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510 Spectrum User Manual

1. Z CORPORATION SpectrumZ 510 3D Printer HardwareManual Rev J Part Number 09537 August 2007 www 3dpuser com All Rights Reserved 10 2 07 Spectrum Z 510 3D Printer Hardware Manual TABLE OF CONTENTS 1 lt 1 0 ee EAO ee eee ee 1 1 Use Of Equipment ccccccccceccceeeeeeeseeeseeeeceeeeeeesseesaeees 1 2 Manual Sections isiacaranccts cecsewcnecucdeenensesudaxvenssdecacnedchwsseoncsasees Whats NeW A ee oe ee E ee eee ae ee ne eee ae ener PTE CG OE ereinen nt nate nate nee EEE N AEO E eid 3 1 How lt Works sancecasetecacexsanadsanavatsleoedeteansdecsaenennouunialacdadadbond aes 3 2 System Components ccccccccscccseecseeceeeceueecseecseeceueeeeeeeees 3 3 Printer COMPONENMS ccccccseecseeecseeceeeceeeceeeecseeseeesaeeeaees 3 4 Printer Control Panel ccc ccceeeceseeeeceseeeeeeseeeeeeeeeeeeeseeaes GO N 3 5 Internal Printer Assembly and Service Station Components 3 6 ZD5 Powder Recycling System cccceccseccseeeseeeeeeeeaeeeaees 3 7 Z510 Powders Accessories and Tools ccccceceeeeeeeeeees 3 8 New Accessories Available for 3D Printers ceees 3 9 ZPrint Software Installation ccccccscccseceseeeseeeseeeeaeeeaees A QUICK Start GUJE sercis aa a aAA Na 4 1 Preparing The 3D Printer cccccccsccceeseeeeeeeeeseeeseeesaeees 4 2 Preparing the Build in ZPrint Software ccccceceseeeeeeees 4 3 Remo
2. eb Bd Spectrum Z 510 3D Printer Hardware Manual Overview 1 Overview 1 1 Use Of Equipment Z Corporation s Equipment and use of the Equipment may be subject to limitations imposed under pat ents 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 dis tributors in the original packaging Other uses may be restricted contact Z Corporation for further informa tion Consult the User s Manual before operation of any Z Corporation Equipment The Equipment may be covered by the following U S Patents and or U S Patent Applications 9 204 055 9 340 656 9 387 380 6 007 318 6 375 874 9 902 441 60 558 940 08 771 009 60 612 068 60 789 758 10 999 847 11 000100 60 741 573 60 808 721 09 706 350 09 835 292 11 453 695 60 472 221 10 848 831 6 416 850 6 610 429 6 403 002 6 989 115 7 037 382 7 087 109 11 335 282 10 817 159 10 650 086 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 agai
3. User Website for tips and best prac tices information or click the following link Best Practices for Powder Management www 3dpuser com 60 10 2 07 All Rights Reserved iene Spectrum Z 510 3D Printer Hardware Manual Troubleshooting 9 Troubleshooting 9 1 The binder solution is being applied in erratic stripes If the binder appears to be applied in fragmented stripes check the following 1 Rinse the squeegee clear of any debris 2 Make sure binder supply is full If this does not correct the problem your print heads may be worn out Replace the print heads as outlined in Change Print Heads 9 2 ZPrint Software freezes up during the print job Exit the software by pressing Ctrl_Alt_Delete Check to see if the software is responding or not Complex parts can take some time to load render and compute slices during printing Look for excessive disk activ ity which may indicate lack of RAM If it is not responding choose End Task from the Task Manager and restart the software You may choose to go to the Detailed Log Report under the View menu for the last layer printed for that build and continue from the last printed layer 9 3 Thin planar parts are warping In general warping is caused by uneven drying of parts By adjusting print orientation and drying time warping can be minimized You can take steps to ensure that drying is occurring evenly by e Reorienting your part within the build box If a thin pla
4. If the st file is not near perfect you will have problems printing the part Open the file in the soft ware and inspect it layer by layer to ensure there are no gaps and the part does not overlap other parts e Is there enough binder in the feed bottles When you start the build a reminder box will pop up asking you to check if there is enough binder in the feed bottles If you plan to start a large build make sure binder bottles are full e Is the saturation too low lf your parts are unusually crumbly check to make sure your saturation levels are not set too low for this type of part Return to working with the default saturation values for the material type If this does not work please contact your authorized Z Corporation Service Provider 9 6 Printer looks like it is printing but is not laying down binder If you are using Bleed Compensation it is not uncommon for the printer to move and lay down little or no binder for the first few layers of a part As you begin printing carefully watch the printer to see if it is printing normally It may be that the print heads are not properly seated in the carriage This can cause a bad connection with the temperature sen sor and the print heads will overheat Prolonged periods of attempting to print without binder flow will dam age the print head You will need to replace the print heads 9 7 Air has Entered the Binder Fluid Lines Bleed Air maintenance is performed if air bubbles
5. ccccccscccseceeeeeeeeeeeeeeaeeeaes 7 4 Depowdering the Patt cccccccsseesseceseeceeceeeceueeeeeseasenaes ED Diving he Parn seisnig kie ni AE AAEE T6 Pan WAIN AMOI ecT 7 6 1 Using Paraplast X TRA Wak ccccceccceeeeeeeeeeeeeeeeaes 7 6 2 Using Z Bond Cyanoacrylate ccccccceeceeeeeeeeeees 7 6 3 Using Z Max Epoxy cccccccccccceseeeeeceeeseeeseeeeeeeeeeeeaes 8 Service Menu and Other Maintenance cccccceseeeeeeeeeeeeeeees od UNDI e e E E EE www 3dpuser com i 10 2 07 All Rights Reserved eb Bd 8 2 Change Print Heads cccccccccesecceeeceeeceeeceeeceueeseeceueesaeeseessuetseeseeeeges 43 9 3 Purge FIDE Head ss ccscencnetaanewennnsnd countandeddersuntaasacemasacatannanonddeecenteesancdntuestons 47 8 4 Check Powder LeVel ccccscccsccceeeceeeceeeeceeeceeceeeeceeeceeesaeeseeesaeeesenens 47 8 9 Drop Feed PISTON sicccosssnsanteasansdavensspendacteuendudenas seneemensagiededateadecexdscqunsddedataads 47 DO FUBE ae cde epee ee cee ett eoce eset s ene caece seat salad E ccaton admeceeoeusie 47 94 Preheat Printer ape scre stoves saacassnenasencnacsaese AAEE ESASEN AnA 47 S0 TVAAUIN UTA Ost seer acice esceetsse tones sented E E 47 8 8 1 Fast Axis Lubrication seccudencesenntocdacasacadasdedensetcadanedniuiesnadaceddeceanouunnetes 48 C 0 2 SIOW AXIS Lubrcati n scssi aE eii 50 8 8 3 Piston Screws Lubrication cece ceccc secs eeeeceeeseeeseeeseeese
6. 0 0875 0 1 mm thick The printer then prints these cross sections one after another from the bottom of the part to the top Inside the printer there are two pistons see diagram below The feed piston is represented in the dia grams below Starting on the left the piston is shown in the down position filled with powder The build pis ton is the piston on the right and is shown below in the up position Also represented in the diagrams are the roller drawn as a circle and the print assembly drawn as a square On the printer the roller and the print assembly are mounted together on the gantry which moves horizontally across the build area To begin the 3D printing process the printer first soreads a layer of powder in the same thickness as the cross section to be printed The print heads then apply a binder solution to the powder causing the powder particles to bind to one another and to the printed cross section one level below The feed piston comes up one layer and the build piston drops one layer The printer then spreads a new layer of powder and repeats the process and in a short time the entire part is printed fe _ Or oF Me i a Step 1 As the gantry Step 2 The roller spreads a Step 3 The roller discharges traverses left to right the thin layer of powder over the excess powder down the roller collects powder build piston powder overflow chute www 3dpuser com 4 1
7. 21 Thin Planar Parts Are Warping 61 Tips On Gross And Fine Depowdering 32 Tips On Setting Up The Build 27 U Unpark Command 43 Use Of Equipment 1 Using Paraplast X TRA Wax 38 Using Z Bond Cyanoacrylate 38 Using Z Max Epoxy 39 V Vacuum Attachment 3 Vacuuming Operation Warning 35 View Binder Levels 25 View Printer Log 59 Void Warranty 20 W Waste Fluid Disposal 25 7H BAT Spectrum Z 510 3D Printer Hardware Manual Wide Blade Utility Scraper 32 Wipe Metal Spit Cover 24 Z z Cast Description 12 Z510 3D Printer Image 7 Z510 Powders Accessories And Tools 11 Z510 Toolkit Tools 12 Z Bond Application Notes 39 Z Bond Curing Information 39 Z Bond Safety Precautions 38 ZD5 Depowder Unit 10 Z Max Application Notes 40 Z Max Curing Information 41 Z Max Mixing Instructions 40 Z Max Safety Precautions 39 Z Max Spraying Instructions 40 Zp 15e Description 12 ZPrint Dialog 58 ZPrint Software Freezes 61 www 3dpuser com 7H BAT
8. Bleed Air maintenance is performed if air bubbles are visible in the binder lines that run from the Binder bottles to the print heads in the Carriage Air in the binder system will prematurely expire the print heads If you see air bubbles in any of the binder lines use the syringe and tubing included with the printer toolbox to bleed the air out of the line The most likely time that you may find you need to bleed the binder lines is if the printer has been sitting idle and has not been in use If this is the case it is recommended that you check the binder lines for air bubbles before preceding with a print e Visually inspect the lines where the binder bottles are stored to see if air bubbles are present www 3dpuser com 53 10 2 07 All Rights Reserved a BL Spectrum Z 510 3D Printer Hardware Manual Service Menu and Other Maintenance e Visually inspect the lines where they connect to the Carriage to see if air bubbles are present BINDER LINES Follow the procedure below if you see air in one or more of the binder lines 1 In ZPrint select Service gt Bleed Air gt Start to move the carriage to the front of the printer where you have easy access to the carriage 2 Open the carriage cover and remove the print heads for each binder line that has air bubbles present 3 Use an alcohol crush swab to wipe the pogo pins clean for each removed print head www 3dpuser com 54 10 2 07 All Rights Reserved
9. Open the printer top cover 4 Clean the Fast Axis rails of residue with a dry paper towel www 3dpuser com 48 10 2 07 All Rights Reserved a BL Spectrum Z 510 3D Printer Hardware Manual Service Menu and Other Maintenance 7 Move the Carriage back and forth manually to distribute the grease When finished close the printer top cover www 3dpuser com 49 10 2 07 All Rights Reserved e a BL Spectrum Z 510 3D Printer Hardware Manual Service Menu and Other Maintenance 8 8 2 Slow Axis Lubrication 1 Assemble the grease gun as instructed on its packaging 2 Select Service gt Unpark 3 Open the printer top cover 4 Wipe off the slow axis rail with a dry paper towel 5 Locate the two grease fittings located behind the gantry Manually move the gantry if you need to gain access to the grease fittings 7 Wipe off the excess grease with a dry paper towel and close the printer top cover www 3dpuser com 50 10 2 07 All Rights Reserved Prec Sioa Baad Spectrum Z 510 3D Printer Hardware Manual Service Menu and Other Maintenance 8 With the printer offline press the Spread button on the control panel to distribute the grease 8 8 3 Piston Screws Lubrication 1 Lower both the feed and build pistons all the way down 2 Open the front cabinet tray 3 Locate the piston screws and apply grease from top to bottom F 4 Use your finger to distribute the grease evenly
10. aa el OC ast ogre head sapere eer age cel Re See Tjd Baa hiki fees an k AD LEFT jt a ES Hj Horia a harie HE ajio 8 Rorgertal door hadit BETEA CA WTH OPPS es OF tke Pug ee Ester Caarg se ELAME PU LTI OE mney eg en eee ede et jet THART por Manca PLAY LE PAUP peel Dja TORAS g B MEDIA PLA eA HEALED por Of AMER AD P52 rhe G merged engre of 2 kang erg Pica ee ee eS Oe Cae Pry med iF Miray vane pod SS gt Atte or PF is PeR el 2 6000 Daa ei ea UCA VADE ee 2 Choose the file you wish to open 3 Click Open or double click the file 4 Choose the dimensions and powder type you will be using 5 Click OK 6 The file will be brought into the software in a new window 7 If you would like to add additional files to this build choose the Import option on the File menu www 3dpuser com 28 10 2 07 All Rights Reserved a BL Spectrum Z 510 3D Printer Hardware Manual Using the ZPrint Firmware and Software 6 5 Part Orientation 6 5 1 Parts Containing an Opening or Hollow Area If the part has an opening or is hollow place the opening or hollow side up This will allow for the removal of powder during the depowdering process Ee eS ES SS Ee Ss 6 5 2 Parts Containing Overhangs e Unsupported overhangs should be placed on the left hand side and as close to the build plate as pos sible The high definition composite powder being extremely fine is more fluid in the build For increased
11. fluid in the printer and preparing the system to print a part www 3dpuser com 1 10 2 07 All Rights Reserved eb Bd Spectrum Z 510 3D Printer Hardware Manual Overview e Using the ZPrint Firmware and Software This section gives you an overview of how to download firmware and how to set up a build on the ZPrint Software For more information about the software and its features please refer to the ZPrint Software Manual e Post Processing the Part This section guides you through removing your printed part depowdering and infiltrating the part with resin to improve strength and finish It will also explain how to use the most common infiltrants available from Z Corporation For information on other infiltrants or applications visit the 3DP User Website at www 3dpusers com e ZPrint Service Menu and Other Maintenance This section contains instructions for keeping your printer in proper condition through regular preventative maintenance e Troubleshooting This section offers some troubleshooting tips For service contact information see our Service page on the 3DP User Website e 3D Printer System Details This section contains system specifications about the Z510 3D Printer and material storage recommendations e Appendix This section contains useful information on how to setup your printer and shows a list of common error codes e Index www 3dpuser com 2 eb Bd 10 2 07 All Rights Reserved Spectrum Z
12. these components as long as the Activate Maintenance Reminder option is checked in the Settings gt General Preferences gt General tab Only perform maintenance on these components when you are prompted to in ZPrint www 3dpuser com 47 10 2 07 All Rights Reserved a BE Spectrum Z 510 3D Printer Hardware Manual Service Menu and Other Maintenance While lubrication of the Fast and Slow Axis is very important it is equally important not to over grease the bearings when lubricating Only a very small amount of grease is required to keep these parts working opti mally Using too much grease will create a situation where the grease will leach onto the Fast Axis and buildup on the bumpers located at each end of the Fast Axis When this happens you need to clean the Fast Axis rails and bumpers See Section 8 8 4 for instructions on how to clean these components Maintenance Service ltem Lube Fast Asis Bearngs 16g SERVICE I5 UYVERDUE Lube Piston Screws 246 SERY ICE IS OVERDUE Lube Slow Axis Bearings 188 SERVICE 15 OVERDUE Odometer Current Value Next Service Fast Axis Inches 2 562241e 007 7 489089e 007 Life Hours 2154398e 004 1 385993e 004 Help Dismiss The following sections detail the instructions for lubrication and cleaning maintenance when the need arises 8 8 1 Fast Axis Lubrication 1 Assemble the grease gun as instructed on its packaging 2 Select Service gt Unpark to unpark the Carriage 3
13. 8A max or 220 240 VAC 50 60Hz 3 4A max or 100 VAC 50 60Hz 7 8A max Network Ethernet 10 100 base T Temperature 68 85 F 20 30 C Relative Humidity 20 60 non condensed Weight 470 lbs 210 kg 3D Printer Z510 Dimensions Cover Closed 42 x 31 25 x 50 5 107cm x 79cm x 128cm Cover Open 42 x 31 25 x 73 107cm x 79cm x 185cm Click System Requirements for additional information regarding system specifications for all 3D Printers on the 3DP User Website Lithium Battery Internal to the 3D Printer is a lithium coin cell type battery This may be any one of the following Type CR2032 either Maxell Panasonic Renata Sanyo or Sony PLEASE NOTE This battery is not in a user accessible area and is not user replace able The expected lifetime of the battery is in excess of five years Replacement will be handled by your Z Corporation Customer Service Representative FCC Notice This equipment has been tested and found to comply with the limits for a Class A digital device pursuant to part 15 of the FCC rules These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instruc tion manual may cause harmful interference to radio communications Operation of this equipment in a residential area is likely
14. Powder Management RTV Molding Thermoforming Tough Durable Parts Water Transfer Water Transfer High Strength Parts www 3dpuser com 42 10 2 07 All Rights Reserved a BL Spectrum Z 510 3D Printer Hardware Manual Service Menu and Other Maintenance 8 Service Menu and Other Maintenance The ZPrint Service menu is the primary interface from the desktop when performing routine maintenance on the Spectrum Z 510 3D Printer 8 1 Unpark Unpark moves the Carriage from its parked position at the Service Station to the opposite side of the Fast Axis to allow easy access for routine cleaning Saas Help Change Print Heads Auto Alignment Purge Print Heads 8 2 Change Print Heads 1 Determine which print head needs to be changed This is done either by an error message during printing or by accessing the Print Head Report command located on the ZPrint Service menu M Print Head Report Binder Diop Mace Mak Fire Fed mi Feed Temp Curent Voltage 575 30524010 3 005 Q30 607 3133 010 oof 03u 57a Jie 3 005 Q3 578 3 044e 010 3 005 O30 2733 12730011 2 Place the printer Online 3 Select Service gt Change Print Heads gt Start When you click Start in the Change Print Heads dia log the printer moves the Carriage over to the opposite side of the Fast Axis for easy access Change Print Heads Press Stat to begin the pent head change procedure When the pant heads sre changed press
15. a print job running on your printer For a more detailed explanation see Routine Operations Using the ZPrint Firmware and Software and Post Process ing the Part 4 1 Preparing The 3D Printer 1 Fill the feed box with powder 2 With the printer offline soread powder over build area by pressing the Spread button on the control panel for four spreads The printer will automatically spread powder over the build area www 3dpuser com 15 10 2 07 All Rights Reserved Pn Spectrum Z 510 3D Printer Hardware Manual Quick Start Guide 4 Check the binder bottles Fill if necessary l 6 Put printer online by pressing the Online button on the control panel Technical Tip LEAVE THE PRINTER ON This allows the printer to perform a periodic self maintenance www 3dpuser com 16 10 2 07 All Rights Reserved Pres ies 8 Eee Spectrum Z 510 3D Printer Hardware Manual 4 2 Preparing the Build in ZPrint Software 1 Launch ZPrint and open or import your file s Lom ri fo Demp Fae SCOT PUSE Djar eyre head srembly rma Lage std duces ogee head eeenbly oor ge Ay hi ajii BET CARR Te OPRET E pete ae oe Quick Start Guide z Dom Djp riin E ALPLES ebal BJH LET jabel OF Homia door harie BEC 8 Horeontal door handit gor Glaic Pure er ret LADIES PUP LET ae External Caarg ed Gj iag ot rai EEE CHART or O MEDU PLAY MOLE HEALED rbd PROC Toate the oly MEDIA PLAY MOUS
16. and how they are oriented in the build box so you do not accidentally bump or brush against a fragile part during the depowdering process e When performing the gross depowdering removal of excess powder in the build box do not plunge the vacuum nozzle into the powder bed Begin at the outer perimeter of the build box and slowly work your way into the build Hold the tip of vacuum nozzle approximately 0 25 6 4 mm to 0 375 9 5 mm away from the powder and allow the vacuum to pull the powder up Slanting the vacuum nozzle will enable you to control the suction This will decrease the chance of breaking a part that is hidden beneath the surface of the powder e While fine depowdering always start with a low air pressure and gradually increase the pressure as the fine details and features of the part become visible When the top and sides of the part are com pletely depowdered tilt the part onto one of its sides Handle the part carefully The part may be fragile and brittle before infiltration If none of the sides of the part will be able to support the weight of the part you can apply a small amount of resin or epoxy to strengthen it You want to be careful not to let any of the infiltrant come into contact with any unprinted powder that may still be on the part Let the infiltrant dry before continuing to depowder 7 2 Post Processing Tools There are six tools included in the accessories kit that assist the user with gross depowdering and cle
17. are visible in the binder lines that run from the Binder bottles to the Printheads in the Carriage Air in the binder system will prematurely expire the Printheads If you see air bubbles in any of the binder lines use the syringe and tubing included with the printer Toolbox to bleed the air out of the lines See Bleed Air for instructions on how to bleed air out of the binder lines The most likely time you may find you need to bleed the binder lines is if the printer has been sitting idle and has not been in use if a binder line is disconnected from a binder bottle or if the binder runs out while printing If any of these are the case it is recommended that you check the binder lines for air bubbles before preceding with a print www 3dpuser com 62 10 2 07 All Rights Reserved a BE Spectrum Z 510 3D Printer Hardware Manual 9 8 Air has Entered into the Wash Fluid Line Troubleshooting You will need to use the Prime Wash Fluid feature when there is no wash fluid or air has entered the wash fluid line This can occur in a few instances such as when first installing the Printer when running out of wash fluid or when the connection to the fluid line has been disconnected Air can be easily detected by looking to see if there are air bubbles in the wash fluid line To remove air from the line follow the instruc tions below 1 Place the printer Online 3 Click Start Unpark Change Print Heads Auto Alignmen
18. cover and press Cancel to close the Bleed Air dialog in ZPrint 8 10 Service Print Heads Service Print Heads will initiate a standard service on the print heads 8 11 Prime Wash Line Prime Wash Line will remove any air from the wash fluid pumping system This should be performed upon Initial machine setup and any time the wash fluid is allowed to run dry 8 12 Stripe Test Authorized Z CORPORATION service personnel use Stripe Test to aid in troubleshooting 8 13 Cleaning the Spreader Roller Toggle Roller 1 Open the top cover of the printer 2 Remove all powder from the build side 3 Close the printer top cover and place the printer Offline 4 Lower the build piston all the way down 5 Manually move the gantry over the build area www 3dpuser com 57 10 2 07 All Rights Reserved a BL Spectrum Z 510 3D Printer Hardware Manual Service Menu and Other Maintenance 6 Put the printer Online 7 Select Service gt Toggle Roller On Off 8 Using a moist paper towel wipe under the gantry making sure to remove all powder residue Dry the area with a paper towel Select Toggle Roller On Off to turn off the roller 8 14 Check Status Check Status prompts a window that states information that may be valuable to a service provider such as firmware version and compile date as well as the current position of the feed and build pistons Print Feed Piston has 6 98 inches remaining Build Position has 9
19. over each piston screw Close the front cabinet tray www 3dpuser com 51 10 2 07 All Rights Reserved Spectrum Z 510 3D Printer Hardware Manual Service Menu and Other Maintenance 5 Raise and lower both the feed and build pistons a couple of times to evenly distribute the grease Any excess grease should be wiped off with a paper towel 8 8 4 Cleaning the Fast Axis Rails and Bumpers 1 Select Service gt Unpark After the Carriage is unparked you can manually move it in order to clean Change Print Head Purge Print Heads Check Powder Level 2 Place the printer in Offline mode and open the printer top cover 3 Locate the rubber bumper at each end of the Fast Axis Wipe away any grease you see on the bumper Be sure to clean both bumpers Thoroughly clean the Fast Axis rail of any visible grease Bumper with grease buildup 4 Manually move the Carriage back and forth and wipe the entire axis clean www 3dpuser com 52 10 2 07 All Rights Reserved e a BL Spectrum Z 510 3D Printer Hardware Manual Service Menu and Other Maintenance q CS x i 5 Check that there is no grease buildup on the Carriage as well Check both sides of the Carriage where the axis rails and the Carriage join 6 When finished close the printer top cover and place the printer back Online 7 Press OK on the Unpark dialog in ZPrint to close the dialog 8 9 Bleed Air
20. powder First empty the powder from the overflow bin and then add fresh powder if needed 9 Tamp powder and raise the feed piston until the powder reaches the top edge of the feed box www 3dpuser com 21 10 2 07 All Rights Reserved POT AT Spectrum Z 510 3D Printer Hardware Manual Routine Operations 10 Close the top cover of the printer Fill the build area with powder by pressing and holding the Spread button on the control panel for four complete spreads This will initiate the Fill Bed mode The LCD will display Filling bed Online to cancel 11 Lift the top cover of the printer and vacuum loose powder from the area surrounding feed and build box Technical Tip Keep powder containers closed when not in use to keep powder dry Scoop powder carefully to minimize airborne powder Make sure that you carefully vacuum up excess powder It only takes a minute and the tidier the machine is the less often it will need maintenance See Best Practices for Powder Management Carefully read the Material Safety Data Sheet for powder before use 5 2 Cleaning the Service Station The Service Station cleans the array of the print heads during printing The Service Station MUST be cleaned before every build This will remove any deposits of powder Make sure Parking Caps are dry before beginning a build 1 Select Unpark on the Service menu in ZPrint which will move the carriage out of the parking position allowing access to
21. several light coats of material Allow all mixed materials to cure prior to disposal Spraying Instructions 10 2 07 www 3dpuser com 40 All Rights Reserved Use Gravity Feed High Volume Low Pressure Sprayer Z Corp Part 14206 We recommend Devilbiss Sprayer with 14 18 mm tip Other sprayers are compatible however the use of a HVLP sprayer will minimize the amount of overspray generated The Devilbiss Sprayer is available with disposable canister liners Z Corp Part 14207 and will minimize the amount of cleanup Have the sprayer parts and materials ready before mixing the resin Mix resin and pour into the disposable liner in the canister Always spray in a vented hood Use of a respirator is also recommended Spray resin between 15 20 psi a BL Spectrum Z 510 3D Printer Hardware Manual Post Processing the Part When finished remove the disposable liner and clean sprayer with ethyl alcohol or acetone Remove the tip and thoroughly clean by hand to avoid resin buildup Cleanup takes approxi mately 15 minutes Curing Information Tips Allow the part to cure for 1 hour at ambient temperature to avoid discoloration prior to placing in the oven for accelerated cure The resin can be cured at an accelerated rate in an oven The oven must be vented Ventilation designs need to meet each customer s respective governmental health and safety requirements A reference frequently used by U S firms to comp
22. the Service Station Sai Help Change Print Heads Auto Alignment Purge Print Heads www 3dpuser com 22 10 2 07 All Rights Reserved Prec Oe Spectrum Z 510 3D Printer Hardware Manual Routine Operations 2 With the Service Station exposed rinse rubber Parking Cap with distilled water If needed remove rubber Parking Caps and rinse under running water Wipe dry with paper towel PLEASE NOTE Make sure the Parking Caps are sitting flat in their holders 3 Clean squirt manifold holes by carefully inserting the luer lock needle into the squirt manifold holes DO NOT PRESS HARD The needle should go in Clean one by one all six holes Be careful not to scratch or score holes 4 Rinse rubber wiper blade with distilled water and wipe dry with paper towel Ensure that there is no powder buildup anywhere in the proximity of the rubber wiper www 3dpuser com 23 10 2 07 All Rights Reserved a BL Spectrum Z 510 3D Printer Hardware Manual Routine Operations 5 Wipe metal spit cover with damp paper towel 5 3 Checking Fluid Levels 1 Open front cabinet tray www 3dpuser com 24 10 2 07 All Rights Reserved ronePnnATIONN Spectrum Z 510 3D Printer Hardware Manual Routine Operations 3 Check waste fluid If it is half full empty fluid Empty contents in accordance to local or company safety regulations Close front cabinet tray WARNING Do not recycle waste solution The waste is
23. the left Press the lt Build UP gt or lt Build DN gt keys to change the value at the current cursor position If the cursor is at the rightmost IP ADDRESS field and the lt Feed UP gt key Is pressed the LCD display reads SUBNET MASK 0 0 0 0 Press the lt Feed UP gt key to move the cursor to the right Press the lt Feed DN gt key to move the cursor to the left Press the lt Build UP gt or lt Build DN gt keys to change the value at the current cursor position If the cursor is at the rightmost SUBNET MASK field and the lt Feed UP gt key is pressed you are returned to the Configuration menu If the cursor is at the eftmost SUBNET MASK field and the lt Feed DN gt key is pressed you are returned to IP ADDRESS If the cursor is at the eftmost IP ADDRESS field and the lt Feed DN gt key is pressed the LCD display reads DHCP STATIC IP USE DHCP YES Press the lt Build UP gt or lt Build DN gt keys to toggle YES NO If YES is selected and you press the lt Feed UP gt key you are returned to the Configuration menu Selecting RESTORE FIRMWARE displays RESTORE FIRMWARE RESTORE FIRMWARE NO Press the lt Build UP gt and lt Build DN gt keys to toggle YES NO YES means the printer will use the previous version of firmware prior to the firmware you just installed Press the lt Feed UP gt key to return to the Configuration menu Selecting DIAGNOSTIC MODE displ
24. 0 2 07 All Rights Reserved a BL Spectrum Z 510 3D Printer Hardware Manual Step 4 As the gantry traverses right to left the print head prints the part cross section Introduction Step 5 The feed piston moves up one layer the build piston moves down one layer and the pro cess is repeated The printer employs several techniques to quickly build parts First binder solution is applied in a higher concentration around the edges of the part creating a strong shell around the exterior of the part Within parts the printer builds an infrastructure by printing strong scaffolding within part walls with a higher con centration of binder solution The remaining interior areas are printed with a lower saturation which gives them stability but prevents over saturation which can lead to distortion of the part Other interior areas printed at lower saturation Interior infrastructure printed at a higher saturation Exterior walls printed at higher saturation After printing the part is removed from the powder bed depowdered and dried The part can then be infil trated with wax epoxy or other materials to increase strength and durability More information on different infiltrants can be found in Infiltrating the Part You will have the part in your hands and can start improving your design within the same day usually within hours Because the powder layers support the structur
25. 21 inches remaining Firmware version 3 191 Compile date Oct 42005 8 15 Report Capabilities Report Capabilities is a tool used by authorized Z Corporation service providers to evaluate the logical state of your 3D Printer www 3dpuser com 58 10 2 07 All Rights Reserved Prec Oe Spectrum Z 510 3D Printer Hardware Manual Service Menu and Other Maintenance 8 16 Print Head Report Print Head Report is a useful tool for identifying how old each print head is The user should access Print Head Report prior to each print job to determine if there is enough print head life to complete a job or to see if any or all of the print heads require changing 8 17 View Printer Log View Printer Log is a text file that stores usage information error codes and any event that occurs during operation As part of the troubleshooting process you may be asked by your service provider to save and submit the log There is no proprietary information about printed parts in the Printer Log 8 18 Other Service Menu Items The other Service menu items are to be used only under the direction of an authorized Z Corporation ser vice provider Incorrect usage of these items will result in an inoperable machine Upload New Firmware Upload New Printer Configuration Edit INI File Send File Receive File 8 19 Printer Storage Preparation If the printer will not be in use for more than two weeks replace all the binder lines with di
26. 3D Printer System Vacuuming powder can generate static electricity and use of a non grounded vacuum will create static charges which may affect the operation of the 3D Printer System and harm the operator www 3dpuser com 35 10 2 07 All Rights Reserved a BL Spectrum Z 510 3D Printer Hardware Manual Post Processing the Part 7 4 Depowdering the Part 1 Place parts inside the depowdering station 2 Turn on the vacuum cleaner 3 Turn on the air compressor 4 Change the air pressure as needed and check the pressure with your hand before applying air on the part Technical Tip The air pressure on your depowdering station is adjustable For bulky parts turn the air pressure up For delicate parts turn the air pressure down www 3dpuser com 36 10 2 07 All Rights Reserved a BL Spectrum Z 510 3D Printer Hardware Manual Post Processing the Part 7 5 Drying the Part Although the part can be handled when it is not completely dried the part reaches full strength when dried Placing the part in an oven at temperatures less than 200 F 93 C for 2 4 hours will dramatically increase the strength of the part This is only recommended for high definition composite powders If using the removable build plate remove the part from the build plate before placing in the oven Click the following links for additional information on our 3DP User website regarding Accessories Frequently Ask
27. 4 Detailed Log Report 61 Devilbiss Sprayer 40 Diagnostic Connections 66 Diagram Of 3D Printing Process 4 www 3dpuser com Diagram Of Interior And Exterior Saturation 5 Drop Feed Piston Command 47 E Empty The Powder From The Overflow Bin 21 Error Codes Table 70 Ethernet Connector 66 Excess Powder 22 F Fast Axis Lubrication 48 Feed Piston 4 Fil Bed Command 47 Fill Feed Box 15 Firmware Description 27 Fixture 28 Fragmented Stripes In Binder Application 61 Front Cabinet Tray 24 G Gantry 4 H Hold For Unload command 20 How It Works 4 Increase Strength Of Thin Parts 28 Initiate The Fill Bed Mode 22 Install Firmware 27 Internal Printer Assembly And Service Station Components 8 International Symbol For Warning Or Caution 66 Introduction 4 L Lithium Coin Cell Battery 65 Lower Feed Piston 20 Maintenance Command 47 Material Storage Precautions 67 N Network Connection Troubleshooting 68 New Accessories Available 13 New Overflow Bin Cover 13 7H BAT Spectrum Z 510 3D Printer Hardware Manual New Vacuum Attachment Image 14 O Offline Mode 20 Online Mode 43 Open Or Hollow Area Of Part 29 Open Or Import Files 28 Orient Parts 28 Other Service Menu Items 59 Overflow Bin Cover 3 Overview 1 P Paraplast Application Notes 38 Paraplast Curing Information 38 Paraplast Safety Precautions 38 Part Accuracy 6 Part Infiltration 37 Part Orientati
28. 510 3D Printer Hardware Manual What s New 2 What s New This section briefly describes what s new in this version of the Spectrum Z510 3D Printer Hardware Man ual e New firmware installation instructions The function of firmware is to test and check certain diag nostics related to printer cleaning lubrication maintenance prior to each build When the firmware detects that this type of maintenance is required a message is displayed in the ZPrint software and on the printer control panel Click 3D Printers to go to our 3DP User Website and download firmware for the Z510 Printer See Section 6 2 for instructions on how to download the latest firmware for the Spectrum Z510 3D Printer e New Overflow Bin Cover minimizes airborne powder from the overflow bin during a build See Best Practices for Powder Management e New Vacuum Attachment fits your 3D Printer vacuum hose and attaches to the side of the feed box to capture airborne powder as powder is being added to the feed box See Best Practices for Powder Management www 3dpuser com 3 10 2 07 All Rights Reserved a BL Spectrum Z 510 3D Printer Hardware Manual Introduction 3 Introduction 3 1 How It Works The 3D Printer System is based on the Massachusetts Institute of Technology s patented 3DP 3D Print ing technology The software first converts a three dimensional design built using 3D CAD into cross sections or slices that are between 0 0035 0 004
29. DP User Website at www 3dpuser com www 3dpuser com 67 10 2 07 All Rights Reserved a BE Spectrum Z 510 3D Printer Hardware Manual Appendix 11 Appendix 11 1 Restoring Network and Firmware Settings Configuration mode is obtained by pressing and holding the ONLINE key on the printer control panel Configuration mode is indicated when the LCD displays NETWORK SETTINGS The Configuration menu consists of these 5 choices NETWORK SETTINGS RESTORE FIRMWARE DIAGNOSTIC MODE SAVE AND EXIT DISCARD AND EXIT Press the lt Build UP gt or lt Build DN gt keys to scroll through the Configuration menu Press the lt Feed UP gt key to select an item on the Configuration menu to edit The LCD displays your selection Selecting NETWORK SETTINGS displays NETWORK SETTINGS www 3dpuser com 10 2 07 USE NETWORK YES Press the lt Build UP gt or lt Build DN gt keys to toggle YES NO Selecting NO means the serial port will be used Press the lt Feed UP gt key to display DHCP STATIC IP USE DHCP YES Press the lt Build UP gt and lt Build DN gt keys to toggle YES NO If NO is selected and the lt Feed UP gt key is pressed the LCD dis plays IP ADDRESS 0 0 0 0 68 All Rights Reserved a BL Spectrum Z 510 3D Printer Hardware Manual Appendix Press the lt Feed UP gt key to move the cursor to the right Press the lt Feed DN gt key to move the cursor to
30. Done Start www 3dpuser com 43 10 2 07 All Rights Reserved a BL Spectrum Z 510 3D Printer Hardware Manual Service Menu and Other Maintenance 4 Open printer top cover and then open the Carriage cover 5 Remove the print head s you need to change www 3dpuser com 44 10 2 07 All Rights Reserved roo eA Spectrum Z 510 3D Printer Hardware Manual Service Menu and Other Maintenance 7 Re insert a new print head s and press down Press firmly on both ends of the print head to secure into place 8 Close the Carriage cover 9 Using a moist paper towel wipe the alignment window located on the bottom left side of the Carriage Dry off with a dry paper towel and close the printer top cover 10 Click Done on the Change Print Heads dialog Change Print Heads Press Start to begin the print head change procedure When the print heads are changed press Done 11 Select Service gt Purge Print Heads You can choose to purge only a new print head or all of the print heads The printer will purge the print head s of all of its ink and replace it with binder www 3dpuser com 45 10 2 07 All Rights Reserved e a BL Spectrum Z 510 3D Printer Hardware Manual Service Menu and Other Maintenance Change Print Heads Auto Alignment Purge Print Heads Purge All Print Heads Check Powder Level E S Drop Feed Piston 12 When p
31. E HEALED tow OF GAMEPAD P52 rhe mengei ere Oy OSes hep Harek Pra renged eigre 1 1 Goat Putter 2d j Mew vane pat Soot ete ao OD Prag Mn _ Winter abel 1 GOO0 Sag B HING OCAT WE ree fa The ot tere am Pa Fie bel t bid gly sep aie M EZ Prim 2 Orient and scale the file if needed ee eas i rier lowly Liha G Dia Le E fm fas fe bea ie boa b e Dame mR ee oe tin e A e Ia ae ame ci www 3dpuser com 17 10 2 07 All Rights Reserved e a BL Spectrum Z 510 3D Printer Hardware Manual Quick Start Guide 3 Open the File menu and select 3D Print Setup In the 3D Print Setup dialog select your Printer Powder Type and Layer Thickness options 2510C 2510 66073 EMPEROR Selec Pinter Powder Type amo Layer Thickness 00H i Bleed Compensation T 4 Select 3D Print on the File Menu or click the 3D icon L on the Toolbar Choose your settings in the Printing Options dialog and click OK Proceed through the series of preparation dialogs that appear before the build starts 4 3 Removing the Part 1 Wait for part to complete printing Check the software for part orientation www 3dpuser com 18 10 2 07 All Rights Reserved POT AT Spectrum Z 510 3D Printer Hardware Manual Quick Start Guide 3 Fine depowder part and post process as needed www 3dpuser com 19 10 2 07 All Rights Reserved Spectrum Z 510 3D Printer Hardware Manua
32. IGNMENT FAILED 40204 MOTOR DRIVE OVERLOAD 40205 MOTOR DRIVE OVERLOAD 40207 24V FAIL 40208 MOTOR DRIVE OVERLOAD 40800 PRINTHEAD d ERROR 40801 HEADCARD POWER FAIL 40802 PRINTHEAD d NOT HP11 40901 TEMP SENSOR FAILED 40902 TEMP OUT OF RANGE www 3dpuser com 70 10 2 07 All Rights Reserved a BL Spectrum Z 510 3D Printer Hardware Manual Numerics 3D Print Setup Dialog 30 A Air In The Binder Fluid Lines 62 Air In The Wash Fluid Line 63 Air Pressure When Depowdering 36 Alcohol Swabs Part Number 66 Alignment Pattern 46 B Best Practices For Powder Management 60 Binder Solution 5 Binders And Printing In Monochrome 25 Bleed Air 53 Bleed Compensation 28 Build Piston 4 Build Plate Holders 21 Bulls Eye Pattern 46 C CENELEC Class A Warning 65 Change Print Heads 53 Check Binder Bottles 16 Check Build Settings 29 Check Fluid Levels 24 Check Powder Level Command 4 7 Check Status 58 Check Wash Fluid And Waste Fluid 16 Class A Digital Device Disclaimer 65 Clean Alignment Window 45 Clean Service Station 15 Clean Squirt Manifold Holes 23 Cleaning The Service Station 22 Cleaning The Spreader Roller 57 Cleaning The Toggle Roller 57 Collision Detection 29 Communication Errors Between Print Head And Printer 64 Cylindrical Features 29 D Data File Errors 62 Depowdering The Part 36 Description Of Rear Panel 67 Description Of The 3D Printing Process
33. Piston Screws Lubrication Change Print Heads www 3dpuser com 26 10 2 07 All Rights Reserved a BL Spectrum Z 510 3D Printer Hardware Manual Using the ZPrint Firmware and Software 6 Using the ZPrint Firmware and Software This chapter will briefly describe firmware and how to install it from the 3DP User Website how to set up a build check the build settings and print For more information about the features in the ZPrint Software please refer to the ZPrint Software Manual 6 1 Firmware Overview Firmware tests and checks certain diagnostics related to printer maintenance prior to each build When the firmware detects that maintenance is required a message appears in the ZPrint software and on the printer control panel alerting the user to perform a cleaning lubrication maintenance task before the printer will start the current build You only need to perform this type of maintenance when you are prompted to in the ZPrint Software or via a message on your 3D printer LCD The 3DP User Website contains the most recent firmware file for your 3D Printer Users purchasing a new printer will not need to download this file as it is already installed on all new printers but all others should download the file and replace the firmware they are currently running on their system The installation only takes a few seconds PLEASE NOTE Make sure you install the firmware on the computer that is connected to your 3D Printer and that the p
34. a BL Spectrum Z 510 3D Printer Hardware Manual Service Menu and Other Maintenance s 20A 70 m2z2 roarFre 4 Attach the syringe tubing to the tip of the syringe and ensure the plunger is pushed all the way down VEN FITTING E PLu NGER gt A j TUBING _ir 7 5 SYRINGE 5 Place the syringe tube fitting over a printhead septum and slowly pull the syringe plunger to draw binder through the tubing and into the syringe You will see the air bubbles come through the syringe tubing When there is no air present the tubing looks solid with binder www 3dpuser com 55 10 2 07 All Rights Reserved a BL Spectrum Z 510 3D Printer Hardware Manual Service Menu and Other Maintenance 6 Have a paper towel ready as you lift the syringe tube fitting off of the septum to prevent binder from dripping onto the print head contacts or into the print head housing 7 In most cases you can empty the syringe contents into a waste container but you should check your company local and state regulations to ensure you dispose of the binder in accordance to those guidelines 8 Repeat Steps 5 6 and 7 for each binder line that needs bleeding When finished re insert the print head s and close the Carriage cover www 3dpuser com 56 10 2 07 All Rights Reserved roe ATH Spectrum Z 510 3D Printer Hardware Manual Service Menu and Other Maintenance 9 Close the printer top
35. accuracy the software provides a fixture feature that creates a cradle for the overhanging area e Cylindrical features will be more accurate when their axis is parallel to the z axis For example if you were to print a bottle the bottle would best be printed standing up with the mouth of the bottle facing the top of the printer 6 6 Checking Build Settings ALWAYS check build settings before printing e Itis also strongly recommended that slice viewing and collision detection if more than one part is being printed be used before beginning the build Collision Detection is located on the View menu of the software The slice view is toggled on the 3D View menu when you select the Switch Layer View 3D View command www 3dpuser com 29 10 2 07 All Rights Reserved fidedeesis naa Spectrum Z 510 3D Printer Hardware Manual Using the ZPrint Firmware and Software Slice viewing allows you to view the cross sections of the part to identify any errors in the file Collision detection will scan through the slices and report the layer in which part overlapping is found Follow the steps below to check your build settings 3 Choose the 3D Print Setup on the File menu or click the L 30 Print Setup Preies 7510 Cx 510 bers EMPEROR Select Printer Powder Type 2P102 Laver Thickness foou ri Bleed Compensation D Pmt im Monechome OF Cancel Check that the selected printer powder type and po
36. al z axis Less Strong Strong es ee y axis Accuracy The accuracy of the system depends on the materials you choose You can employ the anisotropic scaling feature in the software to adjust for expected shrinkage and bring your parts into true scale More information on anisotropic scaling factors can be found in the ZPrint software Manual a BL Spectrum Z 510 3D Printer Hardware Manual Introduction 3 2 System Components Z510 3D Printer ZD5 Powder Recycling System 3 3 Printer Components www 3dpuser com T 10 2 07 All Rights Reserved POT AT Spectrum Z 510 3D Printer Hardware Manual Introduction 3 4 Printer Control Panel Spread Button This button aloes he user to more ihe aniry from left to right Moving the gantry from left to night allows you to Spread powder over he Build box Holding doam thes pulton will reset it continuous spreading of power Build Up Down Buttons Allows the user to raise or lower the build box A ighi lap Mises Of lowers Ore layar tieknass holding down causes conbnwouws maton LCD Display Shows you the currant status of N Online Button Enables and disables printer communication Feed Up Down Buttons Allows the user to raibe or lower the piston in the feed bax A bight tap raises or aera ore layer inickhness hong down causes continuous motion Holding down the feed down bution will cause the
37. ance Composite materials can be reliability printed to be within a 1 0 or 0 007 dimensional tolerance Zp 130 High Performance Powder zp 131 Premium Performance Powder www 3dpuser com 10 2 07 11 Improves on the properties of zo 102 with up to 8x increase in early strength 25 faster print times Prints finer details richer colors and a better surface finish Accurately represents design details Read the zp 130 MSDS Zp131 is a multi purpose powder that offers the strongest parts the best resolution and great color accuracy It is ideal for fit and functional testing Stronger Parts Optimized when infiltrated with Z Bond 50 stronger than our zp130 powder when infiltrated with Z Bond Improved Process Higher green strength great surface appearance and less dust Great Color Accuracy Robust color gamut with more addressable colors as well as improved color consistency and uniformity Read the zp131 MSDS Read the zp131 User Guide All Rights Reserved a BL Spectrum Z 510 3D Printer Hardware Manual Introduction Zp 140 High Performance Plus Powder zp140 is a multi purpose material system that offers significantly easier post processing and exceptional color performance The Plus in our High Performance powder is the new Water Cure process e Water Cure The easiest and safest post processing available Only tap water is required to seal and stre
38. aning the part Wide Blade Utility Scraper This tool is used to move powder from the build cham ber or deck surface back into the feed cham ber Polypropylene Scraper When gross depowdering a bulky part such as the engine block the user may choose to carve powder away from the part instead of mov ing it away with the vacuum www 3dpuser com 32 10 2 07 All Rights Reserved a BL Spectrum Z 510 3D Printer Hardware Manual Post Processing the Part Soft Horsehair Brush This brush has very soft bristles and assists the user with the gross depowdering process Brushing pow der away from the part is a useful technique prior to the vacuuming step Stiff Detailing Brush This brush has very stiff bristles which is useful for scrubbing caked powder out of tight areas of a part The brush is also used for removing fringing from color part surfaces Stiff Handle Brush This tool serves the same purpose as the Stiff Detailing Brush It is slightly larger and is used for working with a larger surface area Soft Acid Brush This tool is used to remove caked powder from hard to reach areas The soft bristles make this brush per fect for delicate features www 3dpuser com 33 10 2 07 All Rights Reserved POT AT Spectrum Z 510 3D Printer Hardware Manual Post Processing the Part 7 3 Removing the Finished Part After the build is complete remove the finished parts from the build box as follows 1 Le
39. art user friendly no odor non blooming resin that may eliminate the need for special ventilation This resin is easily sanded and enhances the vibrancy of color parts Z Bond 100 is available in several quantities in both bottle and spray forms Read the Z Bond User Guide to learn more Safety Precautions e Do not use or handle this product until the Material Safety Data Sheet has been read and under stood e Wear lab coat gloves we recommend Nitrile Examination Gloves face shield or goggles Face shield is required if spraying Apply in ventilated hood e Specialized containers recommended for dispensing and application System for avoiding spills Catch pan waxed paper or plastic drop cloth www 3dpuser com 38 10 2 07 All Rights Reserved renePnRATiON Spectrum Z 510 3D Printer Hardware Manual Post Processing the Part e Label disposal materials e Wear dust mask when sanding finished parts General Application Notes e Part should be fully dried before applying resin Resin reacts with water and produces heat If the part is not dried it will heat up the part and produce gas that may be an irritant to the mucous membranes e Material can be brushed dipped or dripped e Material will penetrate between 0 08 0 12 inches 2 3 mm e Do not over apply the material as it will pool off the part during cure cycle Curing Information e The part should be placed on a non stick material wax paper Teflon etc to preve
40. ave the part in the bed for approximately 30 60 minutes Take a moment to look at the computer screen and determine exactly where parts lie in the build box 4 Remove powder away from the buried parts and clean powder out of the margins against the walls of the build box 5 Without raising the build piston begin removing powder around the part either by using the vacuum or post processing tools When vacuuming hold the end of the hose on a 20 to 30 degree angle over the powder so the hose inlet is 1 4 to 3 8 above the surface of the powder This generates enough of a draft to lift loose powder without damaging the parts For more information about the post processing tools refer to Post Processing Tools www 3dpuser com 34 10 2 07 All Rights Reserved a BL Spectrum Z 510 3D Printer Hardware Manual Post Processing the Part 6 To gain access to the sides of the parts raise the build piston by holding down the Build UP button 7 When finished you may remove the part by hand or press the Build UP button on the control panel When it stops moving press Build UP one more time to initiate the unload feature The build plate will now be exposed and easy to lift off the build envelope 8 Place a tray on the top of the feed area Remove the build plate and place on the tray The part is now ready to be fine depowdered WARNING When performing any vacuuming operation use the vacuum provided as part of the
41. ays DIAG MODE www 3dpuser com 10 2 07 DIAG MODE NO Press the lt Build UP gt or lt Build DN gt keys to toggle YES NO NO is normal operation YES will skip the rezero calibration fast slow axis and pistons for the current session and causes the pistons to rezero on the next powerup Press the lt Feed UP gt key to return to the Configuration menu 69 All Rights Reserved Mione Spectrum Z 510 3D Printer Hardware Manual Appendix Selecting SAVE AND EXIT displays SAVE AND EXIT Press the lt Feed UP gt key to save your changes and terminate the Configuration menu selecting DISCARD AND EXIT displays DISCARD AND EXIT Press the lt Feed UP gt key to terminate the Configuration menu Your changes for the current session will not be saved 11 2 Error Codes PLEASE NOTE d is a placeholder for numbers corresponding either to a print head number or a value Contact our Service Department at service zcorp com if you need additional help Error Code LCD Display 1000 PRINTHEAD ERROR 1001 PRINTHEAD POWER FAIL 1003 PRINTHEAD d ERROR 1004 PRINTHEAD POWER FAIL 1005 PRINTHEAD d ERROR 1006 PRINTHEAD d OVERTEMP 1007 PRINTHEAD POWER FAIL 1009 PRINTHEAD POWER FAIL 1010 PRINTHEAD d ERROR 1802 USE SERIAL PORT 1905 LAYER TOO BIG 2303 AXIS d ERROR 2304 AXIS d ERROR 2305 AXIS d ERROR 2400 AXIS d REZERO ERROR 40006 CLEAN SENSOR WINDOW 40007 ALIGNMENT FAILED 40008 AL
42. contaminated with powder and use of this waste in the your 3D Printer will clog the fluid system Use only binder and wash fluid supplied by Z Corporation Use of any other material may impact the performance and safety of your 3D Printer System and will void the warranty 4 Check binder bottles The Z510 3D Printer is not equipped with binder level sensors The user must check the binder levels prior to each build to ensure the Z510 3D Printer has enough to complete the build View the binder levels through the cutout windows in the binder bottle cover on the top cover If it is half full fill binder bottles h PLEASE NOTE When printing in monochrome it is still necessary to have binder in the color bottles for servicing WARNING If this is the first time you have added binder to the binder bottle on the Z510 3D Printer you must bleed the air out of the lines Please refer to Bleed Air for detailed instructions on how to perform this important procedure Air in the binder fluids system will cause premature print head burnout resulting in more frequent replacement www 3dpuser com 25 10 2 07 All Rights Reserved Tair DERE Spectrum Z 510 3D Printer Hardware Manual Routine Operations Refer to the following links to learn about other periodic maintenance tasks The following tasks should only be performed when prompted to by ZPrint or when you see a message on your 3D Printer LCD Fast Axis Lubrication Slow Axis Lubrication
43. ed Questions regarding Ovens Despatch Oven General Description 7 6 Part Infiltration All parts can be infiltrated with a variety of resins to produce a range of material properties As an early stage design tool it may not be necessary to infiltrate the parts at all However the true versatility of the Z510 3D Printer System is derived from the variety of material properties that can be achieved by applying one of our infiltration materials to parts that will be exposed to a variety of product testing environments For additional information on how customers are utilizing our line of infiltration products visit our 3DP User website at www 3dpusers com For an updated infiltrant product selection guide please visit the 3DP User Website at www 3dpusers com or click one of the links in the table below INFILTRANTS MATERIAL SYSTEM APPLICATION High High Composite Material Material Z Bond iach teacamaaae a Composite Material R or Drizzle Z Max Epoxy High Composite Material Spray or Brush To learn more about finishing moving parts finishing color parts and finishing a part using the dipping method click Application Resources and view additional applications information on the 3DP User web site www 3dpuser com 37 10 2 07 All Rights Reserved a BL Spectrum Z 510 3D Printer Hardware Manual Post Processing the Part 7 6 1 Using Paraplast X TRA Wax Paraplast X TRA is a low viscosity general purpose
44. ed hood e Use specialized containers recommended for dispensing and application A system for avoiding spills includes Catch pan waxed paper or plastic drop cloth www 3dpuser com 39 10 2 07 All Rights Reserved a BE Spectrum Z 510 3D Printer Hardware Manual Post Processing the Part Label disposal materials Wear dust mask when sanding finished parts Read the Material Safety Data Sheet for Z Max prior to the use of this material Mixing Instructions When using the 250 gm Z Max kit simply pour the entire contents of the Z Max Hardener container into the Z Max Resin container and mix the two parts thoroughly for two minutes prior to applica tion If less than 250 grams is desired follow the instructions for mixing by weight or volume Mix 100 parts Z Max Resin to 37 parts Z Max Hardener by weight or 100 parts Z Max Resin to 41 parts Z Max Hardener by volume Mix the two parts thoroughly for two minutes before application The material has a working time of 35 minutes in a 425 gram mass Please be aware of the gel time while preparing quantities of material as the gel time decreases as the quantity of material increases It is recommended not to mix quantities over 425 grams General Application Notes Material can be brushed or sprayed Material will penetrate between 0 079 0 28 inches 2 7 mm Material will pool off the part during curing if it is over applied Better penetration depth is achieved by applying
45. eeeseeeseeess 51 8 8 4 Cleaning the Fast Axis Rails and Bumpers cccceceeeeeeeeeeeeees 52 oT DIE PI esses set es atic teins csiac T deve sc a em So ape seats E E 53 8 10 Service Print Heads cccdadecccees ncseacdchecwasscedeeasdecndtdiened de ceuvedbaveteneedetuadordedone 57 S211 Prime Wash MNCs nore sce ncscmeumnccnsaennasdeaseradanne dectintseundseaesiedacadeecacekeeneuvaceieeds 57 8 12 Stripe Test asirctiec teenie gecesi tinct onert anass eran aesaadensueed danas aehapa se asepanceensaaeee 57 8 13 Cleaning the Spreader Roller Toggle Roller cccccecceceeeeeeeeeeees 57 8 14 Check Status ee en eee eee ee 58 8 15 Report Capabilities cccccccccecccsccceeeceeecseeeceeeeeeeceeeseeseeeseeeeaeeseaeens 58 8 16 Print Head REport cccccccccccccceeeceeeeeeeeseeeseeeseeeeeeeeeeeeseeeseeeseeeeaeeeaeeeges 59 CL VIEW PIner LOO sessie taco ents cosa a aa aE a a ea E NE 59 8 18 Other Service Menu ltemS cc cccccceecceeeceeeeeeeese esse eeseeseeeesaeeeaeeeees 59 8 19 Printer Storage Preparation ccccccceeccececeeceeeeaeeeeeeeseeeeseeeseeeseeeseeees 59 8 19 1 Replace Fluid Lines with Distilled Water cc cceccceeeeeeeeeeees 59 8 20 Best Practices for Powder Management ccccccseeeceeeeeeeeeeeeaeeeseeens 60 9 Troubleshooting noni daisies css acronis sestreacedi cetsnesaaue dedeiowieidddecussaunt sd udacdier diene tap eesedcd gageies 61 9 1 The binder solution is being a
46. es being printed the printer creates parts without support structures and will print parts with complex geometries that are impossible for other systems There are several important characteristics of the 3D Printer that will help you print the best parts for your intended purpose e Part Placement The software will place the parts within the build box to maximize build speed the most important criteria for the majority of our users The software positions the parts with the smallest dimension in the z vertical axis For more information refer to the ZPrint Software Man ual In addition to part placement the following other characteristics should be considered e Strength The ultimate strength of the part will be somewhat affected by its orientation within the print box The part will be strongest along the y axis and the x axis and less strong along the z axis This is because the cross sections are printed in continuous strips along the y or the fast www 3dpuser com 5 All Rights Reserved a BL 10 2 07 Spectrum Z 510 3D Printer Hardware Manual Introduction 10 2 07 www 3dpuser com 6 All Rights Reserved axis the print heads direction of travel bands across the x or the slow axis the gantry direction of travel and laminated layers along the z axis This discussion only applies to untreated parts once parts are infiltrated they uniformly take on the strength characteristics of the infiltrating mate ri
47. feed piston to drop te the bottom 3 5 Internal Printer Assembly and Service Station Components Heating Component m aes Ece Station Frinter Assembly Internal Components www 3dpuser com 8 10 2 07 All Rights Reserved a BL Spectrum Z 510 3D Printer Hardware Manual www 3dpuser com 10 2 07 Py Fluid Disconnect E Fast Axis Rails Mii ye Grease Fittings sM Slow Axis Rail W r Th Fast Axis Rail Grease Fitting Service Station 9 All Rights Reserved Slow Axis Rall R Carriage Cover Introduction a BL Spectrum Z 510 3D Printer Hardware Manual Introduction 3 6 ZD5 Powder Recycling System Depowdering Compartment vki ile ee Transition to Vacuum om Air Compressor Vacuurt Power Switch a peee Click ZD5 Depowder Unit to see the User Manual for this unit and other accessories available for your 3D_ Printers www 3dpuser com 10 10 2 07 All Rights Reserved e a BL Spectrum Z 510 3D Printer Hardware Manual 3 7 2510 Powders Accessories and Tools Introduction Refer to the following table regarding powder types available for use with the Z510 Printer Click Applica tions for additional information regarding high performance casting specialty materials and infiltrants Click MSDS to see information about material storage and safety precautions on the 3DP User Website NOTE Parts printed with High Perform
48. ignment Purge Print Heads Purge All Print Heads g Purge New Print Heads Check Powder Level Drop Feed Piston Purge All Print Heads will initiate a purge cycle for all print heads regardless of whether they are new or not Purge New Print Heads will initiate a purge cycle only for the new print heads 8 4 Check Powder Level Check Powder Level will see if the Z510 3D Printer currently has enough powder in the feed piston to complete the build currently active in ZPrint based on the feed pistons current position 8 5 Drop Feed Piston Drop Feed Piston will drop the feed piston to its lowest position so you can easily add additional powder or begin gross depowdering a printed part in the build envelope 8 6 Fill Bed Fill Bed initiates a cycle that will prepare the build envelope for printing by automatically spreading powder from the feed piston to the build piston 8 7 Preheat Printer Preheat Printer will activate the heater in the Z510 3D Printer and heat the build chamber to a predeter mined temperature based on the material being used While the build chamber is pre heating to the desired temperature the heat powers on and off for 2 5 minutes until the target temperature is reached 8 8 Maintenance The Maintenance dialog keeps a record of the distance travel by the Fast Axis Slow Axis and the Pistons The Maintenance dialog will open automatically when it is time to perform lubrication maintenance on
49. infiltration wax formulated to melt at very low temper atures 122 F or 50 C and strengthen parts This material cures rapidly and enhances the vibrancy of color parts Paraplast is available in a case of eight 2 2 Ib 1 kilogram bag of chips Paraplast X TRA Wax can be used in both the ZW3 and ZW4 Waxers Read the Paraplast X TRA Wax User Guide to learn more Safety Precautions e Liquid wax is hot and may cause burns Follow all manufacturer recommended safety precautions for your dip tank prior to use e Wear gloves when handling hot parts General Application Notes e Parts should be dried in an oven at 100 F 38 C prior to infiltrating with wax for deeper wax pen etration e If the part is bulky you may preheat it at 150 F 66 C for up to 30 minutes e Soak part in liquid wax tank follow all tank manufacturer s instructions e Remove infiltrated part from dip tank e Place part in an oven at 150 F 66 C until the wax has penetrated or melted off your part usu ally around 15 minutes e Be aware that these are simple guidelines Your specific applications may require additional steps Curing Information e Allow your parts to cool after removal from the oven until the part is no longer warm to the touch 7 6 2 Using Z Bond Cyanoacrylate Z Bond cyanoacrylate is an extremely fast setting low viscosity general purpose infiltration resin This resin is designed to rapidly strengthen parts Z Bond is a one p
50. ing Tools Use Instructions Service Form Documents to be com pleted and returned to Z Corp OAON Ooh WND Scraper 5 Wide Utility Brush Double Ended Brush 2 China Bristle Brush Acid Brush Toothbrush Style Scraper 3 Wide Utility No longer included in kit Extra Screws Syringe for cleaning Service Station Syringe Tube and Fitting Grease Gun Mini for 30z Cartridge Grease Silicone with PTFE 3oz Wash Bottle 8oz Lubriplate White Grease Syringe Luer Lock 20cc 10 Small Philips Screwdriver 11 Grease Gun Nozzle 12 L Hex Key Set e New Overflow Bin Cover minimizes airborne powder from the overflow bin during a build www 3dpuser com 10 2 07 13 All Rights Reserved a BL Spectrum Z 510 3D Printer Hardware Manual Introduction e New Vacuum Attachment fits the Z510 3D Printer vacuum hose and attaches to the side of the feed box to capture airborne powder when powder is being added to the feed box 3 9 ZPrint Software Installation The ZPrint Software is the file processing tool that sends information from the user s workstation to the 3D Printer Please refer to the ZPrint Software Manual for installation and use instructions www 3dpuser com 14 10 2 07 All Rights Reserved POT AT Spectrum Z 510 3D Printer Hardware Manual Quick Start Guide 4 Quick Start Guide This section is a short step by step process of how to get
51. l Routine Operations 5 Routine Operations The routine maintenance tasks described in this chapter should be performed before every build 5 1 Preparing the Build Area IMPORTANT Use only powder supplied by Z Corporation Use of any other material may impact the performance and or safety of your 3D Printer System and will void warranty of equip ment 1 Preheat printer if needed Preheating the printer will reduce the print time if the printer has not reached the required temperature To preheat the printer select the Preheat Printer option under the Service menu saaa Help Unpark Change Print Heads Auto Alignment Purge Print Heads Check Powder Level Drop Feed Piston Fill Bed Preheat Printer 2 Lower feed piston by pressing down on the Feed DOWN button until the feed piston automatically drops 4 Lift the top cover of the printer 5 Raise build piston by pressing Build UP Once build piston has stopped press Build UP once You will see Hold for Unload on the control panel www 3dpuser com 20 10 2 07 All Rights Reserved a BL Spectrum Z 510 3D Printer Hardware Manual Routine Operations 6 Hold the Build UP button until the build piston raises The build piston will expose the build plate hold ers 7 Place build plate on top of holders Make sure build plate is secure Press any button on the control panel to lower the build piston 8 Fill the feed box with
52. ly with OSHA regulations is the American Con ference of Governmental Industrial Hygienists Industrial Ventilation Manual At 160 F 71 C your part will reach full strength in 2 hours The part should be placed on a non stick material wax paper Teflon etc to prevent it from adhering to the surface it is sitting on while curing Wear gloves when handling the parts when they are still at an elevated temperature Parts will attain full strength and be safe to handle once they cool to room temperature The resin will cure at room temperature after 24 hours If the part has delicate features infiltrate them last as the feature will be less strong after being infiltrated until the epoxy begins to cure This will decrease the chance the feature will break from the part if nudged or bumped If the part has multiple delicate features or it is impossible to handle the part without breaking a feature you may infiltrate these features only Allow the Z Max to cure Then infiltrate the rest of the part This will add time to post processing the part but it ensures that you have a good strong part without any fractures Open the following links to learn about Casting Methods Electroplating Finite Element Analysis Functional Testing of Molded Plastic Parts www 3dpuser com 41 10 2 07 All Rights Reserved 3 a BL Spectrum Z 510 3D Printer Hardware Manual Post Processing the Part Creating High Finsh Color Parts Painting
53. nar surface of a part lies flat along the top of the build box the broad exposed area may dry unevenly and bow towards the top Reorient the part so that the thin planar surface lies perpendicular to the top of the build box e Ensure that you are not over drying the part Reduce drying time to a minimum Refer to Section 7 5 Drying the Part to ensure you allow enough drying time e Decreasing the layer thickness without proportionally changing the minimum and maximum satu rations will over saturate the part causing it to warp and may also cause individual layers to curl during printing 9 4 Nothing happens when I try to print e Is the network connection connected properly Remove the cord and carefully reinstall Reboot the Printer The LCD will display Spectrum Z510 when booting It will then display Use Serial if a network connection is not found To restore net work settings see Restoring Network and Firmware Settings in the Appendix e Are any of the lights on the control panel illuminated www 3dpuser com 61 10 2 07 All Rights Reserved a BL Spectrum Z 510 3D Printer Hardware Manual Troubleshooting If the control pad illuminates but nothing happens after that shut the machine off and turn it back on again The machine should come online But if it does not please contact your authorized Z Corporation Service Provider 9 5 Parts are unusually weak or crumbly e Is the data file known to be without errors
54. ngthen your printed parts and it has the lowest cost per in e Vivid Colors zp140 delivers the most vivid colors when infiltrated with Z Bond e Brightest Whites 180 whiter than zp130 Read the zp 140 MSDS Read the zp140 User Guide Z Cast 501 Direct Casting Powder Our zCast 501 Direct Casting Material can be used to create sand casting molds for non fer rous metals This material is a blend of foundry sand plaster and other additives that have been combined to provide strong molds with good sur face finish It is designed to withstand the heat required to cast non ferrous metals Read the z Cast MSDS Zp 15e Specialty Powder The zp15e Elastomeric Material has been opti mized for infiltration with an elastomer to create parts with rubber like properties Read the zp 15e MSDS The Z510 Accessories Kit and Tool Kit contain parts for user maintenance and items frequently used while post processing printed parts Accessories Kit Includes 12 Disposable Pour Spouts 38 400 Thread 1 32 oz Scoop 1 10 Ethernet Cable blue 1 CAT5e RJ45 Crossover Cable red and 1 Box of Nitrile Gloves 100 Count Large Not Pictured Powder Tamp ZPrint Software CD and trays www 3dpuser com 12 10 2 07 All Rights Reserved e a BL Spectrum Z 510 3D Printer Hardware Manual 3 8 New Accessories Available for 3D Printers To order contact Z Corporation Tool Kit Introduction Document 09523 Post Process
55. nst 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 If the customer has purchased all relevant casting specific products as recommended by Z Corp casting specific service contract hardware software and consumables as well as a casting license then the customer may also utilize the Equipment to fabricate molds for casting using new Z Corporation supplied consumables from Z Corporation or its authorized distributors in the original packaging 1 2 Manual Sections This Z510 3D Printer Hardware Manual will soeed you along the path towards quickly and inexpensively building parts The manual contains the following sections e What s New in the 3D Printer User Manual This section briefly describes the new updates and changes to the manual e Introduction This section will give you an overview of the principles behind the 3D Printer System familiarize you with the terminology we will use to describe the 3D Printer System and illustrate the dif ferent parts of the printer e Quick Start Guide This section contains a short step by step process of how to get a print job running on your printer For a more detailed explanation see Routine Operations Using the ZPrint Firmware and Software and Post Processing the Part e Routine Operations This section will guide you through putting powder binder solution and wash
56. nt it from adhering to the surface it is sitting on while curing e Wear gloves when handling the parts to avoid contact with uncured resin e Parts will attain full strength in two minutes Tips e Always infiltrate the most delicate features of the part first Z Bond resin gives almost immediate strength to the area of the part that has been infiltrated As you handle the areas of the part that have been infiltrated it will be less likely to break it e Try to avoid infiltrating the part by applying Z Bond resin from spot to spot Pick a good starting place hold that area upward relative to the rest of the part With your free hand place the tip of the Z Bond bottle against the part and allow the cyanoacrylate CA to flow from the bottle It is impor tant that the CA flows at a uniform rate making it easier for you the judge how quickly it will flow from the tip of the bottle before it wicks into the part By seeing how quickly it wicks into the part you will be able to judge where and how quickly to move the tip of the bottle while applying the CA being sure not to apply the CA to the same place more than once 7 6 3 Using Z Max Epoxy A Z Max Epoxy User Guide is also available on the 3DP User website For more information on the uses of Z Max epoxy please logon to our website Safety Precautions e Wear lab coat gloves we recommend PVC Examination Gloves face shield or goggles Face shield is required if spraying Apply in ventilat
57. on 29 Part Orientation 28 Part Placement 5 Part Strength 5 Parts Are Weak Or Crumbly 62 Parts Containing Overhangs 29 Piston Screws Lubrication 51 Place Printer Online 16 Polypropylene Scraper 32 Post processing Tools 32 Powder Recycling System Components 10 Powder Recycling System Image 7 Preheat Printer 20 Preheat Printer Command 47 Preparing The 3d Printer 15 Preparing The Build Area 20 Preparing The Build In Zprint Software 17 Prime Wash Line 57 Print Assembly 4 Print Dialog 30 Print Head Report 59 Print Head Report Dialog 43 Printer Assembly With Carriage Insert 9 Printer Components 7 Printer Control Panel 8 Printer Periodic Self Maintenance 16 Printer Storage Preparation 59 Printing The Build 30 Purge Print Head Command 43 Q Quick Start Guide 15 www 3dpuser com R Removing The Finished Part 34 Removing The Part 18 Replace Fluid Lines With Distilled Water 59 Report Capabilities 58 Restoring Network And Firmware Settings 68 Rinse Rubber Parking Cap 23 Rinse Rubber Wiper Blade 23 Roller 4 Routine Operations 20 S Saturation Troubleshooting 62 Serial Port Connection 66 Service Menu 43 Service Print Heads 57 Service Station 9 Slice View 30 Slow Axis Lubrication 50 Soft Acid Brush 33 Soft Horsehair Brush 33 Stiff Detailing Brush 33 Stiff Handle Brush 33 Stripe Test 57 System Components 7 System Specifications 66 T Tamp Powder
58. pplied in erratic Stripes ceeeeeeeeees 61 9 2 ZPrint Software freezes up during the print job ec eecceeeee eens eeees 61 9 3 Thin planar parts are warping ccccceseccceecceeeeeeecaeeeeeeeseeeseeeseeeseeeseeees 61 9 4 Nothing happens when try to Print cece ccceeeeeeeeeeeeseeeseeeseeeseeees 61 9 5 Parts are unusually weak or CrUMDIY ccccccceeeceeeeeeeeseeeeeeeeseeeseeeseeees 62 9 6 Printer looks like it is printing but is not laying down binder 62 9 7 Air has Entered the Binder Fluid Lines ccccccceccseeeceeeceeeceeeeeeeeaeeees 62 9 8 Air has Entered into the Wash Fluid Line ccecceccceeeeseeeeeeeeeeeeeeees 63 9 9 Communication Errors Between Print Head and Printer 00 64 10 3D Printer System Detalls 0 ccccccccseeeseeeceeeeeeeseeeseeeeeeeseeeseeseeseeeeaes 65 10 1 System SDSCHICATIONS wa c ccecrccncecstenccomese aceumelageocneivunicscewieibesadaansawandaastiecss 66 10 2 Symbols WSC Oats cee ets cceead Sees des ane setter ode ectniecd Seen benatseend ame seenieteatacaceeastees 66 10 3 Description of Rear Panel cccccccecccseeceececeeeseeeeeeseeeeeeeeeseeesaeesaeeeaes 67 11 91 gt 90 b Canna es nnn ee ane eee E E ee 68 11 1 Restoring Network and Firmware Settings cccccsecceeeeeeeeeeeeaeeeaes 68 11 2 Eror CodeS ae ee ee eee 70 www 3dpuser com ii 10 2 07 All Rights Reserved
59. rinter is Online Click 3D Printer to locate the latest version of firmware for your Z510 3D Printer on the 3DP User Web site or follow Step 1 Section 6 2 below Complete the procedure in 6 2 to install your firmware 6 2 Install Firmware from the 3DP User Website 1 Goto the 3DP User Website and log on From the homepage click on Products and then select the 3D Printer Drivers Software link Select your printer and scroll down the page until you see the Firm ware section Click on the Download Z510 3D Printer Firmware link Save the zipped file to a loca tion on your system 2 Unzip the file 3 From your ZPrint Software open the Service menu and select Upload New Firmware Browse to the V42 file location and select the file 4 When the installation has completed your system will need to reboot After rebooting open the Ser vice menu and select Check Status Check that the current firmware version number is listed and cor rect 6 3 Tips on Setting up the Build PLEASE NOTE lf the ZPrint Software has not been installed install the software Instructions are located in the ZPrint Software Manual e Do not tightly pack parts into the build Keep in mind that you will need to depowder and remove them from the build box Allowing a little bit of room around the part so you can vacuum the powder away and get your fingers around or under it www 3dpuser com 27 10 2 07 All Rights Reserved a BL Spec
60. s cable is supplied with your 3D Printer System if a replacement is required order Z Corporation part 10267 Diagnostic Connections Video and keyboard These connections are used while servicing your 3D Printer System Nothing should be connected to them in normal operation The diagnostic video connection is standard VGA output video The keyboard connection is PS 2 style compatible Ethernet Connection An Ethernet connection allows the printer to be network compatible For more information contact the Z Corporation Service Department at 781 852 5050 or via email at Service zcorp com www 3dpuser com 66 10 2 07 All Rights Reserved a BE Spectrum Z 510 3D Printer Hardware Manual 3D Printer System Details Material Storage Precautions Review the Material Safety Data Sheets MSDS carefully before using any Z Corporation materials Powder Store powder on pallets in a cool dry ventilated Use of powder in area away from sources of heat moisture and environments with incompatible materials Keep containers tightly more than 30 rela closed tive humidity will affect powder perfor mance Binder and Store in cool dry place away from sun Keep Binders and wash Wash Fluid tightly capped fluids are NOT RECYCLABLE Printheads Store in cool dry place away from sun Life expectancy depends on usage Infiltrants Store in cool dry place away from sun Keep For more informa tightly capped tion visit the 3
61. stilled water to prevent binder from coagulating in the lines Follow the procedure below to properly store the printer if you will not use it for more than two weeks 8 19 1 Replace Fluid Lines with Distilled Water 1 Remove binder from each bottle and place in its own airtight container You need a separate airtight container for each color 2 Rinse out each binder bottle 3 Fill each binder bottle halfway full with distilled water 4 Select Service gt Bleed Air in ZPrint 5 Open the Carriage cover and remove all of the print heads 6 Use the syringe and tubing found in Toolbox to draw water through each fluid line Draw fluid through each line until the line is clear minimum of 50 cc 7 Close the Carriage cover and the printer top cover 8 Click Cancel in the Bleed Air dialog to close www 3dpuser com 59 10 2 07 All Rights Reserved a BL Spectrum Z 510 3D Printer Hardware Manual Service Menu and Other Maintenance 8 20 Best Practices for Powder Management It is important to use best practices to maintain a clean working environment during the operation of your 3D printers A small amount of extra care to follow these practices can go a long way to keep your powder in your printer where it is most valuable to you Good powder management promotes a clean work environ ment and will keep your printer optimally running so you can be productive Z Corporation recommends all users go to the Z Corporation 3DP
62. t Purge Print Heads Check Powder Level Drop Feed Piston Fill Bed Preheat Printer Maintenance Bleed Air Service Print Heads Prime Wash Line Stripe Test Prime Wash Fluid Prime Wash Fluid ee eee eee eee o a o Un www 3dpuser com 10 2 07 Cancel 63 Press Start to begin priming the wash Fluid Start 4 The Prime Wash Fluid status box will close when priming is completed Cancel All Rights Reserved a BL Spectrum Z 510 3D Printer Hardware Manual Troubleshooting 9 9 Communication Errors Between Print Head and Printer In general clean the pogo pins whenever you replace or remove a printhead Doing this will greatly reduce errors in communication between the printhead and printer To clean the pogo pins follow these instruc tions 1 Get an alcohol swab Toolbox and remove it from its packaging Crush the plastic casing to release the alcohol into the swab 3 Open the carriage cover and remove the printhead 4 Wipe the pogo pins and reinsert the printhead 5 Close the carriage cover and repark the gantry www 3dpuser com 64 10 2 07 All Rights Reserved a BL Spectrum Z 510 3D Printer Hardware Manual 3D Printer System Details 10 3D Printer System Details 10 1 System Specifications Warning Check ratings marked on product BEFORE plugging into a power source Dedicated power outlet requirements 110 120 VAC 50 60Hz 6
63. to cause harmful interference in which case the user will be required to correct the interference at their own expense CENELEC Class A Warning This equipment has been tested and found to comply with the limits for a Class A digital device pursuant to EN 55022 Class A devices are for office and light industrial environments and are not generally suit able for home use WARNING This is a Class A product In a domestic environment this product may cause radio inter ference in which case the user may be required to take adequate measures www 3dpuser com 65 10 2 07 All Rights Reserved Spectrum Z 510 3D Printer Hardware Manual 3D Printer System Details 10 2 Symbols Used This is the international symbol for Warning or Caution It indicates the need to consult your manual for further information It is located on the rear lower left side of your printer to call your attention to the fact that only trained personnel should open the 3D Printer rear cover None of the normal operation proce dures described in this manual requires you to remove this cover 10 3 Description of Rear Panel Serial Port Connection This is an RS 232 serial port for data transfer to and from the ZPrint software The 3D Printer uses 115k baud and has the same pin out as a standard PC compatible computer The connection to the Windows computer running the software requires a 9 pin to 9 pin null modem cable also known as a laplink cable Thi
64. trum Z 510 3D Printer Hardware Manual Using the ZPrint Firmware and Software e Orient parts so delicate features are supported in the z axis i e keep the attaching feature directly below the fragile features If a delicate feature is only supported by unprinted powder the chances of breaking that small feature during depowdering is greatly increased e When building delicate parts use the Fixture function to cradle the part Raising the part 0 25 6 4 mm from the bottom of the build and creating a fixture under the part will produce a cradle that can be handled The part inside the cradle can easily be transported to an oven or the depowderer e Do not enable the bleed compensation feature if you are building a part with features under 0 050 1 27 mm Enabling bleed compensation may reduce the feature size e To increase the strength of thin parts you can decrease the layer thickness to 0 0035 0 089 mm if you are using high composite powder systems Choose to override the saturation values and input the saturation values used for printing at 0 004 0 102 mm This increases the binder to powder ratio and wets more of the resins in the powder system As you increase the strength of the part in this manner you are also increasing the amount of time to dry the part Oven drying the part is recommended 6 4 Open or Import the File s 1 Launch the ZPrint Software The Open dialog box appears ri gt Dero or at t EF m ot AD 2
65. urging is completed return to the Service menu and select Auto Alignment Unpark Change Print Heads Auto Alignment Purge Print Heads 13 The printer will print out an alignment pattern The first several layers will be gray based and then the color alignment pattern is printed 14 The last part of the color alignment pattern that is printed is a bulls eye pattern for you to confirm that all print heads are aligned A good alignment will look like the example below where the color does not overlap into the red circle If the alignment is not good try cleaning the sensor window again and re run the Auto Alignment If the pattern still fails call your local service provider Please Note You may wish to start a build while the print heads are aligning To do so click Cancel to close the Auto Align dialog The part builds on top of the alignment pattern If you choose to begin a build before the alignment is finished you will be unable to confirm the bulls eye pattern for proper print head alignment www 3dpuser com 46 10 2 07 All Rights Reserved e POT AT Spectrum Z 510 3D Printer Hardware Manual Service Menu and Other Maintenance 8 3 Purge Print Head Always purge a new print head immediately after replacing an expired print head When you initiate a purge cycle there are two options to choose from Purge All Print Heads and Purge New Print Head aii Help Unpark Change Print Heads Auto Al
66. ving the Palt ccccseccsseceseeceeeceeeseeeeeeesseeseeneneees 5 Routine Operati ns ereere EEA ATEENA AEE 5 1 Preparing the Build Area cccccccscccseeceeeeeeeeceeeseeesaeeeaees 5 2 Cleaning the Service Station cece cceccceeeceeeeeeeeeeeeseeeaees 5 3 Checking Fluid Levels cccccccscccsseceeeceeeeceeesaeeceueeeeeeaaes 6 Using the ZPrint Firmware and Software cccccccseeeseeeeeeeeees 6 1 Firmware OVErVvVieW cccccccccseccseeeceeeceeeceeeeseeeseeseeesaeeeaees 6 2 Install Firmware from the 3DP User Website 6 3 Tips on Setting up the Bulld ec ecccececeeeeeeeeeeeeeeeeaees 6 4 Open or Import the File S ccccccesseeeeeeeeeeseeeeeseeeeeseeeeees 6 5 Part Onlentatlon c cc0csieccesccednccuase lt essanenadectnenasdncddecdaensaenesenedencess 6 5 1 Parts Containing an Opening or Hollow Area 6 5 2 Parts Containing OverhangS cccccceseeeeeeeeeeeeeeeeees 6 6 Checking Build SettingS cccccccceccseceeeeeeeeeseeeseeeeeeeeaees 67 TOFINO the BS UNG ise ses onensincmtnnseascbnenactosindadsaakddecunieeeesiededeaancaee TY Post Processing the PAM chasse ceccecdcachcesencdcccnuccetadsanceneabsmctsmeoatenecesds 7 1 Tips on Gross and Fine Depowdering ccceeceeeeeeeeeees 7 2 Post Processing TOOIS ccccscccscceseeseeeceeeeeeeeeeeeseeeseeeeaees 7 3 Removing the Finished Part
67. wder settings for the build are correct The soft ware settings are the recommended values If the settings need to be changed select Override Press OK to confirm For more information on how to change these settings please refer to the ZPrint Software Manual 6 7 Printing the Build It is strongly recommended that the build settings be confirmed before printing To check build settings choose 3D Print Setup on the File menu or click on the icon located on the taskbar After all build settings have been confirmed 3D Choose 3D Print on the File menu or click the icon on the Toolbar 1 2 Adialog box will appear asking that powder and fluid levels be checked Check off the boxes to con firm that these have been inspected before beginning the build 3 Once the build has begun a dialog box will appear reporting the status of the build www 3dpuser com 30 10 2 07 All Rights Reserved a BL Spectrum Z 510 3D Printer Hardware Manual Using the ZPrint Firmware and Software www 3dpuser com 31 10 2 07 All Rights Reserved Pee AT Spectrum Z 510 3D Printer Hardware Manual Post Processing the Part 7 Post Processing the Part 7 1 Tips on Gross and Fine Depowdering e For additional information regarding post processing click Applications to go to the 3DP User web site or Knowledge Base to use our searchable knowledge base on the website e Become familiar with where the parts are placed

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