Required supplies:
Formlabs:
- Replacement Z motor and drive assembly (RP-FS1-ZMTR-01)
Third-party:
- 2 mm hex driver (flat-end)
- 2.5 mm hex driver (flat-end)
- 3 mm hex driver (flat-end)
- 6.5 mm slotted screwdriver
- Safety glasses
- Nitrile gloves
WHITE PAPER
Replacing the Fuse 1 generation Z motor and drive assembly
Replacing the Fuse 1 generation Z motor and drive assembly
Fuse 1 generation printers use a gear and motor mounted at the back of the print enclosure to interact with the build chamber and drive the print bed up and down. A faulty or malfunctioning Z motor or drive will prevent the printer from moving the print bed and printing correctly.
Use this guide to replace the Z motor and drive assembly in a Fuse 1 generation printer.
Estimated time: 30–45 minutes
Danger:
Read and follow all safety instructions and warnings in the operator manual. Replacement with incorrect parts can lead to burns, shock, fire, or explosion. Dispose of all parts in accordance with local regulations.
Warning:
Do not perform this procedure if the printer was printing less than six hours prior. Failure to do so may result in serious burns. Allow the print enclosure to cool to room temperature before touching or inspecting any Fuse 1 components.
Preparing the workspace
Overview: Prepare the printer and a dust-free workspace for replacing the Z motor and drive assembly.
Notice:
Fuse 1 generation printers contain sensitive electronic components. Ground yourself before touching any electronics in the printer by using a grounding strap or touching a grounded piece of metal.
Step 1: Prepare the workspace
Clear a workspace around your printer. Ensure that the workspace is well-ventilated and free of dust.
Step 2: Unplug the printer
Disconnect the power cable before continuing with maintenance. Do not perform maintenance on the printer while it is connected to power. Wait five minutes after disconnecting the printer from power before proceeding.
Danger:
Performing maintenance on the printer while it is plugged in increases the risk of electric shock. Never remove the back panel of the printer while the printer is plugged in. Never reconnect the printer to power while the back panel is uninstalled.
Step 3: Remove the Wi-Fi antenna
Unscrew and remove the Wi-Fi antenna, if it is connected.
Step 4: Disconnect the nitrogen source (Fuse 1+ 30W only)
Disconnect the nitrogen hose from the quick-disconnect fitting, if connected.
Removing the rear panels
Overview: Remove the rear panels to access the interior of the printer.
Step 1: Remove the lower rear panel screws
The six black lower rear panel screws are circled in red. The four chrome lower rear panel grounding screws are circled in blue.
Using a 2.5 mm hex driver, remove the six black panel screws and the four chrome panel grounding screws securing the lower rear panel to the printer. Set the screws aside, taking care to separate the black and chrome screws for later reinstallation.
Step 2: Remove the lower rear panel from the printer
Pull the lower rear panel straight back and away from the printer. Lay it down on a flat, clean surface.
Step 3: Locate the exhaust duct and ring clamp
Locate the ring clamp attached to the exhaust duct in the center of the printer.
Step 4: Loosen the ring clamp screw
Using a 6.5 mm flathead screwdriver, loosen the ring clamp screw. Do not remove the screw. Pull the exhaust duct away from the exhaust pipe.
Step 5: Locate the exhaust inlet
Open the filter cabinet door on the printer. Locate the exhaust inlet on the right side of the cabinet.
Step 6: Remove the exhaust inlet screws
Using a 2.0 mm hex driver, remove the four screws attaching the exhaust inlet to the filter cabinet. Set the screws aside.
Step 7: Remove the upper rear panel screws
The two black upper rear panel screws are circled in red. The two chrome upper rear panel grounding screws are circled in blue.
Using a 2.5 mm hex driver, remove the two black panel screws and two chrome panel grounding screws securing the upper rear panel to the printer. Set the screws aside, taking care to separate the black and chrome screws for later reinstallation.
Step 8: Remove the upper rear panel screws
Using a 2.5 mm hex driver, remove the eight screws securing the upper rear panel to the printer:
- Two 6 mm screws on the buffer side of the printer
- Four 6 mm screws on the top of the printer
- Two 6 mm screws on the hopper side of the printer
Set the screws aside.
Step 9: Remove the upper rear panel
Pull the upper rear panel straight back and away from the printer. Lay it down on a flat, clean surface.
Removing the Z motor
Overview: Disconnect and remove the original Z motor before removing the Z drive from the print enclosure.
Step 1: Locate the Z motor
With the rear panels removed, there are four motors visible at the back of the printer. From left to right, when looking at the back of the printer, they are the doser motor, hopper-side flipper motor, Z motor (circled in red here), and buffer-side flipper motor. Locate the Z motor.
Step 2: Disconnect the motor and encoder cables
Disconnect the encoder cable by depressing the white tab and pulling the connector housing away from the socket. Disconnect the motor cable by gripping the white housing and pulling it away from the socket.
Step 3: Prepare the Z drive coupling (Fuse 1 only)
The Z motor is mounted to a plate. Look behind the motor, between the plate and adjacent insulation panel, and locate the Z drive couping. If the coupling resembles the pictures here, continue. Otherwise, skip to step 4.
Rotate the Z drive coupling by hand so that the screw closest to the insulation panel is visible. Using a 2 mm hex driver with a flat end, loosen but do not remove the set screw. Do not use a ball-end hex driver, as it will strip the screw.
Apply a small piece of tape to the coupling such that both black ends are connected to the plastic disk in between. This will ensure the disk will not be dropped and get lost.
Step 4: Remove the Z motor
Using a 3 mm hex driver, loosen and remove the four 10 mm M4 socket head screws securing the Z motor to the printer. Set the screws aside. Remove the Z motor and set it aside for disposal with electronic waste.
Removing the Z drive
Overview: After removing the Z motor, remove the corresponding Z drive inside the print enclosure.
Step 1: Locate the Z drive
Open the filter cabinet door, then manually open the print enclosure door by pulling the blue release handle. Locate the Z drive, positioned on the back wall of the print enclosure.
Step 2: Remove the Z drive
Using a 3 mm hex driver, loosen and remove the two 10 mm M4 socket head screws securing the Z drive to the printer frame. Set the screws aside. Pull the Z drive forward and remove it from the printer. Set the Z drive aside for disposal.
Installing the replacement Z drive
Overview: Mount and secure the replacement Z drive
Step 1: Mount the new Z drive
Orient the replacement Z drive with the ball at the lower-right. Insert the replacement Z drive inside the print enclosure, aligning the screw holes in the Z drive with the corresponding screw holes in the back of the print enclosure.
Step 2: Secure the Z drive
Thread one 10 mm M4 socket head screw into both of the screw holes in the Z drive. Using a 3 mm hex driver, tighten the screws until snug.
Installing the replacement Z motor
Overview: After installing the replacement Z drive, mount and secure the corresponding Z motor.
Step 1: Mount the new Z motor
Bring the new motor assembly to the printer with both the encoder and motor connector sockets facing down. Insert the replacement Z motor into its place at the rear of the printer, aligning the four screw holes in the Z motor with the corresponding screw holes in the printer frame.
The motor should sit flush against the printer, with the square shaft on the Z drive mated with the square socket on the Z motor coupling. Turn the bevel gear on the Z drive or the motor coupling as necessary.
Step 2: Secure the Z motor
Thread one 10 mm M4 socket head screw into each of the four screw holes in the motor. Using a 3 mm hex driver, tighten the screws until snug.
Step 3: Reconnect the encoder and motor cables
Connect both the encoder and motor cables to the motor. They only fit into the appropriate socket in one orientation.
Reinstalling the rear panels
Overview: After installing the replacement Z motor and drive assembly, reinstall and secure the rear panels.
Step 1: Align the upper rear panel with the printer
Lift the upper rear panel and align it with the four screw holes on the top of the printer.
Step 2: Secure the upper rear panel top screws
Thread the four 6.0 mm screws into each of the screw holes on the top of the printer. Using a 2.5 mm hex driver, tighten the screws until finger tight. You may need to adjust the exhaust duct to correctly position the upper rear panel.
Step 3: Secure the buffer side panel screws
Thread the two 6 mm screws into the screw holes on the buffer side and the two 6 mm screws into the screw holes on the hopper side. Using a 2.5 mm hex driver, tighten the screws until snug.
Step 4: Secure the hopper side panel screws
Thread the two 6mm screws into the holes on the hopper side. Using a 2.5 mm hex driver, tighten the screws until snug.
Step 5: Secure the upper rear panel grounding screws
The two black upper rear panel screws are circled in red. The two chrome upper rear panel grounding screws are circled in blue.
Thread the panel screws into the indicated screw holes on the upper rear panel. Refer to the image for the correct locations of the black and chrome screws. Using a 2.5 mm hex driver, screw in the two black panel screws and two chrome grounding screws securing the upper rear panel to the printer.
Notice:
The placement of the chrome screws is critical to the printer's electrical grounding. Incorrect placement may lead to printer damage.
Step 6: Slide the exhaust duct into position
Slide the end of the exhaust duct with the ring clamp back onto the exhaust pipe. Ensure the exhaust duct presses against the insulation panel.
Step 7: Tighten the exhaust duct ring clamp
Using a 6.5 mm flathead screwdriver, tighten the ring clamp until finger tight.
Step 8: Secure the exhaust inlet screws
Open the filter cabinet door on the printer. Thread the four 8.0 mm screws into the screw holes. Using a 2.0 mm hex driver, screw in the four exhaust duct screws until finger tight.
Step 9: Check the exhaust duct seal
To ensure there is no gap between the exhaust duct’s mounting plate and the filter cabinet housing, shine a flashlight or other light source around the exhaust inlet inside the filter cabinet. If any light is visible behind the filter cabinet, the duct is not properly sealed. If necessary, use a 2.0 mm hex driver to tighten the exhaust duct screws. Close the filter cabinet door when finished.
Step 10: Secure the lower rear panel grounding screws
The six black lower rear panel screws are circled in red. The four chrome lower rear panel grounding screws are circled in blue.
Thread the panel screws into the indicated screw holes on the lower rear panel. Refer to the image for the correct locations of the black and chrome screws. Using a 2.5 mm hex driver, screw in the six black panel screws and four chrome panel grounding screws securing the lower rear panel to the printer.
Notice:
The placement of the chrome screws is critical to the printer's electrical grounding. Incorrect placement may lead to printer damage.
Step 11: Reinstall the Wi-Fi antenna (optional)
Screw the Wi-Fi antenna onto the jack on the back of the unit.
Step 12: Reconnect the nitrogen supply (Fuse 1+ 30W only)
Reconnect the nitrogen hose to the quick-disconnect fitting, if previously installed.
Finalizing the repair
Overview: After installing the replacement Z motor and drive assembly, start a print and perform final checks.
Step 1: Power on the printer
Connect the power cable to the printer and the power supply. The printer initializes.
Step 2: Test the repair
Insert and connect a build chamber, close the print enclosure door, and start a print. Monitor the printer to ensure that the new flipper moves smoothly and the print proceeds normally. Contact Formlabs Support or your certified service provider to share the results of the procedure.