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Replacing the Form 4L LevelSense board

The LevelSense board detects the amount of resin in the resin tank. The LevelSense board sits at the left side of the tower in the printer. A malfunctioning LevelSense board may prevent the printer from printing properly.

Use this guide to replace the LevelSense board on a Form 4L generation printer.

Required Supplies:

Formlabs:

LevelSense board
2 mm hex driver (included in the Form 4L tool caddy)

Third-party:

Nitrile gloves
Small plastic card (e.g., identification card)

Estimated time: 10–15 minutes

Preparing the workspace

Overview: Prepare the Form 4L and workspace for replacing the LevelSense board.

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.

Removing the LevelSense board

Overview: After preparing the printer and workspace, remove the LevelSense board.

Step 1: Remove the LevelSense shroud

Open the printer door and locate the plastic shroud at the back left of the printer. Use a 2 mm hex driver to remove the four screws securing the plastic shroud to the printer. Set the shroud aside.

Step 2: Remove the LevelSense board mounting screws

Support the LevelSense board from below to prevent it from falling when the screws are removed. Use a 2.5 mm hex driver to remove the three screws securing the LevelSense board to the metal bracket. Set the screws aside.

Step 3: Disconnect the LevelSense board cable

Press the plastic tab on the connector to release the cable that connects to the LevelSense board. Once the plastic tab is pressed, the cable easily slides from the connector. Do not pull on the wires. Remove the LevelSense board and set it aside for disposal with electronic waste.

Installing the replacement LevelSense board

Overview: Connect and install the replacement LevelSense board.

Step 1: Connect the cable

Reconnect the cable that connects the LevelSense board. The connector makes an audible and tactile click when secured.

Step 2: Mount and secure the LevelSense board

Position the LevelSense board so that the screw holes align with the holes in the bracket. Use a 2 mm hex driver to install the three screws that secure the LevelSense board to its bracket. Tighten until snug.

Step 3: Mount and secure the LevelSense shroud

Place the LevelSense shroud on top of the LevelSense bracket. Align the four screw holes in the shroud with the corresponding holes in the bracket. Use a 2 mm hex driver to install the four screws securing the plastic shroud to the printer. Tighten until snug.

Finalizing the repair

Overview: After installing the replacement LevelSense board, power on the printer and perform final checks.

Step 1: Power on the printer

Close the printer door and connect the power cable to the printer and the power supply. Turn on the switch at the back of the printer. The printer turns on and initializes.

Step 2: Calibrate the LevelSense board

On the printer touchscreen, tap Settings > Tools > Calibration > Resin Level Sensor. The Calibrate resin level sensor screen appears. Tap Start and follow the on-screen instructions to calibrate the LevelSense board. You will need a small plastic card with no embossing, such as an identification card.