08634

ZPrinter®310 Troubleshooting Guide

Rev B

Revision History:
Rev 06: JPK 1/6/2003 Unreleased revision
Rev A: JPK 2/24/2003 Released
Rev B: BRS 8/12/04 Revised ECN 1323

Z, zp, zb, ZPrinter, ZCast and the Z Corp. logo are trademarks of Z Corporation.

Information contained in this document is the confidential property of Z Corporation. Recipient shall not
disclose such Information to any third party, and shall not use it for any purpose whatsoever other than to price
or provide services to Z Corporation.
© Z Corporation 1995-2002. All rights reserved.
 LIKELIHOOD
SYMPTOM CAUSE / PROBLEM
+ HIGH
- LOW
Print head failure
Binder bottle not plugged into top cover
Out of binder
Air in fluid system
Binder tubing blocked or kinked
Error 1006 Message Binder valve at head card not connected or loose
(Head Temp too high) Poorly seated carriage flex cable
Bad carriage cable (open circuit)
Bad head card
Binder cap vent clogged
Pogo pin / pins are bent or broken
Fluid filter clogged
Organisms growing in binder
No print head installed
Tape still in place over print head contacts
Carriage cable damaged / not seated in connector
Error 1000 Message
(Unknown head error) Pogo pin / pins are bent or broken
Bad carriage cable (open circuit)
Bad head card
SOLUTION
+ Replace print head
+ Check connection to binder bottle
Refill binder bottle and bleed fluid system
+ (see users manual chapter 6)
- Bleed fluid system (see users manual chapter 6)
Check for kinks and replace tubing if necessary
- (see 08632 Benchwork manual)
- Check valve connection
- Check carriage flex cable connections
Check carriage flex cable integrity,
- replace if necessary
- Replace head card
- Check cap vent for blockage
- Change pogo card (See 08632 Benchwork manual)
Replace or clean fluid filter
- (See 08632 Benchwork manual)
Flush fluid system with bleach solution,
- change binder
Install and purge new print head
+ (see users manual chapter 12)
+ Remove tape and re-install pen
- Check cable and connector
- Change pogo card (See 08632 Benchwork manual)
Check carriage flex cable integrity,
- replace if necessary
Replace head card
- (See 08632 Benchwork manual)
 Error 1002 Message
(Rom read failed for head)
Error 1003 Message
(I2C read failed for head)
Machine will not boot or
come online
(Power LED is on)
Interlock switch not connected to Igus harness properly
Online / Error lights flash
and long sustained beep
Binder dripping onto top
deck
Power cable not connected to middle connector on the
Error 2303(0) message
(Axis excessive position
error)
Print head not seated correctly
Pogo pin / pins are bent or broken
Head card ribbon cable disconnected at either end
Tape still in place over print head contacts
Print head failure, bad smart chip
Pogo card malfunction
Flash card not connected to ATX power supply
Bad PCI card
Flash card corrupt or erased
Dead CMOS battery on motherboard
Voltage selector set wrong on power supply (selector
set to 230V with 110V input)
PCI Card not seated properly
PCI EEPROM chip not seated or bad
or malfunctioning interlock switch
Bad PCI card
Septum / barb fitting leaking or binder tubing not
properly inserted onto barb fitting at print head
PCI card
Slow Axis bearings low on grease or seized
Slow Axis cable disconnected or forced on backward
Slow Axis motor failure
Slow Axis idler pulley seized
+ Re-seat pen and restart build
- Change pogo card (See 08632 Benchwork manual)
- Check head card ribbon cable connections
- Remove tape and re-install pen
- Print head failure, bad smart chip
Inspect pogo cards. Pins should be clean and not
+ bent or broken
+ Check power connection to flash card
Replace PCI Card
+ (See 08632 Benchwork manual)
- Replace flash card or check master slave switch
Change CMOS battery.
- (See 08632 Benchwork manual)
- Unplug printer and set selector to proper voltage
- Check PCI to motherboard connection
- Re-seat or replace EPROM chip
Check connection to switch or replace switch
+ (See 08632 Benchwork manual)
Replace PCI Card
- (See 08632 Benchwork manual)
Replace septum if necessary. Check tubing
+ connection at barb fitting
+ Check connection at PCI card.
Grease slow axis bearings or replace slow axis
+ bearings if necessary.
- Check slow axis cable connection
Replace slow axis motor.
- (See 08632 Benchwork manual)
Change Slow Axis idler
- (See 08632 Benchwork manual)
 Low on Fast Axis oil
Fast Axis motor cable not properly
connected at the head card
Error 2303(1) message
Debris in Fast Axis bearings
(Axis excessive position
error)
Fast Axis belt too tight
Fast Axis bearing seize
Fast Axis tensioner seized
Fast Axis motor failure
Fast axis anti-rotate bearing missing
Print head failing
Pogo Pins contaminated or dirty
Printing stripes
Service Station out of cleaning fluid
Powder build – up on service station cap
“Packet Timeout” Bad serial port on PC or printer
message
AC cord to printer not plugged in
Power switch failure
Printer will not turn on Power supply failure
(won’t power up)
Power supply shorted
Voltage selector set wrong on power supply (selector
set to 110V with 230V input)
Control panel switches malfunctioning
Control panel won’t Bad PCI Card
respond to inputs
Bad control panel cable
Control Panel cable not properly connected
+ Oil Fast Axis felt washers (see users manual)
+ Check Fast Axis plug connection
Inspect Fast Axis Bearings and clean or
+ replace if necessary
Adjust belt to proper tension
+ (See 08632 Benchwork manual)
- Replace Fast Axis bearings
- Replace tensioner
- Replace fast Axis motor
- Replace Anti-rotate bearing
+ Replace print head
+ Clean Pogo Pins with alcohol swab
- Fill cleaning fluid reservoir
- Clean service station cap
+ Replace motherboard
+ Plug in printer AC cord
- Check switch, test and replace if necessary
- Change power supply
Unplug AC cord, wait 10 seconds, reconnect AC
- cord and reboot printer
- Replace power supply
Replace control panel
+ (See 08632 Benchwork manual)
Replace PCI Card
- (See 08632 Benchwork manual)
Replace control panel cable
- (See 08632 Benchwork manual)
- Check control panel cable connections
 Waste bottle not installed / halfway installed to valve at
Service Station
Overflowing
“Before printing you must
fix this problem” Message
Binder leaking from back
of machine
Wet piston seal has dried against build box wall
Build piston is stuck and
or will not move through
its full range of travel
Build piston will not come
Piston positions incorrect. Pistons not re-zeroed after
all the way to the top of
the build box
Excessive overspread into
service station / gantry
jams
Uneven or rough
spreading
front panel
Waste tube clogged
Waste bottle vent clogged
Waste Bottle not plugged in properly
Main harness disconnected at PCI card.
Binder filter leaking
Debris jamming the piston
Energizer jamming the piston
Faulty PCI card
PCI / E Box replacement.
Feed piston raised too far before spreading
Powder is contaminated or over-recycled
Roller scraper worn
Binder/powder caked on roller
Spreader roller motor failing
Roller belt skipping teeth
+ Check connection at waste bottle mount
- Unclog or replace waste tube
- Check and unclog cap vent or replace cap
+ Check connection of Waste Bottle to check valve
+ Check main harness connection at PCI card
Check filter o-ring and filter body for proper
+ assembly
Replace piston seal
+ (see 08632 Benchwork manual)
Check for any debris and remove; clean the build
- box walls if ant buildup has occurred
Replace energizer and seal
- (see 08632 Benchwork manual)
Replace PCI card
- (see 08632 Benchwork manual)
+ Re-zero pistons
Clean away excess powder, clean print head
+ and reboot printer
Discard old powder and fill feed box with fresh
+ powder
Replace roller scraper
- (See 08632 Benchwork manual)
- Check scraper for wear or clean roller
Replace spreader roller motor
- (See 08632 Benchwork manual)
See 09813 Service bulletin for instructions

Parts weak, crumbly, wet
or caked with powder
Excessive powder on top
deck
Snowplows not attached or severely worn
Error light when booting
Carriage ribbon cable not connected at either end
Squeaking noise from
inside cabinet while
raising or lowering the
pistons
Slow axis belt skipping
teeth / chattering
Gantry slams and carriage
is not parked at service
station after booting
Carriage slams and will
not park at service station wired improperly or disconnected from head card
after booting
Print head failing
Incorrect saturation setting
Wrong binder being used
User recycled binder
Powder is contaminated or over-recycled
Head card PLD not programmed
Lead screws running without lubricant
Slow axis belt too loose
Slow Axis idler pulley seized
Slow Axis zeroed in wrong location
Slow axis motor encoder malfunctioning
or wired improperly
Bad head card
Fast Axis zeroed in wrong location
Fast axis motor encoder malfunctioning,
Bad PCI Card
+ Replace print head
Set correct saturation for powder /binder
+ system being used
+ Replace binder with correct formula
- Replace binder with correct formula
Discard old powder and fill feed box with fresh
- powder
+ Attach snowplows correctly or replace
+ Program head card PLD
- Check for proper ribbon cable connection
+ Grease lead screws
+ Tighten Slow Axis belt to proper tension
Replace slow axis idler
- (See 08632 Benchwork manual)
+ Re-boot printer
Replace or re-wire slow axis motor encoder
- (See 08632 Benchwork manual)
Replace head card
- (See 08632 Benchwork manual)
+ Re-boot printer
Replace, reconnect or re-wire
- fast axis motor encoder
(See 08632 Benchwork manual)
Replace PCI Card
- (See 08632 Benchwork manual)
Fast axis belt skipping
teeth / chattering
Fast axis belt too loose
Can’t find printer on
network
Poor Ethernet connection or improper setup
Service Station out of cleaning fluid
Powder build – up on service station cap
Pogo Pins contaminated or dirty
Print head not seated correctly
Short Print Head Life Pogo pin / pins are bent or broken
Concentration of color binder too high
Air bubbles in fluid system
Contaminated binder
Error 30004 message Igus Ribbon cable disconnected at either end
+ Tighten Fast Axis belt to proper tension
See 08606 Ethernet setup
+ procedure for instructions
+ Fill cleaning fluid reservoir
+ Clean service station cap
- Clean Pogo Pins with alcohol swab
- Re-seat pen and restart build
- Change pogo card (See 08632 Benchwork manual)
Bleed fluid system and verify correct color binder
- concentration before restarting
- Bleed fluid system (see users manual chapter 6)
Flush fluid system with bleach solution, change
- binder
+ Check Igus ribbon cable for proper connection