zortrax M200 Use and care manual

Heater and Thermocouple
Replacement
SOURCE:
https://support.zortrax.com/thermocoupler-and-heater-replacement/
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Table Of Content
Unloading the Material 4
Unplugging the Power Cable 5
Material Guide Removal 6
Unplugging the Extruder Cable 7
Hotend Removal 8
Heater and Thermocouple Removal (from the Hotend) 9
Unplugging all Cables from the Extruder PCB 10
Unscrewing the Extruder PCB 11
Extruder Lower Printed Cover Removal 12
Heater and Thermocouple Removal (from the Extruder) 13
New Heater and Thermocouple Assembly (in the Extruder) 14
Extruder Lower Printed Cover Assembly 15
Extruder PCB Assembly 16
Plugging all Cables into the Extruder PCB 17
Heater and the Thermocouple Assembly (in the Hotend) 18
Hotend Assembly 20
Plugging the Extruder Cable 21
Material Guide Installation 22
Plugging the Power Cable 23
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The heater and thermocouple are responsible for providing and maintaining the
appropriate temperature in the hotend during material loading and the printing
process. Also, the heater transfers the signal required for the printer to complete
the platform calibration. Therefore, if the extruder is overheating or the heating is
insufficient, or if your prints have blisters and hanging strands on their surface,
the heater and thermocouple may be faulty and require replacement. Also, the
extruder heating problems are indicated by the firmware messages: Error #010
Extruder heating error, Error #011 Extruder temperature is too high, and Error
#013 Unexpected extruder temperature drop. Sometimes, if you are unable to
finish platform calibration or if the nozzle hits the platform during the pre-print
calibration, it may be necessary to replace the heater and thermocouple.
Before replacing the heater and thermocouple, make sure that they are properly installed
in the hotend.
If you have the heater&thermocouple v1, you also have to replace the hotend and the
extruder PCB.
The following manual shows the M200 repair work. For the M300, these procedures are
the same.
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Unloading the Material
If the material is loaded into the extruder, unload the material using the “Material” ->
“Unload the material” option in the menu.
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Unplugging the Power Cable
Turn off the printer and unplug the power cable.
Wait until the printer – especially the hotend – cools down completely.
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Material Guide Removal
Detach the material guide from the extruder cover. Next, separate the guide from the
extruder cable.
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Unplugging the Extruder Cable
Detach the extruder upper printed cover and unplug the extruder cable.
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Hotend Removal
With a 1.5mm Allen key loosen the two screws that secure the hotend and remove the
hotend from the extruder.
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Heater and Thermocouple Removal (from the
Hotend)
With a 1.5mm Allen key loosen the two screws that secure the heater and thermocouple
in the hotend. Then remove the heater and thermocouple.
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Unplugging all Cables from the Extruder PCB
Unplug all the cables from the extruder PCB.
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Unscrewing the Extruder PCB
Unscrew the two screws that secure the extruder PCB using a 2mm Allen key. Remove
the PCB from the extruder.
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Extruder Lower Printed Cover Removal
Remove the extruder lower printed cover.
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Heater and Thermocouple Removal (from the
Extruder)
Remove the heater and thermocouple from the extruder block and from the heat shrink
tubing. Unplug the cables from the extruder PCB.
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New Heater and Thermocouple Assembly (in the
Extruder)
Plug the heater and thermocouple cables into the extruder PCB. Put them through the
heat shrink tubing and inside the extruder’s block.
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Extruder Lower Printed Cover Assembly
Attach the extruder lower printed cover to the extruder.
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Extruder PCB Assembly
Place the extruder PCB in its place and secure it with the two screws.
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Plugging all Cables into the Extruder PCB
Plug all the cables in. Remember to arrange the cables so that they don’t get damaged,
e.g. by wrapping against each other.
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Heater and the Thermocouple Assembly (in the
Hotend)
Insert the heater and thermocouple into the hotend and firmly tighten the two screws that
secure them (using a 1.5mm Allen key).
Make sure that the screws don’t go through the insulation that covers the wires (this can
happen if the heater goes too deep into the slot).
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This picture shows the heater inserted
correctly. This picture shows the heater pushed too far into the slot in the hotend.
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Hotend Assembly
Insert the hotend into the extruder and tighten the two screws that secure it (using a
1.5mm Allen key).
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