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Replacing the Form 3 LevelSense board

The LevelSense board senses the position of the float in the resin tank, which the printer uses to determine the amount of resin in the tank. The LevelSense board sits at the back of the printer, at the base of the Z-tower. A malfunctioning LevelSense board will prevent the printer from printing properly.

Use this guide to replace the Form 3 LevelSense board.

Required Supplies:

Formlabs:

LevelSense board

Third-party:

3 mm hex driver
2.5 mm hex driver
2 mm hex driver
T8 Torx driver
T10 Torx driver
Nitrile gloves

Estimated time: 20–30 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.

Preparing the workspace

Overview: Prepare the Form 3 and a dust-free workspace for replacing the LevelSense board.

NOTICE:

The LevelSense board is a sensitive electronic component. Do not remove the LevelSense board from its packaging until instructed.

Step 1: Remove the build platform

Remove the build platform first to avoid dripping resin onto the LPU or into the printer cavity.

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

Remove the resin tank, place it in the resin tank carrier, and cover it with its lid. Set the carrier and 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. Prepare additional space for storing the rear panel of the printer during maintenance.

Step 5: Clean the printer cavity

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. Clean any resin pooled on the printer floor, inside the printer cavity, with paper towels. Dampen the paper towels 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 back panel of the printer while the printer is plugged in. Never reconnect the printer to power while the back panel is uninstalled.

Removing the rear shell

Overview: Remove the rear shell of the printer to gain access to the LevelSense board.

NOTICE:

The Form 3 contains 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: Remove the rear shell screws (internal)

Open the printer cover. There is one screw on each side of the Z-tower. Depending on the age of your printer, they may be 2 mm hex screws or T10 Torx screws. Use the appropriate driver to loosen and remove the two screws on the side of the Z-tower.

Step 2: Remove the rear shell screws (external)

Rotate the printer to access the rear. Use a 3 mm hex driver to loosen and remove the two screws on the back of the printer, near the power and data ports.

Step 3: Remove the rear shell

Gently flex the sides of the rear shell outwards to unclip it from the printer frame. Pull the rear shell directly away from the printer to remove it. Set the rear shell aside.

Locate—but do not remove—the two nuts, retained in the lower shell, that previously secured the external rear shell screws. Ensure that they did not come loose while removing the rear shell.

Removing the side shell

Overview: Unscrew and remove the side shell on the same side of the printer as the LevelSense board.

Step 1: Remove the side shell screws

Lay the printer gently on its back. Remove the two screws holding the left side shell onto the printer with the 2.5 mm hex key.

Step 2: Remove the side shell

Gently pull the side panel towards the bottom of the printer. It should easily slide free. Set the side panel aside and lift the printer upright again.

Removing the LevelSense board

Overview: Unplug, unscrew, and remove the LevelSense board from the printer.

Step 1: Lift the top shell

The black plastic top shell surrounds the tank carrier and printer cavity. To access the LevelSense board more easily, the rear end of this shell must be lifted out of the way.

Unclip one side of the top shell from the frame by pulling the clips (circled in the image below) straight out away from the printer body.

Then, bend the shell upwards gently to reveal the LevelSense board. Do not bend sharply or the top shell may be damaged.

NOTICE:

Do not fully remove the top shell. The tank tensioner, located underneath the other side of the top shell, is not serviceable. Modifying the tensioner may result in personal injury or damage to the machine.

Step 2: Remove the retaining screws

Use the T8 Torx driver to loosen the two Torx screws that attach the LevelSense board to the printer frame. Remove the screws and their plastic spacers.

Step 3: Disconnect the LevelSense cable

Locate the LevelSense board cable. Hold the connector by its plastic housing and disconnect the cable from the LevelSense board. Do not pull on the individual wires.

Step 4: Remove the LevelSense board

Carefully remove the LevelSense board from the printer. Pull gently by the connector and exposed edge of the board.

Installing the new LevelSense board

Overview: After removing the old LevelSense board, connect and install the replacement LevelSense board.

Step 1: Mount the LevelSense board

Place the new LevelSense board on the two plastic posts. Press the board towards the front of the printer to ensure that it is seated flush against the printer frame.

Step 2: Reconnect the LevelSense cable

Plug the LevelSense cable into the LevelSense board. The cable will only enter the connector in the correct orientation. Be careful not to bend the pins in the connector.

Step 3: Install the LevelSense screws

Place the plastic spacers on the LevelSense board screws. Screw both screws back in using the T8 Torx driver. Do not overtighten to avoid stripping the screw threads.

Reinstalling the shells

Overview: After installing the replacement LevelSense board, reinstall and secure the shells.

Step 1: Secure the top shell

Press the top shell downward onto the frame until the retaining clips click into place.

Step 2: Replace the side shell

Lay the printer gently on its back. Align the four pins on the side panel with the corresponding slots on the printer frame.

Press the side shell inward, toward the printer body, and slide it toward the top of the printer. When the side shell is fully seated, there is no gap between the side shell and the other printer shells.

Step 3: Secure the side shell

Using the 2.5 mm hex driver, screw the two 2.5 mm hex screws into the side shell of the printer.

Reinstalling the rear shell

Overview: After performing any other maintenance procedures, reinstall and secure the rear shell.

Step 4: Replace the rear shell

Place the rear shell back onto the printer. Press it towards the front of the printer to ensure that it fully seats in place. There should be no gaps between the rear shell and the side or bottom shells.

Step 5: Secure the rear shell

Using a 3 mm hex driver, screw the two 3 mm hex screws into the rear of the printer.

Open the printer cover. Using a 2 mm hex driver or a T10 Torx driver (depending on the type of screws in your printer), screw the two Z-tower screws into the sides of the Z-tower.

Finalizing the repair

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

Step 1: Power on the printer

Close the printer cover and connect the power cable to the printer and the power supply. The printer will initialize. If the printer reports that its cover is open, repeat this maintenance procedure and ensure that the LevelSense cable is fully plugged into the new LevelSense board.