamber is full of powder while de-powdering......................................................49
No Compressed Air or not enough Compressed Air......................................................................49
Powder is seeping out of printer........................................................................................................50
Boot Failure and Inverter Issues: Printer will not come online....................................................51
60200: LOWLEVEL: 15v supply voltage out of tolerance..............................................................51
61300: INVERTER: bad version number..........................................................................................51
61301: Timeout waiting for SPI bus..................................................................................................52
61302: INVERTER: comm error........................................................................................................52
61305: INVERTER: Heater driver over temp...................................................................................52
61308: INVERTER: Line under voltage............................................................................................53
Blank Illuminated LCD.........................................................................................................................53
Net Init Failed........................................................................................................................................53
Boot Failure: No Power.......................................................................................................................54
Communication and Software Errors: Errors that are caused by communication and software
problem.......................................................................................................................................55
Packet timeout: Printer not found: Before Printing..........................................................................55
Packet timeout: Printer not Found: While Printing..........................................................................56
1905: LAYERS: layer is too big..........................................................................................................56
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09915ZPrinter650TroubleshootingGuide
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3900: SOCKETS: can't initialize WinSock interface.......................................................................56
Fluids: Fluid leaks within the printer............................................................................................57
Service station is full of fluid...............................................................................................................57
Binder on Top deck..............................................................................................................................57
Binder leaking from bottom of printer................................................................................................57
Air in Lines.............................................................................................................................................58
Software says the binder Reservoir is empty..................................................................................58
Sensors and Switches: Errors that are related to the ZPrinter's Sensors and switches.............59
Top Cover Open...................................................................................................................................59
1008: Head Cover Open.....................................................................................................................59
Heater is not coming up to Temperature..........................................................................................59
Miscellaneous Errors: Errors that do not fall into any other category .........................................60
3202: Monitor thread took too long....................................................................................................60
Appendix:....................................................................................................................................61
AppendixA:Cleaningthealignmentsensor.......................................................................................61
AppendixA:Cleaningthealignmentsensor(cont.)............................................................................62
AppendixB:UnderstandingandtroubleshootingtheZPrinter650LoadCell....................................63
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09915ZPrinter650TroubleshootingGuide
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Print Head and Pogo Issues: Print head, pogo and alignment
issues
1003: I2C read failed for Head x
This error is caused by the printer not being able to read the data off of the HP11 print head's
smart chip and specifically refers to being able to read from the top 4 pins of the pogo card.
Monitor Read-Out or
Secondary
Symptom Cause / Problem Solution Reference Documents
1003: I2C read failed for
Head x Print head not seated properly / contacts dirty
Clean print head contacts
and Pogo Pins; Reinsert
print heads
09577 ZPrinter650 User
Manual
1003: I2C read failed for
Head x Bad/Old HP11 Print Head Replace HP11 Print Head 09577 ZPrinter650 User Manual
After performing the above step try performing a service print head and alignment. If the machine performs both tasks
the problem should be solved.
1003: I2C read failed for
Head x Bad Carriage Cable Replace 50080 Pogo Flex Cable
85026 ZPrinter 650
Carriage Cable Removal
and Replacement
After performing the above step try performing a service print head and alignment. If the machine performs both tasks
the problem should be solved.
1003: I2C read failed for
Head x Bad Pogo PCB Replace 50019 Pogo PCB 85022 ZPrinter 650 Pogo
PCB Removal and
Replacement
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.
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