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Replacing the Fuse 1 RFID board

Fuse 1 generation printers use an RFID reader to interact with powder credit cards and register powder credits. On Fuse 1 printers, this RFID reader is located in the upper cooling shroud, near the IR sensor. A faulty or malfunctioning RFID board will prevent the printer from registering or moving powder credits and could lead to other unexpected errors.

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

Required supplies:

Formlabs:

Replacement RFID board (RP-F3L-RFID-01)

Third-party:

2.5 mm hex driver (flat-end)
3 mm hex driver (must have a 90º head)
T10 Torx driver

Estimated time: 45–60 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 RFID board.

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.

Removing the top panel

Overview: Remove the top panel to access the interior of the printer.

Step 1: Remove the top panel screws

Using a 2.5 mm hex driver, remove the 26 6 mm M4 countersunk screws securing the top panel to the printer:

Six 6 mm screws on the front end of the buffer-side
12 6 mm screws on top of the printer
Eight 6 mm screws on the hopper-side

Set the screws aside.

Step 2: Remove the top panel

Lift the top panel off of the printer by grabbing the IR sensor door and the rear-most edge. Set the top panel aside.

Removing the upper cooling shroud

Overview: Remove the upper cooling shroud to access the RFID board.

Step 1: Remove the IR sensor

Open the access door to the IR sensor panel, located on top of the printer next to the hopper. Lift the IR sensor and disconnect the cable from it. Set the IR sensor aside on a flat surface with the sensor window facing up. Feed the IR sensor’s cable down through the plastic shroud.

Step 2: Remove the upper cooling shroud screws

Using a 3 mm hex driver, loosen and remove the four 8 mm M4 socket head screws securing the upper cooling shroud to the printer. Do not yet separate the upper cooling shroud from the printer.

Step 3: Lift the upper cooling shroud

Gently lift up but do not separate the front edge of the plastic shroud from the top of the printer so that the cables attached to the shroud can be accessed.

Notice:

Take care when lifting the plastic shroud so as to not strain the cables attached to it.

Step 4: Unplug the fan cable

Disconnect the fan cable from the connector labeled C047 by squeezing on the plastic latch. Do not pull on the individual wires; only pull on the plastic connector.

Tip:

It may be helpful to have one person hold the plastic shroud while another person unplugs the cables.

Step 5: Unplug the RFID reader

Unplug the RFID reader board cable from the circuit board by gently pulling on the white connector.

Step 6: Remove the upper cooling shroud

Separate the upper cooling shroud from the printer and set it aside.

Replacing the RFID board

Overview: Remove the original RFID board and mount the replacement.

Step 1: Remove the original RFID board

Using a T10 Torx driver, loosen and remove the two screws securing the RFID board to the upper cooling shroud. Set the screws aside. Separate the RFID board from the upper cooling shroud and set it aside for disposal with electronic waste.

Step 2: Mount and secure the replacement RFID board

Position the new RFID board so that the two screw holes just below the connector are aligned with the screw holes on the upper cooling shroud. Thread one T10 Torx screw into both of the screw holes, then use a T10 Torx driver to tighten until snug.

Reinstalling the upper cooling shroud

Overview: After replacing the RFID board, reinstall the upper cooling shroud.

Step 1: Reonnect the RFID reader cable

Hold the upper cooling shroud above the printer and plug the RFID reader cable connector into the RFID board by gently pushing it into the receptacle. The connector will only fit in one orientation.

Step 2: Reconnect the cooling fan

Reconnect the cooling fan connector to the socket labeled C047.

Step 3: Route the IR sensor cable

Position the top cooling shroud by holding it from the front edge so that the cables covered by the shroud can still be accessed. Feed the IR sensor’s Ethernet cable back through the cutout in the top shroud.

Step 5: Mount and secure the upper cooling shroud

Lower the upper cooling shroud on the printer, aligning the four screw holes in the shroud with the corresponding screw holes in the printer frame. Thread one 8 mm M4 socket head screw into each of the screw holes. Using a 3 mm hex driver, tighten until snug.

Step 6: Connect and mount the IR sensor

Inspect the IR sensor lens for debris and clean it if necessary. Attach the ethernet cable to the IR sensor, then place the sensor back into its mount.

Reinstalling the top panel

Overview: After installing the new RFID board, reinstall and secure the top panel.

Step 1: Align the top panel

Lift the top panel and place it on top of the printer. Align the screw holes in the top panel with the corresponding holes in the printer frame.

Step 2: Secure the top panel screws

Thread a 6 mm M4 countersunk screw into each of the 26 marked screw holes in the top panel:

Six 6 mm screws on the front end of the buffer-side
12 6 mm screws on top of the printer
Eight 6 mm screws on the hopper-side

Using a 2.5 mm hex driver, tighten the screws until snug.

Finalizing the repair

Overview: After installing the replacement RFID 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

Insert a powder credit card (if one is available) and register or transfer powder credit. Contact Formlabs Support or your certified service provider to share the results of the procedure.