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Replacing the Fuse 1 generation interlock board

Fuse 1 generation printers use a variety of interlock sensors to ensure that the required printer doors are closed before starting or continuing a print. A faulty or malfunctioning interlock board could prevent the printer from determining the state of its doors, leading to unexpected behavior.

Use this guide to replace the interlock board on a Fuse 1 generation printer.

Required supplies:

Formlabs:

Replacement Fuse 1 generation interlock board

Third-party:

2.0 mm hex driver (flat-end)
2.5 mm hex driver (flat-end)
Nonreactive nitrile gloves
N95 or better respirator

Estimated time: 15–20 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 air heater.

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.

Remove the inner-right enclosure panel

Overview: Remove the inner-right enclosure panel to access the interlock board.

Step 1: Open the print enclosure door

Open the filter cabinet door, then pull the blue handle to manually open the print enclosure door.

Step 2: Remove the inner-right enclosure panel retention screws.

Using a 2.5 mm hex driver, loosen and remove the 12.0 mm M4 countersunk screw on the hopper side of the printer. Use the same driver to loosen and remove the six 5.0 mm black M4 dome screws on the front of the inner-right enclosure panel. Set the screws aside.

Step 3: Remove the inner-right enclosure panel

Separate the inner-right enclosure panel from the printer and set it aside.

Removing the interlock board

Overview: Disconnect and remove the original interlock board.

Step 1: Remove the interlock board retention screws

Using a 2.0 mm hex driver, loosen and remove the four 5.0 mm stainless M3 button screws securing the interlock board to the printer. Do not pull the board away from the printer, as it is still attached via three cables.

Step 2: Disconnect and remove the interlock board

Turn the interlock board over to reveal three JST cable connectors. Disconnect the JST connectors from the board by depressing the white locking tab, then pulling the connector housing away from the receptacle. Set the original interlock board aside for disposal.

Installing the replacement interlock board

Overview: Connect mount, and secure the replacement interlock board.

Step 1: Connect the interlock cables to the interlock board

Remove the new interlock board from its packaging. Orient the board to that the Formlabs logo is right-side up. Connect the three JST connectors to the corresponding receptacles on the new interlock board.

Step 2: Mount the interlock board

Turn the interlock board over and nest the cable harnesses into the clearance hole behind the interlock board’s mounting points. Align the screw holes in the board with the corresponding standoffs on the printer frame.

Step 3: Secure the interlock board

Thread one 5.0 mm stainless M3 button head screw into each of the four screw holes in the interlock board. Using a 2.0 mm hex driver, tighten the screws until snug.

Reinstalling the inner-right enclosure panel

Overview: After installing the new interlock board, reinstall the inner-right enclosure panel.

Step 1: Mount the inner-right enclosure panel

Hold the inner-right enclosure panel up to the printer frame, aligning the seven screw holes in the panel with the corresponding screw holes in the front and side of the printer frame.

Step 2: Secure the inner-right enclosure panel

Thread one 5.0 mm black M4 button head screw into each of the six screw holes in the front of the inner-right enclosure panel. Thread the 12.0 mm M4 countersunk screw into the screw hole on the hopper side of the printer. Using a 2.5 mm hex driver, tighten all seven screws until snug.

Step 3: Close the printer doors

Close the print enclosure and filter cabinet doors.

Finalizing the repair

Overview: After installing the replacement interlock board, power on the printer 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

Open the print enclosure door using the touchscreen. Close the door and check that the touchscreen responds appropriately. Contact Formlabs Support or your certified service provider to share the results of the procedure.