Zcorporation ZPrinter 650 User manual
09915ZPrinter650TroubleshootingGuide
ZPrinter®650
TroubleshootingGuide
Part Number 09915
Revision B
1
09915ZPrinter650TroubleshootingGuide
Revision History:
Rev A ECN 2590 BWH 10/22/08
Rev B ECN 3209 RAB 11/23/11
2
09915ZPrinter650TroubleshootingGuide
Preface
TroubleshootingZCorporation‘slineof3Dprintercansometimesbeafrustrating,complexand
tediousprocessbutitdoesn’thavetobethisway.Oftenatechniciangoesintoasituationwithblinders
on,focusingononeproblemandjumpingtoconclusionsthathavefixedothermachines.Every
encounterwithanerrororproblemshouldstartthesameway.Thereareafewsimplestepsand
processesthatcanhelpyoutonarrowdowntheproblemyouarefacingandgetyouthehelpyouneed
quicklyandefficiently.
InthePrefacesectionTroubleshooting101youwillfindalistofstepsthatyoushouldperform
EVERYtimeyouencounteraproblemononeofZCorporationslineof3DprintersandinthePreface
sectionGettingHelpfromZCentral101youwillfindachecklistofitemsthattheZCentralDept.needsin
ordertohelpyoumoreefficientlyandeffectively.RememberthatZCentralistheretobeyoursecond
supportoptionandprovideyouwiththehelpthatyouneedbutcanonlydosowiththeproper
information.
Troubleshooting101:
1. Understandtheproblemathand!(example:PrinterWon’tBoot=Notvery
descriptive.PrinterWon’tBoot=Iturntheprinteronanddonotgetanylightsor
readoutonthemonitorpluggedintothemachine)ismuchmoredescriptive.
2. Checktomakesurethatthecustomerisfollowingproperstorageprocedures
forconsumablesandthattheirproductsarenotexpired.
3. Cleanthemachinethoroughly!Thisincludesallpartsoftheservicestation,axis
rails,pulleyteethandtopdeck.Removeanydebrisbuildupattheendsof
travel,ontheaxisrailandevenonaxisrailsupports.
4. Performaquickinspectionofthemachine,removesidepanelsandcovers,
lubricatethemachineandre‐tensionallbelts.Duringtheinspectionyoushould
belookingforanysignsofleaks,loosescrewsornutsandwornparts.Badly
wornitemsshouldbereplacedduringthisservicevisit,screwsandcoversneed
tobetightenedandleaksshouldbefixedimmediately.
5. Turnthemachineoffandmovethecarriageandfastaxistothemiddleofthe
buildbedandre‐bootthemachine.Itisveryimportantthatyouwatch,study
andbecomefamiliarwiththebootprocessoftheZCorp3Dprinteryouare
workingon.
Manyproblemscanbeidentifiedandpossiblysolvedbysimplyperformingthese5steps
butsometimesittakesalittlemorework.
6. Oncethemachinehasrebootedandcomeback“Online”takeaquicklook
throughtheprinterslogfileandtakealookattheprintheadreport.Inthelog
filelookfortrendsleadinguptotheerrororproblemyouare
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09915ZPrinter650TroubleshootingGuide
experiencing(example:repeated1006HeadTooHoterrorswithaheadwilllead
to40800HeadCheckFailedorothererrors).Withthesamepointsinmind,a
clearprintheadwithover1000mlonitoracolorprintheadwithover500mlof
binderthroughitmaystarttoexperience1006HeadTooHoterrorswhichare
normal.
Ifyouhaven’tfoundtheproblemyouwerelookingforbynowyouareactuallyjustgettingreadytostart
thetroubleshootingprocess.Changeonepartatatime.Wearetryingtofindtherootcauseofanissue
notonlytohelpthiscustomerbuttomakeourequipmentbetter.Ifthatpartdoesnotfixtheproblem
thenitneedstoberemovedandplacedbackintoyourspareskitorsentbacktoZCorp.
GettingHelpfromZCentral101:
HavingthebelowinformationreadyfortheZCentralteamWILLmakeyourinitialinformationinquiry
morefruitfulandhelpyoutogetyourcustomerupandrunningintheleastamountoftime.
1. SerialNumber
2. CustomerName
3. LogFile(ServiceMenu>ViewPrinterLog:SaveAs)
4. .INIFile(ServiceMenu>Edit.INIFile:SaveAs)
5. .CSVFile(Z450andZ650:ServiceMenu>ReceiveFile:Typespread.csv)
6. HeadReportInformation
7. Binder/PowderType
8. Binder/PowderExpiration
9. EXACTErrorCode/DescriptionofProblem
a. Understandandbedescriptiveoftheproblemathand.(Remember
example:PrinterWon’tBoot=Notverydescriptive.PrinterWon’tBoot=I
turntheprinteronanddonotgetanylightsorreadoutonthemonitor
pluggedintothemachine)
b. What’schanged?IfyouhaverecentlyreplacedanEBox,FastAxisorany
otherpartandarenowhavingadifferentproblemoreventhesame
problemthenit’sbestforyouandfortheZCentralservicestafftohave
andknowthisinformation.
Failuretofollowtheabovestepsandprovidetheaboveinformationcanresultinyourquestionsnot
beingansweredtoyouoryourcustomers’satisfactionanddefinitelyleadtoamoredrawnoutservice
call.
4
09915ZPrinter650TroubleshootingGuide
Notices
CopyrightandTrademarks
Copyright©ZCorporation1995‐2011.Allrightsreserved.Theinformationinthisdocumentmaynotbe
duplicatedortransmittedinanywaywithouttheexpresswrittenconsentofZCorporation.The
informationcontainedhereinisfortheuseofZCorporationcustomers,whoarepermittedtocreate
briefexcerptsforthepurposesoftrainingandreview.Thisinformationmaynotbeincorporatedinany
commercialprograms,books,databases,orinanykindofsoftwarewithouttheconsentofZ
Corporation.
Z,ZCorporation,zp,zb,ZMap,ZPhoto,Z‐Cure,ZPrints,ZPrinter,ZCast,ZScanner,ZBuilder,CreateMore,
ZScanandtheZCorp.logoanddesignarepending/registeredtrademarksofZCorporation.
ZPrint®7.12SystemSoftwareCopyright(c)1996‐2011ZCorporation.Thissoftwareisbasedinparton
theworkoftheIndependentJPEGGroup.
PNGlibrarylibpngversion1.2.2Copyright(c)1998‐2002GlennRanders‐Pehrson,(Version0.96
Copyright(c)1996,1997AndreasDilger),(Version0.88Copyright(c)1995,1996GuyEricSchalnat,
Group42,Inc.)
ZLIBgeneralpurposecompressionlibraryversion1.1.4,Copyright(C)1995‐2002Jean‐loupGaillyand
MarkAdler.
MicrosoftWindowsisatrademarkofMicrosoftCorporation.
ZCorporationacknowledgesthetrademarksofotherorganizationsfortheirrespectiveproductsor
servicesmentionedinthisdocumentation.
ProprietaryInformation
InformationcontainedinthisdocumentistheconfidentialpropertyofZCorporation.Recipientshall
notdisclosesuchInformationtoanythirdparty,andshallnotuseitforanypurposewhatsoeverother
thanwhatisrequiredtoinstallandusetheZPrinter650.
UseofEquipment
ZCorporation'sEquipment,anduseoftheEquipment,maybesubjecttolimitationsimposedunder
patentslicensedtoorownedbyZCorp.,andistobeusedsolelyforthefabricationofappearance
modelsandprototypesusingnewZCorporation‐suppliedconsumablesfromZCorporationorits
authorizeddistributorsintheoriginalpackaging.Otherusesmayberestricted;contactZCorporationfor
furtherinformation.ConsulttheUser'sManualbeforeoperationofanyZCorporationEquipment.
TheEquipmentisdesignedtobeusedbydesignengineersandotherprofessionalsintheproductionof
early‐stage3Dappearancemodelsandprototypes.TheEquipmentisnottobeusedtoproduce,either
directlyorindirectly,medicalorotherproductsthatmayrequireprecisedimensionsortolerancesto
ensurethesafeandeffectiveoperationofsuchproducts.Youagreetoindemnify,defendandholdZ
Corporationanditsofficers,directorsandemployeesharmlessfromandagainstanyandallclaims,
losses,damages,costsandexpensesresultingfromanyuseoftheEquipmentotherthanforthe
productionofearly‐stageappearancemodelsandprototypes.
5
09915ZPrinter650TroubleshootingGuide
Warranty
YourZPrinterisguaranteedtobefreeofdefectsinmaterialsandworkmanship,whenusedfor
productionofearly‐stageappearancemodelsandprototypesandwithZCorporationconsumables,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.
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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...................................................................................................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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09915ZPrinter650TroubleshootingGuide
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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09915ZPrinter650TroubleshootingGuide
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
AppendixA:Cleaningthealignmentsensor.......................................................................................61
AppendixA:Cleaningthealignmentsensor(cont.)............................................................................62
AppendixB:UnderstandingandtroubleshootingtheZPrinter650LoadCell....................................63
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09915ZPrinter650TroubleshootingGuide
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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09915ZPrinter650TroubleshootingGuide
1004: Head x fire voltage failed
This error is caused by the printer not being able to power the print heads. The most common
causes for this error are a short between the print head and Pogo PCB, a dead print head, or a
short on the Pogo PCB.
Monitor Read-Out or
Secondary
Symptom Cause / Problem Solution Reference
Documents
1004: Head fire voltage
failed Print head not seated
properly / contacts dirty
Clean print head contacts
and Pogo Pins; Reinsert
print heads
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.
1004: Head fire voltage
failed Bad/Old HP11 Print Head ReplaceHP11 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.
1004: Head fire voltage
failed Bad Carriage Cable Replace 50080 Pogo Flex
Cable
85026 ZPrinter 650
Carriage Cable Removal
and Replacement
After performing the above step try performing a service print head and alignment. If the machine performs both tasks
the problem should be solved.
1004: Head fire voltage
failed Bad Pogo PCB Replace 50019 Pogo PCB 85022 ZPrinter 650 Pogo
PCB 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.
1004: Head fire voltage
failed Bad festoon cable
assembly 50108 Festoon Cable
Assembly (Figure 1)
After performing the above step try performing a service print head and alignment. If the machine performs both tasks
the problem should be solved.
1004: Head fire voltage
failed PC104+ Failed Replace 50016 PC104+
PCB 85070 ZPrinter 650 E-Box
Field Repair Procedure
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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09915ZPrinter650TroubleshootingGuide
1006: Head x temperature too high
This error is caused by a print head overheating due to low binder flow, poor cleaning of the
print head by the service station or a failed electrical circuit including the print head. This is a
common error when print heads have reached their life expectancy.
Monitor Read-Out or
Secondary
Symptom Cause / Problem Solution Reference
Documents
Heads are getting powder
on them Out of ZC6 Add ZC6 09577 ZPrinter650 User
Manual
1006: Head x temperature
too high Expired Binder
Check the expiration date
of the materials in the
machine and custom's
stock.
Sanitize System: DO NOT
USE BLEACH: Use 06965
Sanitation Kit
1006: Head x temperature
too high Print head not seated
properly / contacts dirty
Clean print head contacts
and Pogo Pins; Reinsert
print heads
09577 ZPrinter650 User
Manual
1006: Head x temperature
too high Bad/Old Print Head Replace Print head 09577 ZPrinter650 User
Manual
After performing the above step try performing a purge print head, alignment and a small test print. If the machine
performs the tasks the problem should be solved.
1006: Head x temperature
too high Low flow rate of binder to
the print head
Check and verify the flow
rates according to the
reference document
85052 ZPrinter 650 Flow
Rate Test
Heads are getting powder
on them
Service station is dirty or
the squirter block is
clogged
Clean the 6 service station
squirter block holes or
replace the 30008 squirter
block
09577 ZPrinter650 User
Manual
(Figure 2)
Heads are getting powder
on them Service Station Wiper is
Worn Replace 30011 Service
Station Wiper (Figure 3)
Heads are getting powder
on them Parking Spittoon is not
clean or is damaged Clean Parking Spittoon 9572 ZPrinter650 User
Manual
1006: Head x temperature
too high Air in Fluid System See Fluids
1006: Head x temperature
too high Binder system is leaking See Fluids
1006: Head x temperature
too high Air Vent is clogged (May
happen during transport) Replace Air Vent (Figure 5)
1006: Head x temperature
too high Out of binder and float
switch has failed Troubleshoot float switch
and add binder (Figure 6)
1006: Head x temperature
too high Lines are contaminated or
Clogged
Sanitize System: DO NOT
USE BLEACH: Use 06965
Sanitation Kit 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.
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09915ZPrinter650TroubleshootingGuide
1007: Head x current too high
This error is caused by the current for a specific print head being too high. This error can also
be displayed as 1007: Head current too high 255v. In the ZPrinter650, this voltage comes from
the PC104+ card, through the festoon cables, Adapter PCB, and carriage cable to power the
Pogo PCB.
Monitor Read-Out or
Secondary
Symptom Cause / Problem Solution Reference
Documents
1007: Head x current too
high Bad/Old Print Head Replace Print Head 09577 ZPrinter650 User
Manual
1007: Head x current too
high Print head not seated
properly / contacts dirty
Clean print head contacts
and Pogo Pins; Reinsert
print heads
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.
1007: Head x current too
high Bad Carriage Cable Replace 50080 Pogo Flex
Cable
85026 ZPrinter 650
Carriage Cable Removal
and Replacement
After performing the above step try performing a service print head and alignment. If the machine performs both tasks
the problem should be solved.
1007: Head x current too
high Bad Pogo PCB Replace 50019 Pogo PCB 85022 ZPrinter 650 Pogo
PCB 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.
1007: Head x current too
high PC104+ Failed Replace 50016 PC104+
PCB 85070 ZPrinter 650 E-Box
Field Repair Procedure
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.
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09915ZPrinter650TroubleshootingGuide
1009: Head fire voltage stuck
This error is caused by the current for the print heads being locked on. In the ZPrinter650, this
voltage comes from the PC104+ card, through the festoon cables, Adapter PCB, and carriage
cable to power the Pogo PCB.
Monitor Read-Out or
Secondary
Symptom Cause / Problem Solution Reference
Documents
1009: Head fire voltage
stuck Bad/Old Print Head Replace Print Head 09577 ZPrinter650 User
Manual
1009: Head fire voltage
stuck Print head not seated
properly / contacts dirty
Clean print head contacts
and Pogo Pins; Reinsert
print heads
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.
1009: Head fire voltage
stuck Bad Carriage Cable Replace 50080 Pogo Flex
Cable
85026 ZPrinter 650
Carriage Cable Removal
and Replacement
After performing the above step try performing a service print head and alignment. If the machine performs both tasks
the problem should be solved.
1009: Head fire voltage
stuck Bad Pogo PCB Replace 50019 Pogo PCB 85022 ZPrinter 650 Pogo
PCB 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.
1009: Head fire voltage
stuck PC104+ Failed Replace 50016 PC104+
PCB 85070 ZPrinter 650 E-Box
Field Repair Procedure
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
1010: Invalid head temperature
This error is caused by a bad reading of the print head temperature. You can find which head is
causing the problem by looking in the printers log file for the following log entry: Head Alarm 10:
46 45 41 43 256 invalid temp reading
Monitor Read-Out or
Secondary
Symptom Cause / Problem Solution Reference
Documents
1010: Invalid head
temperature
Service station is dirty or
the squirter block is
clogged
Clean the 6 service station
squirter block holes or
replace the 30008 squirter
block
09577 ZPrinter650 User
Manual
(figure 2)
1010: Invalid head
temperature Service Station Wiper is
Worn Replace 30011 Service
Station Wiper (Figure 3)
1010: Invalid head
temperature Print head not seated
properly / contacts dirty
Clean print head contacts
and Pogo Pins; Reinsert
print heads
09577 ZPrinter650 User
Manual
1010: Invalid head
temperature Bad/Old Print Head Replace Print head 09577 ZPrinter650 User
Manual
After performing the above step try performing a service print head and alignment. If the machine performs both tasks
the problem should be solved.
1010: Invalid head
temperature 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.
1010: Invalid head
temperature Bad Pogo PCB Replace 50019 Pogo PCB 85022 ZPrinter 650 Pogo
PCB Removal and
Replacement
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.
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09915ZPrinter650TroubleshootingGuide
3011: SEQUENCER: error in DPC, flags
This error is caused by the PC104+ not being able to communicate with the pogo pcb.
Monitor Read-Out or
Secondary
Symptom Cause / Problem Solution Reference
Documents
3011: Sequencer: error in
DPC flags Bad/Old Print Head Replace Print Head 09577 ZPrinter650 User
Manual
3011: Sequencer: error in
DPC flags Print head not seated
properly / contacts dirty
Clean print head contacts
and Pogo Pins; Reinsert
print heads
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.
3011: Sequencer: error in
DPC flags 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.
3011: Sequencer: error in
DPC flags Bad Pogo PCB Replace 50019 Pogo PCB 85022 ZPrinter 650 Pogo
PCB 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.
3011: Sequencer: error in
DPC flags Bad festoon cable
assembly 50108 Festoon Cable
Assembly (Figure 1)
After performing the above step try performing a service print head and alignment. If the machine performs both tasks
the problem should be solved.
3011: Sequencer: error in
DPC flags PC104+ Failed Replace 50016 PC104+
PCB 85070 ZPrinter 650 E-Box
Field Repair Procedure
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
40006: AUTOALIGN: weak sensor reading
This error is caused by the alignment sensor not being able to read the initial refraction.
Monitor Read-Out or
Secondary
Symptom Cause / Problem Solution Reference
Documents
40006: AUTOALIGN: weak
sensor reading Dirty sensor Window Clean Window and Retry 09577 ZPrinter650 User
Manual
(figure 7 )
After performing the above step try performing an alignment. Watch the alignment pattern to make sure that the light for
the alignment comes on. If you do not see the green light during alignment proceed to Pogo PCB replacement. If the
machine performs both tasks the problem should be solved.
40006: AUTOALIGN: weak
sensor reading Build bed is not Flat Perform Fill Bed 09577 ZPrinter650 User
Manual
(figure 21 )
40006: AUTOALIGN: weak
sensor reading Poor Spread "See Spread Issues" "See Spread Issues"
(figure 18 )
After performing the above step try performing an alignment. Watch the alignment pattern to make sure that the light for
the alignment comes on. If you do not see the green light during alignment proceed to Pogo PCB replacement. If the
machine performs both tasks the problem should be solved.
40006: AUTOALIGN: weak
sensor reading Dirty Sensor on Pogo or oil
has leaked in the carriage
Clean sensor on Pogo with
alcohol and clean inside
the carriage then retry
85022 ZPrinter 650 Pogo
PCB Removal and
Replacement
40006: AUTOALIGN: weak
sensor reading Pogo Card is crooked or
sensor is not snapped in Realign the pogo card
85022 ZPrinter 650 Pogo
PCB Removal and
Replacement
(figure 9 and 9.1)
After performing the above step try performing an alignment. Watch the alignment pattern to make sure that the light for
the alignment comes on. If you do not see the green light during alignment proceed to Pogo PCB replacement. If the
machine performs both tasks the problem should be solved.
40006: AUTOALIGN: weak
sensor reading Bad Pogo PCB Replace 50019 Pogo PCB 85022 ZPrinter 650 Pogo
PCB Removal and
Replacement
After performing the above step try performing an alignment. Watch the alignment pattern to make sure that the light for
the alignment comes on. If you do not see the green light during alignment proceed to Pogo PCB replacement. If the
machine performs both tasks the problem should be solved.
40006: AUTOALIGN: weak
sensor reading Bad Carriage Cable Replace 50080 Pogo Flex
Cable
85026 ZPrinter 650
Carriage Cable Removal
and Replacement
After performing the above step try performing an alignment. Watch the alignment pattern to make sure that the light for
the alignment comes on. If you do not see the green light during alignment proceed to Pogo PCB replacement. If the
machine performs both tasks the problem should be solved.
40006: AUTOALIGN: weak
sensor reading Sensor window is damaged
or missing 50007 Fast Axis Assembly 85021 ZPrinter 650 Fast
Axis Removal and
Replacement
The most common cause is a dirty alignment window. It is imperative that the window is cleaned before every
alignment.
17
09915ZPrinter650TroubleshootingGuide
40007 AUTOALIGN: alignment of Axis x failed
This error is axis specific (Axis0 or Axis1) and 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 AUTOALIGN:
alignment of Axis x failed Dirty sensor Window Clean Window and Retry 09577 ZPrinter650 User
Manual
(Figure 7 )
After performing the above step try performing a service print head and an alignment. Watch the alignment pattern for
print quality. If the machine performs both tasks the problem should be solved.
40007 AUTOALIGN:
alignment of Axis x failed Build bed is not Flat Perform Fill Bed 09577 ZPrinter650 User
Manual
40007 AUTOALIGN:
alignment of Axis x failed Poor Spread "See Spread Issues" "See Spread Issues"
(figure 18 )
After performing the above step try performing a service print head and an alignment. Watch the alignment pattern for
print quality. If the machine performs both tasks the problem should be solved.
40009 AUTOALIGN:
alignment of Axis x failed Stripy printing "See Part Quality
Troubleshooting"
"See Part Quality
Troubleshooting"
(Figure 8 )
After performing the above step try performing a service print head and an alignment. Watch the alignment pattern for
print quality. If the machine performs both tasks the problem should be solved.
40007 AUTOALIGN:
alignment of Axis x failed Dirty Sensor on Pogo or oil
has leaked in the carriage
Clean sensor on Pogo with
alcohol and clean inside
the carriage then retry
85022 ZPrinter 650 Pogo
PCB Removal and
Replacement
(Figure 9 and 9.1)
40007 AUTOALIGN:
alignment of Axis x failed Pogo Card is crooked or
sensor is not snapped in Realign the pogo card
85022 ZPrinter 650 Pogo
PCB Removal and
Replacement
(Figure 9 and 9.1)
After performing the above step try performing a service print head and an alignment. Watch the alignment pattern for
print quality. If the machine performs both tasks the problem should be solved.
40007 AUTOALIGN:
alignment of Axis x failed Bad Pogo PCB Replace 50019 Pogo PCB 85022 ZPrinter 650 Pogo
PCB Removal and
Replacement
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
40008: AUTOALIGN: can't pick reference head
This error is caused by the sensors lack of ability to read the contrast refraction from the yellow
binder just before the alignment pattern is printed.
Monitor Read-Out or
Secondary
Symptom Cause / Problem Solution Reference
Documents
40008: AUTOALIGN Dirty sensor Window Clean Window and Retry 09577 ZPrinter650 User
Manual
40008: AUTOALIGN Build bed is not Flat Perform Fill Bed 09577 ZPrinter650 User
Manual
40008: AUTOALIGN Poor Spread "See Spread Issues" "See Spread Issues"
(figure 18 )
After performing the above step try performing a service print head and an alignment. Watch the alignment pattern for
print quality. If the machine performs both tasks the problem should be solved.
40008: AUTOALIGN Stripy printing "See Part Quality
Troubleshooting"
"See Part Quality
Troubleshooting"
(figure 8 )
After performing the above step try performing a service print head and an alignment. Watch the alignment pattern for
print quality. If the machine performs both tasks the problem should be solved.
40008: AUTOALIGN Dirty Sensor on Pogo or oil
has leaked in the carriage
Clean sensor on Pogo with
alcohol and clean inside
the carriage then retry (Figure 7)
40008: AUTOALIGN Pogo Card is crooked or
sensor is not snapped in Realign the pogo card (Figure 9 and 9.1)
After performing the above step try performing a service print head and an alignment. Watch the alignment pattern for
print quality. If the machine performs both tasks the problem should be solved.
40008: AUTOALIGN Bad Pogo PCB Replace 50019 Pogo PCB 85022 ZPrinter 650 Pogo
PCB Removal and
Replacement
After performing the above step try performing a service print head and an alignment. Watch the alignment pattern for
print quality. If the machine performs both tasks the problem should be solved.
40008: AUTOALIGN PC104+ Failed Replace 50016 PC104+
PCB 85070 ZPrinter 650 E-Box
Field Repair Procedure
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
40800: Head x check failed
The printer cannot perform a continuity check on the indicated print head.
Monitor Read-Out or
Secondary
Symptom Cause / Problem Solution Reference
Documents
40800: Head x check failed Print head not seated
properly / contacts dirty
Clean print head contacts
and Pogo Pins; Reinsert
print heads
09577 ZPrinter650 User
Manual
40800: Head x check failed Bad/Old HP11 Print Head ReplaceHP11 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.
40800: Head x check failed Bad Carriage Cable Replace 50080 Pogo Flex
Cable
85026 ZPrinter 650
Carriage Cable Removal
and Replacement
After performing the above step try performing a service print head and alignment. If the machine performs both tasks
the problem should be solved.
40800: Head x check failed Bad Pogo PCB Replace 50019 Pogo PCB 85022 ZPrinter 650 Pogo
PCB 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.
40800: Head x check failed PC104+ Failed Replace 50016 PC104+
PCB 85070 ZPrinter 650 E-Box
Field Repair Procedure
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
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