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Heater band replacement

Each of the G1’s three heating zones has its own heater band — a 220V / 300W resistive band that clamps around the outside of the barrel (40 mm inner diameter, 35 mm high). If a zone fails to reach temperature or shows a thermal runaway error, the band, its relay or its thermistor may need replacement.

When to replace

Section titled “When to replace”
  • A heating zone reports an error and cannot reach target temperature
  • The zone temperature graph shows a flat line (not rising) after power is applied
  • The band does not warm at all (if it warms slightly then stops, the relay is the fault — the relays are soldered to the extruder_board and are not a field repair)
  • After physical damage to the band wires

Procedure

Section titled “Procedure”

The bands come off downward, over the nozzle end of the barrel. Nothing else on the extruder needs to be disassembled.

Step 1 — Raise the extruder

Section titled “Step 1 — Raise the extruder”

Move the extruder so there is at least 10 cm of clearance between the nozzle and the bed. Without that gap the bands cannot be slid off from underneath comfortably.

Step 2 — Power off

Section titled “Step 2 — Power off”

Switch the printer off at the mains.

Step 3 — Open up the barrel

Section titled “Step 3 — Open up the barrel”
  1. Remove the insulation from the barrel
  2. Remove the sensors
  3. Undo the 2 screws that clamp each band

Step 4 — Slide the bands off

Section titled “Step 4 — Slide the bands off”

Slide the bands downward, off the bottom of the barrel.

Step 5 — Fit the new band and reassemble

Section titled “Step 5 — Fit the new band and reassemble”

Reverse the same steps. For the wiring there is nothing to trace out: fit the new band with its cables in the same position the old one had.

  1. Slide the new band on from below and position it on its zone
  2. Tighten its 2 clamping screws
  3. Refit the sensors
  4. Refit the insulation
  5. Power on and confirm the zone reaches and holds its target temperature
Section titled “Related notes”