My AMUG 2016 slide references for Color-Jet Printer (ZPrinter) users or those looking to start using CJP. Includes tips & tricks, DIY machine maintenance, materials vendor options, cost saving techniques and how to package fragile models for shipping.

1. ProJet x60 Color-Jet Printer Best Practices:
Maintenance, Trouble-shooting & Post-processing
AMUG 2016 Saint Louis
John Lee
JohnLee@Alumni.Rice.Edu

2. Disclaimer
All instructions and recommendations expressed in the presentation are my
own. Neither my employer ABC Imaging of Washington, Inc. nor any other
business entity including 3D Systems Corporation is in any way associated
with this presentation.
Liability
Service, disassemble, use and repair your machines at your own risk. I
assume no responsibility for any damage or injuries resulting from the use of
the information contained in this presentation.
Scope
This collection of information and know-how is intended to compliment and
add to the standard user manuals. It assumes knowledge of CJP standard
operating procedures.

3. DIY Machine Servicing
• Not difficult for those who are mechanically inclined.
• No special tools needed.
• Decrease operating costs and machine down-time.
• Parts-only contracts are possible.
• If not in heavy use, you might save money not being on
contract and buying spares as needed.
• Hard copy instructions are usually included with spares
from the 3DS support department.
• Some dealers may also share the service docs with users.

4. Secret Menus
Activate the Service Menu:
Toggle to Status Report, hold down button for several seconds
until “Service Menu Enabled” displays. Now on the main menu,
Service Menu will be the last option at bottom. (Needs to be
done again if machine is rebooted.)
Boot up in Diagnostic Mode:
Flip power switch in back and keep holding down the button.
Handy when removing padding/bracing under gantry after
moving the unit. Let’s you boot without having the gantry servo
motors re-zero. Networking options are here too.

5. “Z-Monitor”
Plug VGA monitor & keyboard into the electronics box
to see additional info from what the log file & error
messages contain. Also able to edit the .ini file here
as well as through 3DPrint software.

6. Troubleshooting Guides
Officially only dealers can have access to the service
docs. But some primary docs are available online.
Just do a web search for:
“Zprinter 650 Troubleshooting Guide”
“Zprinter 450 Troubleshooting Guide”
A South Korean company has posted links to
download the PDFs. (You didn’t get them from me.)

7. Error Codes
Movement errors like 2303 are followed by (0) for slow axis
(front to back) or (1) for fast axis (right-left).
Head errors are sometimes followed by a number in ()
indicating which head numbered 0 to 4 from right to left in
the carriage.
0=clear, 1=black, 2=yellow, 3=magenta, 4=cyan
In the Troubleshooting Guide, for most errors there is a
chart showing a sequence of steps to follow. They usually
start off with a simple cleaning, then maybe putting in a new
head and then escalate into replacing spare parts.
Some codes are related to others so also use search terms
seen on machine display or associated with the displayed
error code to find other possible steps to try under similar
error code charts in the Guide.

8. A PDF is also available for downloading along with these slides.
It is a check list of the several tasks that should be
done before or after every build cycle. Following this
routine religiously will save you from a lot of
problems. In particular, we clean the roller bar before
every build and the scraper blade weekly.
We laminated this checklist and posted near the CJP’s
as a reminder.

9. Rebranding of Machine Line-Up
There are no differences between the ZPrinter x50’s and the
ProJet x60’s. Just a different paint job.
ProJet 860 Pro is same as ZPrinter 850. (released 2010)
ProJet 660 Pro is same as ZPrinter 650. (released late 2008)
ProJet 460 Plus is the same as ZPrinter 450. (released 2007)
Etc. for smaller 260/260, 160/150.

10. 860 is essentially an elongated version of the 660 but
without the integrated Post Processing Unit.
“Premium Color” -Five HP11 print heads jetting clear, CMYK binder.
460 & 260
“Block Color” – Two heads: One HP11 for clear binder and uses the actual
ink from an HP 57 Tri-Color head.
460 & 660 have integrated PPU’s which doesn’t allow you to print and de-
powder at the same time.
Most error codes are the same across the machine line-up.

11. Rebranding of Consumables
zb63 binders are exactly the same as VisiJet PXL binders.
zp151 powder is the same as VisiJet PXL Core.
They can be used interchangeably. You may just need to break off
plastic keys on some binder cartridges. There was a slight price
difference in 2015 between the two brandings.

12. Don’t toss out liter cartridges without breaking them open. There can be up to $50
worth of binder remaining. Use clean funnel to pour into another cartridge bladder
to load into the unit. Take care not to contaminate binder system. Also don’t mix
up Clear Binder with Cleaning Solution since they are both clear and the only labels
are on the outer cartridge wrapper which you’ve cut off.

13. Alternative Powder & Binder
www.Noble3DPrinters.com (Las Vegas)
• “Vjett PXL” powder & binders. Lower cost.
• Has anyone tried it? Give feedback to AMUG.
• We may test it in one of our older Z450’s.
• Powder is 80 – 90% Plaster of Paris with smaller
amounts of vinyl, starch and other secret additives.

14. Alternative Vendors-Misc. Supplies
Print heads: Buy from Office Depot/OfficeMax, etc. Not from 3DS dealers.
Don’t buy the alcohol crush swabs for $5/each. Q-tips & rubbing alcohol
are much cheaper. Just take care not to rub the pogos too roughly & shred
the cotton tip leaving fibers on the pogos.
No need to use distilled water to clean the service station. Tap water in
most localities is okay.

15. Alternative Vendors: Low-Odor CA Glue
Thinnest viscosity (5cps) cyano-acylate glue is the basic spec. Big price difference
between Low-Odor and High-Odor.
The main CA glue we use for infiltration:
“L5 Low-Odor” from CA Plus Adhesives, Inc. ca-plus.com ($60 per 16 oz. bottle.)
Has long cure time of approx. 2 minutes that allows plenty of time to wipe up the
excess and achieve very good even finishes.
Don’t buy in larger containers since it starts degrading from the humidity once you
open. Write date of receipt on bottle and use “first in, first out” on your stock.
Beware the ink on the bottle label can bleed onto your glue-covered gloves and
could transfer onto your models. Cover the labels with tape.

16. High-Odor CA Glue
Fumes are very irritating but not toxic. Need to wear full face respirator to use it
for regular infiltration. We use it mainly for spot-gluing parts together and for
infiltrating very simple-shaped parts that you can quickly wipe off before it cures in
less than 7 seconds.
SureHold.com
#102 High-Odor Glue $15 per 16 oz. bottle.
Beware they will try hard to upsell their low-odor version which isn’t as
good as CA Plus L5. (It cures more quickly and has slightly higher odor.)
Pro-Tech Supply (S. Calif.) is another source.
CA Accelerator (spray cans) is useful when bonding parts.

17. Epoxy – highest strength CJP infiltrate
3DS StrengthMax – Mix in ratio of 5 parts Resin to 2 parts Hardener for two
minutes. Don’t use the pump dispensers included. Better to use a measuring cup
with milliliters markings. That makes it easier to reseal and store in air tight bags
and there’s less waste. Lasts up to a couple of years in storage.
Alternative lower cost similar epoxy: AeroMarine Resin #300 with Hardener #21
Pot-life working time is shorter than with StrengthMax (40 minutes).

18. Known Issues – Color
Color matching and consistency is not even close to the level of document printing.
• “Premium Color” 660 & 860 cannot make bright white models. The powder
supply turns slightly grayish, off-white. This is due to the combination of the
automated powder handling system and multiple print heads jetting colored
CMYK binder. Micro-droplets of the CMYK binder circulate in the closed powder
handling system which colors the powder supply slightly grayish.
• Darker colors will shift tone on different surfaces of the part especially on more
vertical walls.
• “Block Color” 460 & 260 often have streaking or even crap out entirely during
build cycles.

19. Known Issues – Color
For the graying powder supply problem, 3DS used to offer a kit to
change a 660 or 860 permanently into a monochrome-only
machine. (There was also the release of an ineffective air filter
addition to the front overflow funnels).

20. Prep for Moving
• Separate PPU from Printer if not already. (see other slide)
• Remove binder cartridges and cleaning solution cartridge.
• Remove waste tray.
• Lock-out powder feeder. (powder can be left in)
• Secure gantry with foam. Raise build piston for good fit.
(Boot in Diagnostic Mode to prevent gantry servo motors re-
zeroing when re-installing the unit.
• Remove debris filter and spittoon plate from service station.
• For securing to wall of a truck, there are loops on the
bottom and straps can go around mid-section.
• Custom crates with ramp are available.

21. Prep for Moving: Feeder lock-out
• Hex tool in holder on left.
• Alternately turn each of 4 screws only a few rotations at a
time so the feeder doesn’t get too tilted. Feeder will be
lifted completely off of load cell scale when screws are at
fullest extent.

22. Keep printer and post-processing unit separate.
Allows reach into chassis to check if overflow funnels
and hoses are clogged. Tool to remove the three bolts
is included in the bottom of the PPU.
Installation
CJP should be in
dedicated room due
to the dust emitted.

23. Keep back panel
off.
Allows for access to binder tubes
and easier access to powder
feeder.
Use scrap peg board to secure
left side of top panel. (see
Removable Build Plate slides
ahead)
Shop vacuum cleaner
recommended for non-recyclable
dust and debris.
It’s okay to turn-off the unit for
up to a week at a time. This
saves consumables since the unit
will service the heads every few
hours when idle.
Installation

24. Removing Side Panel for Servicing
Two sets of pins that go into plastic fittings. Pull out on the bottom
first. Can be stubborn to remove. No need to remove the front
panel except to replace the LED display. Beware ribbon cable.

25. Rotary valve can be controlled by Service Menu. Periodically check and
tighten metal band ties at ends of hoses.
Powder System

26. Often after transporting a unit with powder loaded, the
powder will have been compacted by the vibrations and
feeder motor errors will occur. It is necessary to reach
down into the bottom of the feeder to loosen it. The tillers
at the bottom are dull and won’t cut your hand. Metal tools
might damage the tillers. And running “Fluidize Powder”
from the Service Menu can be tried before this dirty manual
unclogging.
Powder System
Z450 empty feeder

27. Clogs can occur in the front and rear overflow funnels. That can
kill a tall build cycle making a terrible mess on the deck, rails and
bottom of the print heads. After each cycle we do a visual check
into the front overflows using a flash light and using a wire coat
hanger to dislodge any clogs. For the rear overflow, reach into
the chassis and gently tug on the hose from the funnel to feel if
it is clogged.
Powder System

28. Low vacuum suction can be caused by clog in perforated
diffusor bar in feeder. It just sits in slots in the walls. Easy
to access: 2 cover clamps, 1 electrical latch connector,
four screws. Take care not to drop screws into the feeder.
They will eventually jam the tillers.
Powder System

29. If you’re desperately low of
powder and can’t start a
build, putting a small weight
on top of the feeder towards
the back side can make the
load cell read a higher level
of powder.
Likely this would work if
you’re only about ½” to 1”
too short for the powder
level your build requires.
(After about 5 hours into a
long build cycle, it will pause
and empty the overflow
funnels so the unit is unlikely
to run out of powder before
finishing the remainder of
the build.)
Powder System

30. Float switches in
binder tanks:
Are mounted too high giving
“low” readings when there’s
plenty of binder left.
Fail frequently. Whole new tank
is replaced.
Machine won’t run if any of the
float switches in any of the
binder tanks or cleaning solution
tank reads the fluid level as low.
Binder System
Tanks can suffer bacterial
growth which causes
reduced flow or blockage.
(overtemp errors)
Flush with diluted bleach or
order 3DS sanitation kit.

31. Hot-wire the
binder tanks
Useful when desperately out of
stock of binder or cleaning
solution. Or if the installed tank’s
float switch is giving a false read.
Remove the float switch from a
used or new spare tank and plug
it in in place of the troublesome
one.
Or a simple spliced wire can be
used.
Binder System

32. Replacing leaky
septum's
Need hemostat clamp. (Harbor Freight
tools)
Pick tool to pull out clip.
Plastic washers on both sides.
Replacing tubing isn’t difficult either.
You need to cut the tubing to 5 different
lengths referencing removed tubing.
Note how Clear+CMYK lines cross over
and under each other.
Binder System

33. Waste System
Tubing that connects to pipe that drips to the waste tray can
get clogged. Scrap FDM filament is handy to unblock them.

34. Reuse waste trays.
Pour down drain. Add back in some water so it has
enough weight to make the load cell not read that the
tray is missing. No need to buy & stock new ones.

35. Most frequently
replaced parts
Orange carriage flex gets abraded
from rubbing against the tubing
thousands of times.
Another frequent part failure is
the Pogo Printed Circuit board
that connects to the flex cable.
Stocking these parts is wise to
avoid machine downtime.
Location of light
diode & sensor.

36. Replacing Carriage Flex Cable
Fast Axis doesn’t have to be removed. Tilt back cover and
brace with padding. If replacing the Pogo PCB, it might take a
few minutes to align the sheath and carriage cable before you
can get the carriage cover into position.
Stuff paper towels over the width of the overflow funnel
grating so that you don’t drop screws into it.

37. Replacing FA & SA Belts
Straight forward for both belts. Spring tensioner is compressed and locked into
place with one of the two hex bolts. Use pick tool to clean pulley teeth and
motor bearing teeth while the belt is removed.

38. Beware loose fit
on cleaning
solution pump.
Whenever removing and putting
back the service station, note
there are two black O-rings that
need to be seated well. It is
common for people to screw the
service station back in place
without the O-rings being seated
and pushed down enough. This
will result in cleaning solution
leaking down onto the waste tray
load cell wires causing a “tray
missing” error.
To test the seal, run Prime
Cleaning Solution from Service
Menu and look to see the
foaming solution around the
squeegee.

39. Removing Fast Axis Assembly
Remove heads and keep track of when color binder they’re filled with.
Rubber-band paper towels around end of binder tubing. Several simple straight
forward electrical connectors plus grounding wire.

40. Removing Fast Axis Assembly
On right side, detach parking cap with waste tubing. Note spring tensioner on
back side needs to be released. And note path of tubing between two rail pads.

41. It mounts onto slow axis bracket with 3 large hex screws. Note two
alignment pins. When the FA is removed, it’s a good time to check
if snow plows are worn and to clean print carriage thoroughly.
Removing Fast Axis Assembly

42. Festoon Cable
Loops down in chassis and
follows movement of the slow
axis. Also wears out periodically.
Needs to be pushed into metal
brackets at three locations where
it is bundled with black sheaths.

43. Removing the Electronics Box
E-Box can tilt back & stay in place while you
detach 13 connectors. They are all different
shapes and sizes so you can’t confuse them when
reconnecting. Only the gray ribbon cable to the
powder feeder can be plugged in upside down.
The notched side faces up.
Fuse protrudes through bottom.

44. Electronics Box
mother board
inverter
PC104
Old type
Flash
drive
Power

45. Newer and older type Mother Boards.
Handle boards by edges & touch bare metal to discharge any static you might have.
Electronics Box
Narrow ribbon cable
connects here
Older type

46. Protective Gear
Clothes & shoes should be covered
when infiltrating. CA glue stains
will not come off of them.
Mapa Trilites 994 gloves/
Uline nitrile gloves (Use baby
powder to dry hands for easier fit.)
Full face respirator when infiltrating
with high-odor CA. Multiple gases
cartridge filter.
When de-powdering:
3M 8211 foam seal respirator
goggles

47. Turn off
automated gross
de-powdering
3DPrint->Preferences->Print
(uncheck “Empty build piston…”)
The vibrations of the build piston
can damage fragile parts and
parts that are nested near each
other can collide.
Not very effective in the first
place.

48. Removable build
plate cut from
peg board.
(See 3DS tech note 1832.)
Less than $10.00/set including
cutting at Lowe’s/Home Depot.

49. Flexible tubing can be handy to vacuum interior
through narrow openings.

50. Slide removable plate onto thin rigid gator board for best
support while de-powdering large or very fragile parts.

51. Thinner air wand
needle lures
Switch to thinner longer needles
for detailed parts. Okay to touch
the models with them to reach
corners and recesses. They
bend.
23 gauge, 1.5” length
McMaster.com

52. De-powdering large fragile hollow models
without breakage requires some creative
gator board fixtures and props.

53. For better color, towards the end of the de-powdering step, dry-brush or
lightly sand colored surfaces. Then air gun away the resulting colored
powder outside of the PPU so as not to contaminate the powder supply.

54. CA Glue
Infiltration
Get a few different sizes of
plastic bins. Don’t use the larger
bins for small parts since the
larger surface area of the bin will
mean more glue is wasted when
you recover and re-bottle it.
For most parts we douse/pour
over the glue. Get two waves of
glue over all exterior surfaces in
order to saturate it and achieve a
uniform finish.
Work bench should be well lit.

55. CA Glue
Infiltration
Good low odor CA glue will allow
a full two minutes or so before
curing completely. So place
infiltrated parts onto wax paper
lined with paper towels at first.
After most of the excess glue
bleeds off, place onto fresh areas
of wax paper and move it around
every minute or so to avoid
sticking.
Good idea to have fans blowing
over the work area so fumes are
dissipated.

56. CA Glue
Infiltration
Use thin pick tool to crease paper
towels into corners where glue
run off will pool or into recessed
details. Avoid wiping or rubbing
fine surface details since they are
still very weak until the glue
cures. Just lightly touch the
paper towels to fine thin
elements.

57. Secondary wax
coating
Bake models at 160 degrees C.
Need to be warm/hot to the
touch before basting in the hot
wax.
Despatch is a good reliable make
of lab oven.
Toaster oven could be used for
small parts instead.

58. Hot waxing metal bin on burner
No need to completely submerge model. Just a shallow pool and metal ladle are enough to
baste all surfaces of the part. (Wax is just a coating over the glued surface and doesn’t
penetrate the part.) We had sheet metal shop make the perfect sized bin. It sits on regular
double burner ($50) set on low-medium. Paraplast Xtra low temperature wax is cheap.

59. Wax excess is
wicked off
Put back into oven for around 10
minutes on cardboard lined with
paper towel. Rotate if the part
details and geometry permit.
Use pick tool to crease paper
towel into corners and recesses
where wax can pool.

60. Print Head Management
• It is okay to push a print head over its standard expected life of 1000 ml for clear, 500 ml
for CMYK by about 200 ml if you’re not running a large critical build cycle. When
replacing one head, replace others at the same time if there’s less than 10% life
remaining.
• When replacing the clear head, the purge cycle will not remove all the black ink from it.
So you’ll get gray streaking on the bottom of your monochrome white or light colored
parts. Have it jet a purge block of 15”x10”x17 layers right on top of the alignment
pattern. But you don’t need to do this if running dark colored parts.
• If having over temp problems, if the head report says max temp > 90, then that head is
shot and has to be replaced.

61. Recycling
HP11 $2.00/each Staples Rewards
HP57 $3.00/each ecyclegroup.com
Binder cartridge shells #6 polystyrene
recyclable in some communities.

62. How to package Color-Jet Printed architectural models with flat bottoms.
Simple-shaped, robustly designed Color-Jet printed models and
most FDM ABS plastic models usually don’t require this packaging
technique. Regular bubble-wrap may suffice in those cases.

63. Making the Packaging Tray

80. Multiple small models can be put onto the same tray base. If they don’t have
any fragile side details, you might arrange them with their sides touching and
then put bumpers around the group of them. But they need bumpers between
them too if there are any thin details on their side walls.
Short models under about 2” height can be shrink wrapped to trays and stacked
in the same box if you put a good amount of Excelsior fiber between them.

81. Excelsior wood fiber vendor:
Vendor is in the Purchasing system. Stark Co. was acquired by S. Walter
Packaging. So Purchasing might still have it under Stark name, but I think they
updated to S. Walter.
http://www.swalter.com/catalogsearch/result/?q=88509732
$54.97 approx. 72 lb. bale #88509732
You also need storage bins for the bale of wood fiber. One bale fits into two
bins.
http://www.uline.com/Product/Detail/S-7900/Drums/Fiber-Drum-55-
Gallon?keywords=S-7900
Pair of 55 gallon drums, stackable
S-7900, Qty. 2 drums

82. Used AM Systems Broker/Dealer
Warren Hill
Commonwealth Trading Co., Inc.
P. O. Box 22709
Hilton Head Island, SC 29925
(843) 342-9208
CommonwealthTrading@hargray.com
www.commonwealth-trading.com
We haven’t done any deals with him yet, but have been in correspondence for
over 8 years.

83. Questions/Problems/Solutions to share?
CJP online forums?
Our downtown Washington, DC shop near Dupont Circle Metro & Georgetown
welcomes visitors. 1919 M Street N.W.
JohnLee@Alumni.Rice.Edu