780 - 09914 ZPrinter 650 Installation Manual Rev B PDF

09914
ZPrinter 650 Installation Manual

Rev B
Description:
This procedure describes how to install a ZPrinter 650 at a customer site. This procedure is
intended to be performed by an installer trained to install the ZPrinter 650.
Prerequisites:
Installer/trainer must have been trained by Z Corporation in proper installation methods

and practices.
ZPrinter 650 must be at the customers facility.
Customer must have any necessary site prep completed. This includes any power,
network, partitions or other work.
The customer must designate a computer that will be used to run ZPrint software and
control the Z650.
It is suggested the customer set up a specific work area for using the Z650 typically this
would include a table or two, the computer workstation, and shelves for supplies and
printed parts.
Equipment / Parts Required:
ZPrinter 650 and its accompanying Starter Kit, Accessories Kit, etc.
Dealer tool kit
Heavy duty wire cutters to remove the metal straps
9/16 Hex socket to remove the fasteners on the pallet
Scissors to remove the shrink wrap
Phillips screwdriver for removing panels
T-Handle Hex Driver (Supplied) to release the lockout screws on the feeder
Procedure:
The high level process is as shown below. More details are provided in the sections that follow.
1
2
3
4
5
Uncrate and Inspect the Printer

Move Into Location
Unpack and Inspect Accessories and Supplies
Inspect Interior of Machine
Remove Shipping Restraints
09914 ZPrinter 650 Installation Manual Rev B.docx
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Lubricate the Slow Axis

Connect to Power and Network
Load With Fluids
Check Fast Axis Alignment
Install Carbon Filter
Bleed Binder Lines
Install Print Heads
Prime the Cleaning Solution Line
Load Powder
Install Software
Tune Feeder Output
Check the Fill Bed Function
Align the Printheads
Replace All Covers
Setup 650 for First Customer Build
Making Electronic Connections with ZCorp.
Complete Required Paperwork
Overview
Installation of the Z650 is a two-day process.
Day 1
Day 2
The installer uncrates, inspects, and sets up the printer.

The customer observes while the installer explains and operates the machine.
The customer checks the printer and starts their first build.
The following training points should be covered:
o Point out key modules of the 650 to the customer (pictures in Quick Start Guide).
o Discuss the Fast Axis Assembly.
o Discuss the purpose of the Service Station and Parking Caps.
o Identify the Electronics Box and the power switch.
o Point out that the vacuum hose may be unplugged and used to clean the build bed.
o Demonstrate how to check and clean the printer for a build.
o Describe the steps in post-processing; demo the tray, air wand, and filter.
o Teach the customer how to use ZPrint, ZEdit and ZEdit Pro. Be sure to register ZEdit
Pro.
o Walk the customer through getting a part into ZPrint and ready to print.
o Monitor file upload and software manipulation
o Monitor printer preparation
o Help the customer as they print a part and perform the post-processing steps.
Explain how to do it and why.
o Reinforce the steps in checking and cleaning the printer prior to and after each build.
The customer completes their first build, and completes post-processing of their part.
The installer observes the customer, being sure to talk the customer through all of their
actions.
The installer reinforces with the customer the critical importance of proper cleaning and
maintenance procedures.
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The following training points should be covered:

o Help the customer and explain how and why as they print a part and perform the
post-processing steps.
o Review customer removing part
o Monitor rough and fine de-powdering techniques
o Ensure that the part is handled carefully to ensure survivability
o Monitor infiltration application methods
o Review customer preparing another build
o Explain the Maintenance Screen feature within the ZPrint service menu
o Show how to assemble the grease gun.
o Demo the lubrication of the build piston screw using grease gun.
o Demo the use of the grease gun on the Slow Axis fitting.
o Demo the use of the oil on the Fast Axis fitting.
The installer completes the necessary paperwork to record the installation.
Installer Notes
It is important to make the customer feel at ease using the machine. While
demonstrating, tell the customer why you do things and why you do them that way. By
the end of the installation, the customer should have done everything in the printing
process by himself or herself.
Keep in mind that the customer has things they need to accomplish during their day.
They will need to take breaks at certain points during the training. So be sure to talk with
the customer about this and have a plan for lunch and other breaks.
Encourage the customer to ask questions. Let them know they can interrupt you at any
point. If you dont know an answer to a question, dont panic. Let them know you can get
the answer with a call back to the office.
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1 Uncrate and Inspect the Printer

1.1 Uncrate
The ZPrinter 650 is shipped on a wooden pallet with a cardboard cover. Uncrating consists of
removing the cover and rolling the machine off the pallet.
1. Position the crate where there is room to attach the ramps and roll out the machine.
CHECK DIAGRAM dimensions are guesses

87
61
82 minimum
2. Remove the shipping straps and lift off the top cardboard cover.
3. Pull out the foam blocks at the four corners and front of machine.
4. Detach the removable side of the wooden frame (9/16 socket).
Crate
Ramp
5. Detach the ramps and position as
shown (9/16 socket). Z650
6. Cut the large zip-ties that attach the machine to the pallet.
7. Carefully roll the machine downRamp
the ramps.
1.
2.
Open the flap on the end of the box and

remove the Power Cord and any shipping
documents.
Cut the metal strapping and lift off the top cover
of the crate.
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3.
Remove the 8 clamps that tie the corners of the

crate together. A flat blade screw driver may be
useful for lifting the clamp.
5.
Remove the three foam pads from the front of

the printer.
4.
Lift away all four sides of the crate and remove

the two foam blocks that protect the rear of the
printer.
6.
Remove the end brackets at both ends of the

printer by pulling up evenly.
7.
8.
Using a 9/16 socket or wrench, remove the

ramps from either side of the pallet.
Attach the ramps to the end of the pallet as

shown.
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9.
10.
Locate the two hold-down brackets under the

printer.
Unbolt the hold-downs and unhook them from

the eye bolts on the printer.
11.
12.
Carefully roll the printer down the ramps. It is

recommended to use two people, one in front
of the printer to slow its descent and another to
steer the wheels down the ramps.
Remove all shrink wrap and bubble wrap from

the printer.
1.2 Inspect Exterior of Machine

Visually inspect the exterior of the machine for any damage incurred during shipping. Notify Z
Corporation Service immediately if anything is evident at this point. DO NOT proceed with the
installation until you have discussed the damage with Service.
2 Move Into Location
Work with the customer to determine the best location for the machine, considering such factors
as ease of access and proximity to the necessary connections.
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2.1 Check Access

Before moving the printer, check the access to the work location. Any corners, doorways, etc.
must be large enough to maneuver the printer through.
Z650
6 min.
6 min.
If the access is too restricted to allow the printer to pass through, the Post-Processing Unit (PPU)
will have to be separated from the printer so the printer and PPU can be moved separately. When
they are in their final location, they can be re-attached.
The separation and attachment are simple procedures, taking only a few minutes. The
procedures are described in Appendix 1 Separating and Attaching the PPU.
2.2 Moving the Printer

Roll the machine to its final location.
Roll along carefully. Go slowly over bumps such as floor expansion joints. Get help when going
down or up ramps.
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3 Unpack and Inspect Accessories and Supplies

3.1 Accessories Kit
The Accessories are packed in a series of foam trays, inside the Post-Processing Storage
compartment.
Check that all items are present and undamaged.

Assemble the plastic tip onto the squeeze bottle.
Attach the tip to the air wand.
Store the Accessories in the door pockets provided. Suggested locations are shown.
Refer to the photos below.
Tray 1
Tray 2
Tray 3
Tray 4
Part
Trays
Tray 1
Tray 2
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Tray 3
Plastic tip installed
Tray 4
Wand tip installed

Quick Start Guide
Small Syringe & Needles
Water Bottle
Oil
Printheads
Alcohol Swabs
Large Syringe
Needle & Tubing Assembly
Pick
Hex Wrench
Printer Door
Grease Gun
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Vacuum Attachments - Near Vacuum Hose

Brushes - Brush Tray in PPU
Accessory Tray PPU Door

Dipping Kit & Part Trays PPU
3.2 Starter Kit

Unpack the Starter kit. Check that all items are present and undamaged. Place everything neatly
in a location convenient to the machine.
Contents of Starter Kit
Item
Packaging
ZCorp. Part No.
Quantity in Kit
Zp131 Powder
8 kg cartridge
50307
7
Zb61 Binder
---
---
---
Clear
1 L cartridge
06971
Black
1 L cartridge
50333
Cyan
300 mL cartridge
50332
Magenta
300 mL cartridge
50331
Yellow
300 mL cartridge
50330
1 L cartridge
50315
HP 11 Print Head
each
Carbon Filter
each
15254
31593
Waste Tray
each
50065
Alcohol Swabs
each
12073
20
Dipping Kit
each
50301
Zc6 Cleaning Solution
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Inspect Interior of Machine
Before powering up the machine, remove the covers and make an internal inspection.
4.1 Remove Covers

1. Locate the 9 screws on the back cover on the
printer side of the machine.
2. Remove 4 screws each on the right and left edges
of the cover. Leave the top center screw in place.
3. Holding the cover against the machine, remove
the top center screw.
4. Tilt the cover back towards you. Remove the cover

by lifting it out of the two slots.
5. Remove the side cover by pulling straight outward

to disengage the spring detents. Pull first at the
top, then pull out at the bottom.
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6. Remove the top cover by lifting the back edge and

sliding the cover toward the rear of the machine.
Then lift it off.
4.2 Inspect Tip and Tell

Check the tip and tell indicator, located near the binder reservoirs in the rear of the printer.
Blue beads above the indicator line means that the system
has been mishandled. Call Z Corporation Service Dept.
immediately if blue beads are above the line. DO NOT
proceed with the installation until you have discussed this
with Service.
4.3 Inspect E-Box Connections

Tilt out the Electronics Box (E-Box) and check that all connections are secure.
1. Unscrew the four screws shown from the E-Box.
2. Tilt the E-Box out toward you.
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3. Check all cable connections at the E Box. Make

sure they are all seated securely.
4. Replace the E-Box in position and reinstall all 4

screws.
4.4 Inspect Rest of Interior

Make a general inspection of the rest of the interior of the machine. Look for any tubing, vacuum
lines, connectors, etc. that may have become dislodged during shipping.
Leave all the covers off until the installation process is complete.
5 Remove Shipping Restraints

5.1 Unlock the Feeder
The Feeder is secured against movement and damage during shipping by four lockout screws.
These screws hold the feeder up off the load cell that monitors its weight. Releasing the feeder
consists of screwing these lockouts in, thus lowering the feeder onto the load cell.
1. Locate the screws, two on each side of the Feeder.
2. Using the 5/32 T-handle wrench (located inside the rear cover of the printer), turn each
lockout screw clockwise as far as it will go.
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5.2 Free the Fast Axis

To free the Fast Axis, carefully remove the cardboard and foam shipping restraints. First lift out
the section in the Build Bed, then slide the Fast Axis toward you and slide the restraints out from
under the Fast Axis. Support the Fast Axis as you do this.
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6 Lubricate the Slow Axis

Before the printer is run, perform the lubrication as described below.
NOTE: Do NOT lubricate the Fast Axis during installation. It was fully lubricated at the
factory. ONLY add oil when ZPrint prompts you to as part of routine maintenance. Too
much oil will damage the printer.
1. Locate the round plastic cover on the Deck to the left of the Build Bed, near the Service
Station.
2. Take a flat head screwdriver or a Pick Tool and pop the round cover off. Be careful not to
scratch the deck surface.
An alternative method is to reach your fingers under the left side of the deck and pop the
cover off from underneath.
3. Pull the Fast Axis forward until you see that hole in the center of the opening on the Fast
Axis. You should see the Slow Axis bearing grease fitting inside the hole.
4. Assemble the grease gun that is part of your Accessories Kit according to the instructions
found in the document 09576 Grease Gun Loading Instructions, which is supplied in the
materials that accompany the printer.
5. Squeeze the handle until grease dispenses from the tip. Wipe clean with a clean paper towel.
6. Place the tip of the grease gun over the grease fitting.
Squeeze the trigger 2 - 3 times or until you feel the
tension change and then STOP. Do not over-grease.
7. Slide the Fast Axis forward and back several times to
distribute the grease evenly.
8. Replace the plastic cover.
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Connect to Power and Network
7.1 Power
Note to Installer
Most facilities have one breaker for 5 or 6 outlets. It is best to not share the circuit that the
ZPrinter 650 is using with other equipment. Sharing the circuit with other equipment might exceed
the Wattage of the supplying circuit breaker and cause it to trip.
1. Install Power Cord.
2. Connect power cord to AC Mains outlet.
Power Switch
Power Cord
Network
Connection
7.2 Connect/Configure Network

Turn system on and wait for the Installation menu to appear.
Follow the instructions and complete each task before selecting CONTINUE.
Notes to Installer
ALL NETWORK CONNECTIONS MUST BE APPROVED BY THE CUSTOMER OR

CUSTOMERS IT MANAGER PRIOR TO INSTALLATION.
If at all possible set up the default connections:
o ZPrinter 650 connected to Ethernet network running DHCP.
o Dedicated computer connected to same network.
If the customer wants one of the following configurations, refer to the document 08605
Setting Ethernet Connections To Z Corporation 3D Printers, available on our Website:
zcentral.zcorp.com .
o Printer connected through a hub or switch with uplink to network.
o Printer connected directly to PC (requires crossover cable).
o Printer connected directly to PC (requires crossover cable); PC has second network
card installed (allows connection to network).
INSTALLATION MODE
RJ-45 Ethernet
Connector
CONTINUE
CONNECT PRINTER TO
NETWORK WITH ETHERNET
CABLE
CONTINUE
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USE AUTOMATIC (DHCP)

NETWORK SETUP?
YES
NO
YES (Default)
Continue to next step.
NO
Please refer to the document
08605 Setting Ethernet Connections to Z
Corporation 3D Printers for static IP address setup
instructions. This document is available on our web
site: zcentral.zcorp.com.
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8 Load With Fluids

8.1 Install Waste Tray
The Waste Tray contains absorbent material to soak up ink, binder, and wash fluid. A load cell
monitors its weight to detect when the tray is full and needs replacing.
NOTE: Always use the correct ZCorp. Waste Tray (part # 50065). Not using the correct
Waste Tray can lead to spillage of waste and/or damage to your printer.
1. Locate the Waste Tray in the Accessories Kit.
2. Slide the Tray into its compartment on the printer.
INSERT WASTE TRAY
CONTINUE
8.2 Load 1st Set of Fluids

1. Locate the fluid cartridges in the Startup Kit.
2. Slide each cartridge into its pocket on the printer.
3. Wait 5 minutes for the cartridges to drain, then select CONTINUE.
INSERT FLUID
CARTRIDGES (SET 1)
CLEAR, BLACK,
CMY AND CLEAN
CONTINUE
Clear
Black
The system is shipped with the internal fluid

reservoirs empty. It takes multiple cartridges to fill
each reservoir.
CMY
Wash
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8.3 Install Debris Separator

INSTALL DEBRIS
SEPARATOR FROM
ACCESSORIES KIT
CONTINUE
8.4 Load 2nd set of fluids

1. Remove all 6 fluid cartridges.
2. Slide a fresh cartridge into each pocket on the printer.
REMOVE ALL EMPTY

CARTRIDGES
CONTINUE
Clear
Black
INSERT FLUID
CARTRIDGES (SET 2)
CLEAR, BLACK,
CMY AND CLEAN
CONTINUE
CMY
Clean
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8.5 Load Final Set of Fluids

1. Remove all fluid cartridges EXCEPT the black (5 total).
2. Slide a fresh cartridge into each of the 5 pockets on the printer.
LOADING OF BLACK
BINDER IS COMPLETE
Only two cartridges are needed to fill the black

reservoir. All other reservoirs will require a third
cartridge.
CONTINUE
REMOVE EMPTY
CLEAR
CMY AND CLEAN
CARTRIDGES
CONTINUE
Do not remove the Black Cartridge
Clear
INSERT FLUID
CARTRIDGES (SET 3)
CLEAR
CMY AND CLEAN
CONTINUE
CMY
Clean
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8.6 Install Spit Plate and

Parking Caps
1. Locate the Spit Plate and Parking Caps. They will be taped
to the Build Plate.
2. Install the Spit Plate on the Service Station as shown.
3. Slide the Carriage to the left and install the parking

caps on the Parking Spittoon as shown.
INSTALL SPIT PLATE AND

PARKING CAPS
CONTINUE
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9 Check Fast Axis Alignment

Check the Fast Axis module to be sure it is not twisted. A twisted Fast Axis can cause incomplete
filling of the build bed (short spreading) and other problems.
1. Pull the Fast Axis out to about the middle of the Build
Bed.
2. At each end of the Fast Axis, press down on the front
and rear corners as shown by the arrows. The end of
the Fast Axis should not rock back and forth. (The
bottom of the Fast Axis should contact the shaft at
both ends with no free play.)
3. If free play is detected, grasp the end plate and
untwist the fast axis so that it sits flat on the shaft.
10 Install Carbon Filter
1. Unlatch the Post-Processing Tray and lower it to the

bottom of the Post-Processing Unit.
2. Press the button to unlatch the Carbon Filter retainer
and lower the retainer.
3. Install the Carbon filter with the label at the top
and facing out at you.
4. Make sure the two tabs on the retainer are properly
seated in their slots below the filter.
5. Lift the retainer into position and latch it closed.
INSTALL CARBON FILTER

FROM ACCESSORIES KIT
CONTINUE
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11 Bleed Binder Lines

1. Open the Print Head Cover on top of the Carriage.
2. Visually locate the 5 Septa (small circular ports).
3. Find the Needle Tubing Assembly that is part of the
Accessories Kit.
4. Place the open end of the tubing in the Service Station
as shown.
5. Press the Print Head fitting over the first Septum so that
the needle in the fitting penetrates the rubber membrane
of the Septum.
6. Observe the fluid running through the tubing. Let it drain
until no more bubbles are visible (approx. 30 seconds).
7. Remove the needle from the Septum, leaving the end of
the tubing in the Service Station.
8. Insert the needle in the next Septum.
9. Repeat the process for all 5 Septa.
10. Close the Carriage Cover.
Septum
These steps are necessary only during installation and are not required as part of future head
changes.
INSTALL COMPLETE
ADD POWDER
AND PRINTHEADS AFTER
PRINTER REBOOTS
REBOOT
PRINTER REBOOTS
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12 Install Print Heads

1. On the LCD, select PRINTHEADS, then CHANGE
PRINTHEADS.
2. Remove the protective tape, and Install the HP11 Print

heads.
3. Check that the Heads are properly seated by pushing
gently on the front edge of the head (the edge
without the arrow). Close the Head cover and select
CONTINUE.
DEPOWDER
PREP BUILD CHAMBER
STATUS REPORT
PRINTHEADS
BUILD CHAMBER
MAIN MENU
CHANGE PRINTHEADS
ALIGN PRINTHEADS
PURGE PRINTHEADS
INSERT NEW HEADS AND

PRESS CONTINUE
CONTINUE
CANCEL
13 Prime the Cleaning Solution Line

VACUUM
DEPOWDER
PREP BUILD CHAMBER
STATUS REPORT
PRINTHEADS
Enable the Service Menu by selecting

STATUS REPORT
and holding in the control knob for 5 seconds
SERVICE MENU ENABLED
CONTINUE
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PRINTHEADS
BUILD CHAMBER
SERVICE MENU
POST PROCESS MENU

GO ONLINE
Select
SERVICE MENU
SERVICE HEADS
TEST HEADS
PRIME CLEAN SOLN
CALIBRATE WASTE
STRIPE TEST
MAIN MENU
UNPARK
TOGGLE ROLLER
EMPTY FRONT OVERFLOW
EMPTY REAR OVERFLOW
EMPTY FEEDER
Select
PRIME CLEAN SOLN
Wait for the automatic priming sequence to

complete.
Then scroll up to the top of the service menu and
select
MAIN MENU
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14 Load Powder
We suggest loading 4 cartridges of powder now to allow you to complete the installation process.
More powder can be added later when the customer needs to run a large build.
NOTES:
The LCD display will not update and show powder levels until after the first 1-2
cartridges are loaded. This is normal. The first cartridge primes the feeder and
the second starts to supply usable powder.
Four cartridges of powder will yield about 5 inches of powder in the feeder.
It takes a total of approximately 6.5 cartridges of powder to fill the feeder.
1. Invert and shake the Powder Cartridge

before opening to help loosen powder
that may have packed down during shipping.
2. Set the Powder Cartridge in the PPU.
3. Remove the gray sealing cap.
4. Insert the hose into the Powder Cartridge.
5. On the LCD, select VACUUM; the vacuum starts.
6. Observe the Debris Separator if powder is

loading into the printer, you will see powder
swirling in the Separator.
7. Shake the Cartridge frequently to keep powder
flowing.
8. The vacuum will automatically shut off when powder
stops flowing into the feeder
VACUUM
DEPOWDER
PREP BUILD CHAMBER
STATUS REPORT
PRINTHEADS
VACUUM STARTING
VACUUM ON
AVAILABLE POWDER: 0.0
Note that you may have to load two complete

cartridges before the powder level on the LCD will
start reading. This is normal and does not indicate a
problem with the Load Cell.
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th
9. Repeat the steps above with 3 more new Cartridges. When the 4 Cartridge is empty, select
GO ONLINE. Four cartridges of powder will yield about 5 inches of powder in the
feeder.
NOTE: In day to day operation, make sure that the build bed and overflows are empty
before adding powder. Otherwise when this powder is recovered, the system could be overfilled and the vacuum will not work.
Always use the STATUS REPORT function to check the actual powder level.
15 Install Software
Install the ZPrint/ZEdit software. Refer to Chapter 1 of the ZPrint User Manual.
Notes to Installer
The customer MUST have administrator privileges on the computer the where software
will be installed on AND the computer must meet or exceed the specifications stated in
the ZPrinter 650 Hardware Manual.
Dont forget to disable any screen savers on the desktop computer. Disable all power
saving settings. (Some computers ship with a 30 minute time-out on the disc drives. This
will stop a print job after 30 minutes.)
ZEdit Pro
If the customer has also purchased ZEdit Pro, install that now.
Note to Installer
Make sure you complete the licensing process to activate this copy of ZEdit Pro. Refer to the
installation paperwork that was shipped with the printer, or consult the ZEdit Pro online User
Manual.
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16 Tune Feeder Output
After loading the powder and binder cartridges, run the TUNE FEEDER CONTROL before
starting a job. This automatic adjustment will run for about 20 - 30 minutes. During this time
the feeder will spread multiple layers of powder while monitoring the output of the feeders load
cell. It will calculate the weight of the powder that has been spread and fine tune the load cell
feedback loop for maximum accuracy of powder feeding. This is required only once during
installation (or if installing a new feeder).
VACUUM
DEPOWDER
PREP BUILD CHAMBER
STATUS REPORT
Select
PREP BUILD CHAMBER
PRINTHEADS
PRINTHEADS
BUILD CHAMBER
The Build Bed rises into position.
Select
SERVICE MENU
POST PROCESS MENU

GO ONLINE
SERVICE MENU
REZERO SERVOS
REZERO PISTON
REZERO AIRVALVE
REZERO FILTER
TUNE FEEDER CONTROL
Select
TUNE FEEDER CONTROL
TUNE FEEDER CONTROL

FEEDER CAL VALUES
WASTE CAL VALUES
NETWORK SETTINGS
REBOOT
Wait for the Tune Feeder routine to complete, then

select
REBOOT
Note to installer: Be sure to reboot the printer to
hide the Service Menu. This will prevent any
potential problems from the customer accessing
Service functions.
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17 Check the Fill Bed Function
Check that the automated FILL BED function is executing enough spreads to completely fill the
Build Bed. If not, edit the [.ini] file to ensure the bed completely fills.
1. Vacuum out all powder from the Build Bed.
2. On the LCD, select PREP BUILD CHAMBER.
3. On the LCD, select BUILD CHAMBER, then FILL BED.
4. Watch the printer and note if it completely fills the bed.
Example of good Fill Bed
FILL_BED_SPREADS set too low
If the Bed is completely filled, vacuum the build bed. You are ready to help the customer
start their first build.
If the Bed is NOT completely filled, you will need to edit the printers .ini file.
o In the ZPrint menu bar, select Service then Edit .INI file.
o In the .ini file, set the variable FILL_BED_SPREADS to a higher number. We
recommend increasing it by 5. The range of input for this variable is 15 to 30.
o Click SAVE AS to save the .ini file. Use the original file name.
o The printer will automatically reboot after the change to the .ini file.
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When the reboot is complete, repeat the steps above beginning with Step 1 (vacuum the Bed).
Again note if the bed fills completely.
If it does, you are done; help the customer set up for their first build.
If it does not, repeat editing the .ini file and use a higher number. Then repeat these steps
until the Bed fills completely.
If using a value of 30 does not fill the bed, there may be something wrong with the Feeder.
Contact ZCorp. Service to resolve the problem.
18 Align the Printheads
As the final step in the installation, align the print heads for best accuracy.
1. Vacuum out all powder from the Build Bed.
2. On the LCD, select PREP BUILD CHAMBER.
3. On the LCD, select FILL BED.
4. On the LCD, select PRINTHEADS.
5. On the LCD, select ALIGN PRINTHEADS.
The printer now prints and scans an alignment pattern.

The printer will automatically adjust its printing
parameters to optimize accuracy.
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19 Replace All Covers

1. Replace the top cover by sliding its front edge into
position and then lowering the back edge into
position. Make sure the screw holes line up.
2. Replace the side cover by aligning the pegs with

the spring detent holes, then pushing straight in
until the pegs snap into place.
Note: Replacing the screws in the following steps

is easiest if you install each screw a few turns,
and then tighten them after all screws are in place.
3. Engage the lower edge of the rear cover with the slots on
the machine. Tilt the cover up into position.
4. Hold the rear cover against the machine so the screw holes
in the top and rear covers are properly aligned.
5. Replace the top center screw.
6. Replace the other two screws along the top edge of the
cover, again aligning the screw holes in the top and rear
covers.
7. Replace the remaining 3 screws on each end of the rear
cover.
8. Tighten all screws securely.
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20 Setup 650 for First Customer Build

Review and demonstrate the printer menus
Go through menu structures on the system LCD panel.

Show the customer the Status Report screens on the LCD panel and explain what
each line means.
Review and demonstrate ZPrint
Set-up the color blocks build in ZPrint.

Click on 3D Setup and walk the customer through the options.
Click on 3D Print and explain the functions of the status dialog box.
Start the print job.
Demonstrate the real-time update of the status dialog. Point out that the LCD system
display shows up in ZPrint.
Explain the pre-build routine (fill bed, purge print heads, print head alignment, spread
layer, and print job).
Discuss post build steps
Demo the gross and fine de-powdering techniques for powder removal.
Demo the infiltration of the part.
Prep the 650 for the next build
Discuss importance of the cleanliness techniques.

Demo cleaning the Service Station and Parking Caps.
Demo overall machine cleaning tips.
Teach the ZPrint and ZEdit Software
Discuss in detail all ZPrint and ZEdit Software menu features and options.
Highlight all features that may pertain to the customers specific applications.
If possible, have the customer set up a build to run overnight.

Note to installer: Review the Overview Section on page 2 and be sure youve covered all the
training topics. Doing a good job now will save time and service calls later!
32/40
21 Making Electronic Connections with ZCorp.

Familiarize the user with the user web site (zcentral.zcorp.com). At a minimum make sure they
know:
Where to download Firmware and Software
Where the MSDSs are located
How to order consumables through Z Shop
Where to find the User Training Modules
How to register for the Message Board
Introduce the customer to applications@zcorp.com for any non-service related technical support.
22 Complete Required Paperwork

Complete and Return the required Service Installation forms to the Z Corporation Service
Department for customer tracking purposes:
Customer Acceptance & Training Form (#09953)

Installation Review Form (#09954)
33/40
Appendix 1 Separating and Attaching the PPU
The steps below are taken from ZCorp. Procedure # 85033 PPU Separation Attachment. The
steps are reproduced here for the convenience of the installer.
For the latest updates on this procedure, check our website: zcentral.zcorp.com.
Procedure:
SEPARATION
Turn the system power switch

OFF and unplug the power
cord from the system.
Remove the 12 Phillips screws
from Post Processing Unit
(PPU) rear cover.
Set cover aside.
A large hex wrench is clipped

inside the rear of the PPU.
This will be used for removing
the bolts that attach the PPU
to the Printer Unit.
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Remove the connectors from

the bottom of the support.
Note- Molex connectors have
locks that must be depressed
before pulling the connector
out.
Loosen the hose clamp and

remove vacuum hose. Move
the hose over to the base of
the main system for safe
keeping.
Reaching in from the rear of

the PPU, remove the two
shoulder screws (one toward
top and the other toward
bottom). Save the screws.
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Open the door at the front of

the PPU and find the access
hole. Remove the shoulder
screw and save the screw.
Pull the PPU away from the

system. Notice the alignment
pin that is used to re-attach the
PPU.
36/40
ATTACHMENT
To attach the PPU to the

system, first push the PPU
toward the system until the
alignment pin (shown in
previous step) mates with the
hole. Make sure the PPU is
pushed tightly against the
system and insert one of the
shoulder screws. It is a good
idea to get all screws started
before tightening the screws.
Re-attach the vacuum hose

and tighten the clamp.
Re-attach the two Molex
connectors.
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Make sure the vacuum hose

and wiring are secure and
install the rear PPU panel (12
screws).
Plug in the power cord and
switch the system on.
38/40
Change History
Rev A ECN 2574 RAB/BWH 10/22/2008

Rev B ECN 2647 RAB/BWH 1/12/2009
Notices
Copyright and Trademarks
Copyright Z Corporation 1995-2009. All rights reserved. The information in this document may
not be duplicated or transmitted in any way without the express written consent of Z Corporation.
The information contained herein is for the use of Z Corporation customers, who are permitted to
create brief excerpts for the purposes of training and review. This information may not be
incorporated in any commercial programs, books, databases, or in any kind of software without
the consent of Z Corporation.
Z, Z Corporation, zp, zb, ZMap, ZPhoto, Z-Cure, Z Prints, ZPrinter, ZCast, ZScanner, ZScan and
the Z Corp. logo and design are pending/registered trademarks of Z Corporation.
ZPrint 7.8 System Software Copyright (c) 1996-2009 Z Corporation. This software is based in
part on the work of the Independent JPEG Group.
PNG library libpng version 1.2.2 Copyright (c) 1998-2002 Glenn Randers-Pehrson, (Version 0.96
Copyright (c) 1996, 1997 Andreas Dilger), (Version 0.88 Copyright (c) 1995, 1996 Guy Eric
Schalnat, Group 42, Inc.)
ZLIB general purpose compression library version 1.1.4, Copyright (C) 1995-2002 Jean-loup
Gailly and Mark Adler.
Microsoft Windows is a trademark of Microsoft Corporation.
Z Corporation acknowledges the trademarks of other organizations for their respective products
or services mentioned in this documentation.
Proprietary Information
Information contained in this document is the confidential property of Z Corporation. Recipient
shall not disclose such Information to any third party, and shall not use it for any purpose
whatsoever other than what is required to install and use the ZPrinter 650.
Use of Equipment
Z Corporation's Equipment, and use of the Equipment, may be subject to limitations imposed
under patents licensed to or owned by Z Corp., and is to be used solely for the fabrication of
appearance models and prototypes using new Z Corporation-supplied consumables from Z
Corporation or its authorized distributors in the original packaging. Other uses may be restricted;
contact Z Corporation for further information. Consult the User's Manual before operation of any Z
Corporation Equipment. The Equipment may be covered by the following U.S. Patents and/or
U.S. Patent Applications:
5,204,055
5,340,656
5,387,380
6,007,318
6,375,874
5,902,441
6,416,850
6,610,429
6,403,002
5,660,621
5,851,465
6,397,922
6,036,777
6,989,115
7,037,382
7,291,002
7,387,359
7,087,109
7,332,537
11/335,282
11/860,087
60/558,940
12/118,899
11/000,100
11/606,960
60/808,721
11/807,325
11/807,329
11/807,175
11/807,237
09/706,350
09/835,292
11/453,695
60/472,221
60/499,220
11/732,490
60/879,703
11/952,727
12/035,743.
39/40
The Equipment is designed to be used by design engineers and other professionals in the
production of early-stage 3D appearance models and prototypes. The Equipment is not to be
used to produce, either directly or indirectly, medical or other products that may require precise
dimensions or tolerances to ensure the safe and effective operation of such products. You agree
to indemnify, defend and hold Z Corporation and its officers, directors and employees harmless
from and against any and all claims, losses, damages, costs and expenses resulting from any
use of the Equipment other than for the production of early-stage appearance models and
prototypes.
Warranty
Your ZPrinter is guaranteed to be free of defects in materials and workmanship, when used for
production of early-stage appearance models and prototypes and with Z Corporation
consumables, for the period described below under WARRANTY PERIOD. All consumables and
materials are guaranteed to perform as described in their specifications when stored and used as
directed, up to the expiry date printed on the label. THE COMPANY MAKES NO WARRANTIES,
EXPRESS OR IMPLIED, AND DISCLAIMS ALL WARRANTIES INCLUDING, BUT NOT LIMITED
TO, IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE AND ANY OTHER OBLIGATIONS OR LIABILITIES WHETHER IN CONTRACT,
WARRANTY, NEGLIGENCE OR OTHERWISE. THE COMPANY IS NOT LIABLE FOR ANY
DIRECT, INDIRECT, SPECIAL, PUNITIVE, CONSEQUENTIAL OR INCIDENTAL DAMAGES
INCLUDING, WITHOUT LIMITATION, DAMAGES FOR LOSS OF BUSINESS PROFITS OR
BUSINESS INTERRUPTION ARISING OUT OF THE USE OR INABILITY TO USE PRODUCTS
OR SERVICES SOLD HEREUNDER. IN NO EVENT WILL THE COMPANY'S LIABILITY
EXCEED THE TOTAL CHARGE OF THIS Z ZPRINTER 650.
WARRANTY PERIOD: In the U.S., warranty is for 90 days and covers service, parts and training
material. In the EU, warranty is for 1 year and covers service, parts and training material.
Symbols
The following symbols are used on the ZPrinter 650 and in this manual.
General Caution: User should use care to avoid possible damage to
equipment.
Hot Surface: User should use care when working near or on the labeled
item.
High Voltage: User should use appropriate electrical safety precautions.
40/40

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09914

ZPrinter 650 Installation Manual

Installer/trainer must have been trained by Z Corporation in proper installation methods

Equipment / Parts Required:

Uncrate and Inspect the Printer

09914 ZPrinter 650 Installation Manual Rev B.docx

Lubricate the Slow Axis

Installation of the Z650 is a two-day process.

The installer uncrates, inspects, and sets up the printer.

09914 ZPrinter 650 Installation Manual Rev B.docx

The following training points should be covered:

The installer completes the necessary paperwork to record the installation.

09914 ZPrinter 650 Installation Manual Rev B.docx

1 Uncrate and Inspect the Printer

CHECK DIAGRAM dimensions are guesses

Open the flap on the end of the box and

09914 ZPrinter 650 Installation Manual Rev B.docx

Remove the 8 clamps that tie the corners of the

Remove the three foam pads from the front of

Lift away all four sides of the crate and remove

Remove the end brackets at both ends of the

Using a 9/16 socket or wrench, remove the

Attach the ramps to the end of the pallet as

09914 ZPrinter 650 Installation Manual Rev B.docx

Locate the two hold-down brackets under the

Unbolt the hold-downs and unhook them from

Carefully roll the printer down the ramps. It is

Remove all shrink wrap and bubble wrap from

1.2 Inspect Exterior of Machine

2 Move Into Location

09914 ZPrinter 650 Installation Manual Rev B.docx

2.1 Check Access

2.2 Moving the Printer

09914 ZPrinter 650 Installation Manual Rev B.docx

3 Unpack and Inspect Accessories and Supplies

Check that all items are present and undamaged.

Refer to the photos below.

09914 ZPrinter 650 Installation Manual Rev B.docx

Plastic tip installed

Wand tip installed

09914 ZPrinter 650 Installation Manual Rev B.docx

Vacuum Attachments - Near Vacuum Hose

Accessory Tray PPU Door

3.2 Starter Kit

Zc6 Cleaning Solution

09914 ZPrinter 650 Installation Manual Rev B.docx

Inspect Interior of Machine

4.1 Remove Covers

4. Tilt the cover back towards you. Remove the cover

5. Remove the side cover by pulling straight outward

09914 ZPrinter 650 Installation Manual Rev B.docx

6. Remove the top cover by lifting the back edge and

4.2 Inspect Tip and Tell

4.3 Inspect E-Box Connections

2. Tilt the E-Box out toward you.

09914 ZPrinter 650 Installation Manual Rev B.docx

3. Check all cable connections at the E Box. Make

4. Replace the E-Box in position and reinstall all 4

4.4 Inspect Rest of Interior

5 Remove Shipping Restraints

09914 ZPrinter 650 Installation Manual Rev B.docx

5.2 Free the Fast Axis