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Replacing the Form 4 power supply

The Form 4 power supply is located behind the touchscreen assembly and powers the printer. A broken or malfunctioning power supply prevents the printer from functioning.

Use this guide to replace the Form 4 power supply.

Required Supplies:

Formlabs:

Power supply
2.5 mm hex driver (included in the Form 4 tool caddy)

Third-party:

Phillips screwdriver
Nitrile gloves

Estimated time: 45 minutes

Preparing the workspace

Overview: Prepare the Form 4 and workspace for replacing the power supply.

Step 1: Remove the build platform

Remove the build platform first to avoid dripping resin onto the Light Processing Unit (LPU).

Step 2: Remove the resin cartridge

Remove the resin cartridge and close the vent cap to prevent resin from dripping off of the bite valve and into the printer.

Step 3: Remove and store the resin tank and mixer

Unlatch the mixer and resin tank. Remove the resin tank and cover it with its lid. Set the tank aside on a clean, flat surface.

Notice:

Wear gloves and hold the resin tank by the tank grips on either side to avoid contamination or damage to the underside of the tank.

Step 4: Prepare the workspace

Clear a workspace around your printer. Ensure that the workspace is well-ventilated and free of dust.

Step 5: Clean the printer

Warning:

Resin may cause skin irritation or an allergic skin reaction. Wear gloves when handling liquid resin or resin-coated surfaces. Wash skin with plenty of soap and water.

Open the printer cover and clean any resin pooled on and around the LPU with non-abrasive wipes. Dampen the wipes with isopropyl alcohol if necessary to fully remove the resin.

Danger:

Fire hazard. IPA is flammable. Keep containers closed, and keep out of the reach of children.

Step 6: 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 printer panels while the printer is plugged in. Never reconnect the printer to power while the panels are uninstalled.

Removing the touchscreen assembly

Overview: Remove the touchscreen assembly from the printer to access the power supply.

Step 1: Remove the touchscreen assembly

To remove the touchscreen assembly, follow the instructions in the repair guide Replacing the Form 4 touchscreen assembly. Complete the steps in the section Removing the touchscreen assembly.

Removing the power supply

Overview: After removing the touchscreen assembly, remove the power supply.

Step 1: Open the plastic shroud

Release the five tabs holding the shroud closed. Unfold the top of the shroud.

Step 2: Unplug the output cable

Unplugging the Form 4 power supply output cable

Hold the connector by its plastic housing and gently squeeze the plastic tab to unplug the output cable from the power supply. Do not pull on the individual wires.

Step 3: Remove the input wire mounting screws

Form 4 power supply input wire ring terminals and screws

The input wires attach to the power supply with a ring terminal and screw. Using a Phillips screwdriver, remove each screw securing the ring terminal to the power supply. Set the screws aside. Do not remove the ring terminal from the input wire.

Step 4: Remove the power supply mounting screws

Use a 2.5 mm hex driver to remove the four hex screws that secure the power supply to the printer. Set the screws aside.

Step 5: Remove the power supply

Once all the cables are disconnected, gently lift the power supply from the printer. Set the power supply aside for disposal with electronic waste.

Installing the replacement power supply

Overview: Mount and connect the replacement power supply.

Step 1: Position the replacement power supply

Align the replacement power supply with the four screw holes on the printer frame. Take care to place the power supply in the correct orientation.

Step 2: Secure the power supply

Securing Form 4 power supply mounting screws

Thread one hex screw into each screw hole. Using a 2.5 mm hex driver, hand-tighten the four hex screws to secure the power supply to the printer. Tighten the screws until snug.

Step 3: Connect the input wires

Match the correct input wire to the correct screw terminal. The black wire with the – label attaches to the upper screw terminal. The yellow wire with the + label attaches to the lower screw terminal. Thread a screw through the ring terminal into the screw terminal. Using a screwdriver, hand-tighten the two screws to secure the input cables to the power supply. Tighten the screws until snug.

Connecting the Form 4 power supply input wires to screw terminals

Step 4: Connect the output cable

Connect the output cable to the power supply. The connector makes an audible and tactile click when secured.

Connecting the Form 4 power supply output cable

Step 5: Close the plastic shroud

Fold the plastic shroud to cover the power supply. Reinsert the five tabs into the corresponding slots.

Closing the Form 4 power supply plastic shroud

Reinstalling the touchscreen assembly

Overview: After replacing the power supply, reinstall the touchscreen assembly onto the printer.

Step 1: Reinstall the touchscreen assembly

To reinstall the touchscreen assembly, follow the instructions in the repair guide Replacing the Form 4 touchscreen assembly. Complete the steps in the section Installing the replacement touchscreen assembly.

Finalizing the repair

Overview: After replacing the power supply, 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: Run a test print

Insert any missing consumables and run a test print. Check that the print starts normally and the parts print successfully. Contact Formlabs Support or your authorized reseller to share the results of the procedure.