Part No. DOC-10002_REV_A

Fortus

®

900mc

OPERATION AND

MAINTENANCE GUIDE

LIABILITY STATEMENT

The information in this document is subject to change without notice. Stratasys, Inc. shall not be liable for errors contained herein or for incidental or consequential damages in connection with the furnishing, performance, or use of this material. Stratasys, Inc. makes no warranty of any kind with regard to this material, including, but not limited to, the implied warranties of merchantability and fitness for a particular purpose. It is the responsibility of the system owner/ material buyer to determine that the Stratasys material is safe, lawful, and technically suitable for the intended application as well as identify the proper disposal (or recycling) method consistent with local environmental regulations. Except as provided in Stratasys' standard conditions of sale, Stratasys shall not be responsible for any loss resulting from any use of its products described herein.

COPYRIGHT STATEMENT

© Copyright 2017 Stratasys Inc. All rights reserved.This document is protected by copyright. No part of this document may be photocopied, reproduced or translated into another language without the prior written consent of Stratasys, Inc. All drawings and information herein are the property of Stratasys Inc. All unauthorized use and reproduction is prohibited.

TRADEMARK ACKNOWLEDGMENTS

FORTUS, Insight, Control Center, FDM Technology, SR-30, SR-100, SR-110, and ABS-ESD7 are trademarks of Stratasys Ltd. and/or subsidiaries or affiliates and may be registered in certain jurisdictions.

FORTUS 900mc is a registered trademark and service mark of Stratasys Inc. in the United States and other countries. ULTEM™ is a registered trademark of SABIC or affiliates or subsidiaries. All other product names and trademarks are the property of their respective owners.

DECLARATION OF CONFORMITY

Declaration of Conformity information is available from the Stratasys website at: http://www.stratasys.com/ customer-support/customer-resource-center/documentation .

EMC CLASS A WARNING

Warning: This is a Class A product. In a domestic environment this product may cause radio interference in which case the user may be required to take adequate measures.

MSDS (MATERIAL SAFETY DATA SHEET)

You can obtain current Material Safety Data Sheets for the material used in the printer is available at: http://www.stratasys.com/materials/material-safety-data-sheets . ii

DISPOSAL OF WASTE EQUIPMENT BY USERS IN PRIVATE

HOUSEHOLDS IN THE EUROPEAN UNION

This symbol on the product or on its packaging indicates that this product must not be disposed of with your other household waste. Instead, it is your responsibility to dispose of your waste equipment by handing it over to a designated collection point for the recycling of waste electrical and electronic equipment. The separate collection and recycling of your waste equipment at the time of disposal will help to conserve natural resources and ensure that it is recycled in a manner that protects human health and the environment. For more information about where you can drop off your waste equipment for recycling, please contact your local city office, your household waste disposal service or the shop where you purchased the product.

REVISION LOG

Revision

DOC-10001_REV_A

Date

September 2017

Description of Changes

Initial release.

iii

TABLE OF CONTENTS

ABOUT THIS GUIDE ............................................................................... 1

FORTUS 900MC PRINTER ..................................................................... 1

PRINTER COMPONENTS......................................................................................................... 1

Access Doors and Panels.................................................................................................................................. 1

Front of System ................................................................................................................................................. 2

Top of System.................................................................................................................................................... 3

Oven Components............................................................................................................................................. 5

Canister Bays .................................................................................................................................................... 8

Rear of System .................................................................................................................................................. 9

Model Tag........................................................................................................................................................ 11

Printer Highlights ............................................................................................................................................. 11

Available Materials........................................................................................................................................... 12

Minimum Clearances ....................................................................................................................................... 12

AC POWER DISCONNECTION............................................................................................... 13

Lockout Tagout ................................................................................................................................................ 13

OPERATING ENVIRONMENT................................................................................................. 15

TOOLS ..................................................................................................................................... 16

Start-Up Kit Contents....................................................................................................................................... 16

SAFETY INFORMATION ....................................................................... 17

HAZARD TYPES...................................................................................................................... 17

SAFETY SYMBOLS ................................................................................................................. 17

SAFETY PRECAUTIONS ........................................................................................................ 19

Oven ................................................................................................................................................................ 19

Gantry .............................................................................................................................................................. 19

Z Stage ............................................................................................................................................................ 19

GUARD DOOR INTERLOCKS................................................................................................. 19

STABILITY WEDGE BLOCKS ................................................................................................. 20

GENERAL SAFETY PRACTICES............................................................................................ 21

BASIC USER OPERATIONS ................................................................. 22

POWERING ON THE SYSTEM ............................................................................................... 23 iv

POWERING OFF THE SYSTEM 23

USER INTERFACE 24

Materials/Tools Display 24

Queue Window ................................................................................................................................................ 25

Tip Offset Menu ............................................................................................................................................... 26

Part Placement Menu ...................................................................................................................................... 26

System Default Values .................................................................................................................................... 27

Building Screen................................................................................................................................................ 28

LOADING/UNLOADING MATERIAL........................................................................................ 29

Loading Material to the Liquefier Tips.............................................................................................................. 29

Unloading Material from the Liquefier Tips ...................................................................................................... 30

CHANGING TIPS OR MATERIAL TYPE ................................................................................. 31

AUTOMATIC CALIBRATIONS................................................................................................. 33

Start Auto Z Zero Calibration ........................................................................................................................... 33

Start Auto Tip Calibration................................................................................................................................. 33

Adjust XYZ Calibration Offsets ........................................................................................................................ 34

AutoHome XYZ................................................................................................................................................ 36

BASIC JOB BUILD TASKS ...................................................................................................... 37

Before a Build .................................................................................................................................................. 37

Select a Job to Build ........................................................................................................................................ 38

Build Job Warnings.......................................................................................................................................... 39

Working with the Job Queues.......................................................................................................................... 41

Pausing or Stopping a Job............................................................................................................................... 41

After a Job Build .............................................................................................................................................. 43

USER MAINTENANCE .......................................................................... 45

DAILY MAINTENANCE............................................................................................................ 46

Clean the Platen .............................................................................................................................................. 46

Empty the Purge Bucket .................................................................................................................................. 47

WEEKLY MAINTENANCE ....................................................................................................... 48

Vacuum the Build Envelope............................................................................................................................. 48

Clean/Inspect Tip Wipe Assembly ................................................................................................................... 48

QUARTERLY MAINTENANCE ................................................................................................ 50

Clean the Tip Sensor Plunger.......................................................................................................................... 50

AS NEEDED MAINTENANCE ................................................................................................. 51

Cleaning The Liquefier Tips............................................................................................................................. 51

Cleaning the Cabinet ....................................................................................................................................... 51

Cleaning Plastic Components.......................................................................................................................... 51

Cleaning the Oven Door, Camera/Lamp, and Touchscreen Display............................................................... 51 v

SUPPLEMENTAL INFORMATION 52

ELECTRICAL PANEL COMPONENTS (GEN 2 ONLY, SERIAL NUMBER > 1030) 52

AUXILIARY PANEL (GEN 2 ONLY, SERIAL NUMBER > 1030) 54

CONNECTION TO ELECTRICAL SUPPLY............................................................................. 55

ELECTRICAL DIAGRAMS ....................................................................................................... 57

Ladder Diagram (Gen 2 only, Serial Number > 1030) ..................................................................................... 57

E-Stop Circuit (Gen 2 only, Serial Number > 1030)......................................................................................... 61

Safety Interlock Circuit (Gen 2 only, Serial Number > 1030)........................................................................... 62

Safety Interlock Summary (Gen 2 only, Serial Number > 1030)...................................................................... 63

900mc Electrical (Gen 2 only, Serial Number > 1030) .................................................................................... 64 vi

ABOUT THIS GUIDE

This guide provides basic instructions for the Fortus 900mc. Instructions and specifications pertain to both the 900mc Gen 1 and Gen 2 models, unless otherwise stated. For additional information, contact your Stratasys representative.

FORTUS 900MC PRINTER

The Fortus 900mc™ 3D Production System incorporates the latest in innovative technologies that produce accurate and functional parts. Stratasys’ Fused Deposition Modeling

®

(FDM) technology provides prototype parts, including internal features, that can be used to field-test form, fit, and function.

PRINTER COMPONENTS

The 900mc printer system consists of the following components.

• Insight™ Software Package

• A generic computer workstation (not sold by Stratasys)

• The Fortus 900mc System

• Modeling Material

• Support Material

ACCESS DOORS AND PANELS

Warning: The access doors should only be removed by an authorized Stratasys service technician.

This system has been designed to allow easy access to the most frequently accessed areas on the system. The doors and top slide covers are highlighted in the following figure.

Top Slide Covers

Oven Door

Canister Bay Door

1

TOP SLIDE COVERS

Allows access to the head, gantry area, and access for changing model and support tips on the head. The cooling fans are located in this area to provide airflow though the upper portion of the system.

Warning: Only use an OSHA or CE approved step stool when accessing the area under the top slide covers.

OVEN DOOR

Allows access to the platen, tip wipe assemblies, purge bucket, and completed parts.

Warning: Always wear safety gloves and long sleeves when working in the oven, with the head, or liquefier tips. these components are very hot.

CANISTER BAY DOOR

Allows access to the four canister bays, canister levers, and canister LEDs.

FRONT OF SYSTEM

The front of the system contains controls and status indicators for the Fortus 900mc printer.

Signal Tower

Touchscreen

Power On Power Off

Emergency Stop

SIGNAL TOWER

Visually displays the status of the Fortus 900mc.

Green: System is OK; it is building a part, or it is finished building a part.

Yellow:

Red:

All monitored parameters are within tolerance.

An indicator has moved beyond its control limit and is now outside of its specification limit. The system will not allow a part to start building. The system may pause, or stop, or power down depending on the condition.

2

EMERGENCY STOP

Pressing the Emergency Stop button immediately removes power to the system. This button should be used only as an extreme measure to remove power to the system and should not be used or tested unnecessarily as the computer hard drive can be corrupted due to the hard shutdown. The system can be restarted by pulling the

Emergency Stop button out to its original position and following the normal startup process.

TOUCHSCREEN

The operator Touchscreen is the user interface to the system. Through this touchscreen the operator can access various screens to control the system, set security, and perform calibrations. The touchscreen also displays the operation of the system as well as displaying warning information.

POWER ON

Pressing the Power On button activates the system.

POWER OFF

Pressing the Power Off button initiates a power down sequence to power off the system.

TOP OF SYSTEM

The top of the system has covers that allow access to the head.

OPENING THE TOP SLIDE COVERS

To access the head, the Top Slide Covers need to be opened. The covers share two safety switches and a locking solenoid. The covers remain locked during system operation or when the user moves the gantry or the Z

Stage and are unlocked when the system is idle.

The system cannot resume operation if the top slide covers or the oven door is open. Additionally, a manual move command cannot be sent to the system until both covers and oven are closed.

HEAD ASSEMBLY

The Head Assembly is designed for use with a wide range of model materials. The board inside the head provides direct heater and thermocouple control. Model and support material are extruded through the head using two liquefiers.

3

HEAD MAINTENANCE BRACKET

The Head Maintenance Bracket is designed to hold the head assembly while performing maintenance on the head such as tip replacement. The red handle is designed so the top slide covers cannot be closed while the bracket is in place.

Head Assembly

Head Maintenance

Bracket

4

OVEN COMPONENTS

The oven is comprised of the oven door and everything that you see through the oven door window, including the platen and the tip wipe assembly. The oven is where parts are built.

OVEN DOOR

The oven door is locked by a solenoid during the building of a part. Pressing the Door button on the Operator

Touchscreen will release the solenoid allowing you to open the door. This command is available only while the system is paused or in an idle state. You do not have access to this command while any mechanism in the system is moving.

Note: By design, the oven door can be partially opened while locked. Do not force the oven door open by pulling on it while the locking solenoid is engaged.

From the Operator Touchscreen, press the Door button to unlock the oven door.

Door Button

Note: Once the oven door is unlocked and/or opened, system operation cannot be resumed. Additionally, a manual move command cannot be sent until the oven door is closed. When the oven door is closed, the solenoid activates and operation can resume.

5

OVEN LAMPS

There are two LED oven lamps mounted in the two front upper corners of the oven. There is a lamp (light) switch on the touchscreen, which you can use to manually turn the light ON or OFF ( Figure ).

Warning: Oven lights are hot and are not a user replaceable item. Do not touch without wearing approved safety gloves.

Light Button

PLATEN

The platen is the surface on which parts are built. A plastic build sheet is held to the 36 in. (91.4 cm) X 24 in.

(61.0 cm) aluminum platen by the vacuum source. The platen has a waffle pattern system into the top surface.

This allows vacuum to pull across the entire surface. A small build sheet 16 in. (40.6 cm) X 18.5 in.

(47.0 cm) can be used in the center zone of the platen.

Debris screens (not a customer removal part) are placed across the vacuum ports to prevent material particles from entering the vacuum lines.

Vacuum Ports and Debris Screens

Tip Sensor

6

CAMERA

A camera is housed within the front-left LED oven lamp mounted within the oven chamber. This camera is used to remotely monitor an active job build.

TIP CLEANING ASSEMBLY

The Tip Cleaning Assembly is located to the front, right side of the oven. The assembly consists of two flicker/ brush assemblies (1 for each tip) and a debris chute. The flicker/brush assemblies keep the liquefier tips free of debris and material buildup. The debris chute directs debris into the purge bucket located under the tip cleaning assembly.

PURGE BUCKET

The debris chute directs debris into the purge bucket located under the tip cleaning assembly inside the oven chamber. The purge bucket is designed to catch debris from the tip cleaning assembly and collects model and support filament waste. The purge bucket is removable from the system and has a door at the bottom of the basket for waste disposal.

Debris Chute

Purge Bucket

Bottom Waste

Door

7

CANISTER BAYS

The four canister bays are accessed by opening the canister bay door on the front of the system. The canister bay door is not a part of the door safety interlock system and can be opened during system operation.

Canister Drive

Levers (4X)

M1

Model Material

Bays (2X)

M2

Canister

LEDs (4X )

S1

S2

Support Material

Bays (2X)

The Fortus 900mc system has four operating material bays - 2 model and 2 support. The upper two bays hold model material; the bottom two bays hold support material. While building, two canisters will be active. An active canister has material filament loaded to the liquefiers (steady green LED).

• Inactive canisters can be replace without pausing the system.

Each individual canister bay has a material drive block and a drive lever. The drive lever is used to engage (and disengage) the drive block with the canister. The drive block feeds filament from the canisters to the liquefiers.

• The drive block is located above the canister which drives the filament up to the liquefiers.

• The drive block is spring loaded and moves up and down on guide pins. The spring provides positive pressure for the drive block against the top of the canister.

• The drive block contains a material sensor. The sensor is used to communicate to the system when material is available to be loaded to the liquefiers.

LED Indicator

Drive Lever

Drive Block

There is one colored LED light above each canister. The LED indicates the canister condition for each bay:

• Green – Steady. Material filament has been loaded into the liquefiers. You cannot remove the canister when the LED is a steady green.

• Green – Flashing (Ready state). Filament has been fed into the canister drive block but is not loaded into the liquefiers. You can unload canisters if necessary.

• Red – Steady. The canister is empty. You can unload the canister if necessary.

• Red – Flashing. The canister has a load failure or a smart-spool-chip read/write failure. You can unload canisters if necessary.

• Off. No canister is present, or the canister is present but the filament has not been fed into the canister drive block.

8

REAR OF SYSTEM

The computer and the UPS are accessible from the back of the system.

Power In

Disconnect Switch

Onboard Computer UPS

ONBOARD COMPUTER

The onboard computer is the central control unit for the Fortus 900mc. This computer also runs the touchscreen software that provides for the system's user interface.

UPS

The UPS unit is a battery standby system that supplies power (AC voltage) to the computer, oven lights, and head cooling fan in the event of a loss of AC power. It does not power the entire system. You can access the

UPS from the back of the system. In the event of an overcurrent condition, the UPS is protected by a combination on/off switch and circuit breaker located directly above the main breaker.

• It shuts itself off if power is not restored to the system.

• If power is lost to the system you may need to manually power the unit back up. However, this should not be necessary unless the UPS has been manually turned off. To regain power, hold the “On” button on the front of the UPS unit until a beep is heard and/or LED lights appear.

• The LED display shows status of the UPS.

Alarm Indicator

(Red)

Up

On/Off

Button

On battery

Indicator

(Yellow)

Escape

Enter

Down

Power On

Indicator

(Green)

9

POWER IN DISCONNECT SWITCH

The Power In Disconnect switch, located at the back of the system, acts as the main circuit breaker. Rotating this switch to OFF will remove AC power to the system. There is a Lockout Bar that can be used to lock the switch in the off position.

Warning: High voltage is present in the system when powered off and unplugged because of the Uninterruptible Power supply (UPS).

Lockout Bar

POWER CONNECTION

Warning: A licensed electrician must perform all wiring from service connect to the transformer, and from the transformer to the system - including all connectors, cables and proper strain relief.

This system requires a high voltage connection, which is made at the top right-hand corner at the back of the system. High voltage is applied to the system using a Delta connection. The main breaker must be off until a

Stratasys authorized Service Technician has verified the connection. This system is only provided with a Delta connection.

High Voltage

Power Cable

Connection

NETWORK AND AIR SUPPLY CONNECTIONS

Processed job files are transferred to the Fortus system through your facility’s Ethernet network. An RJ45 network connector is located on the top right-hand corner at the back of the system. The air supply connection is located next to the RJ45 connector.

Power Cable

Connection

Air Supply

Connector

RJ45

Connector

10

MODEL TAG

Use the following label to identify your system:

• Serial Number - Refer to this number when requesting service.

• Model - The model number, the power requirements, and the company’s address and phone number are given on the label. All patent numbers associated with the system are also listed on the label.

• The label is located on the back of the system on the main electrical box.

Model

Serial Number

PRINTER HIGHLIGHTS

• The vacuum platen is adapted for use with two build sheet sizes:

• The small sheet is 16 in. (40.6 cm) X 18.5 in. (47.0 cm) X 0.02 in. (0.05 cm) thick.

• The large sheet is 26 in. (66.0 cm) X 38 in. (96.5 cm) X 0.02 in. (0.05 cm) thick.

• Envelope Size: 36 in. (91.4 cm) wide X 36 in. high (91.4 cm) X 24 in. (60.96 cm) deep.

• Material Bays: 2 model, 2 support

• Slice Heights:

Model Tip

T12

T14

T16

T20

T20B

T40

Slice Height (in)

0.007

0.010

0.010

0.013

0.013

0.020

Slice Height (mm)

0.178

0.254

0.254

0.330

0.330

0.508

Note: Material choice affects available size/slice height.

11

AVAILABLE MATERIALS

The Fortus 900mc system can use a variety of material types:

• ABSi model material used with SR-20 soluble support.

• ABS-M30 and ABS-M30i model materials used with SR-20, SR-30, or SR-35 soluble support.

• SR-30 is ductile and dissolves up to three times faster than SR-20.

• SR-35 is an alternate support material with up to 40% faster dissolve time (geometry dependent) and longer life of soluble solution than SR-30.

• ABS-ESD7 model material used with SR-30 or SR-35 soluble support.

• UV resistant ASA model material used with SR-30 or SR-35 soluble support.

• Nylon 12 model material, which is the first semi-crystalline Fused Deposition Modeling (FDM) thermoplastic, used with SR-110 soluble support.

• Nylon 6 model material used with used with SR-110 soluble support.

• PC-ABS model material used with SR-20 soluble support.

• High strength polycarbonate (PC) model material used with PC_S breakaway support or

SR-100 soluble support.

• PC-ISO model material used with PC_S breakaway support.

• ULTEM 9085 model material (resin), which is certified for use on commercial aircraft, used with

ULT_S support material.

• ULTEM 1010 model material (resin), which offers the highest heat resistance, chemical resistance and tensile strength of any FDM thermoplastic, used with U1010S1 support material.

• Polyphenylsulfone (PPSF) model material, which s ideal for applications in caustic and high heat environments, with PPSF_S support material.

• ST130 model material, which is used for sacrificial tooling parts, used with ST130-S support material.

MINIMUM CLEARANCES

Left Side Clearance

Right Side Clearance

Rear Clearance

Front Clearance

Overhead Clearance

Minimum 27.16 inches (68.0 cm)

Minimum 29.47 inches (74.8 cm)

Minimum 29.96 inches (76.1 cm)

Minimum 44.42 inches (112.8 cm)

Minimum 115.8 inches (294.1 cm)

12

AC POWER DISCONNECTION

Any time service is being performed on the Fortus 900mc AC power must be removed to the system. Perform the system shutdown sequence on the system before removing power to the system.

Make sure the main breakers at the facility site are in their OFF position before preceding to remove any electrical panels.

Warning: Make sure AC power is removed from the system. Voltage of 230VAC is present and can be lethal.

LOCKOUT TAGOUT

Any time service is being performed on the Fortus 900mc system, especially the electrical panel where high voltage power is present, the incoming power should be locked out to prevent someone else from inadvertently energizing the electrical system.

When line voltage is removed from the system, a UPS (Uninterruptible Power Supply) is designed to provide power to some components in the of the system. Make sure to manually turn off the UPS when servicing the system.

Warning: Make sure the UPS is manually turned off and not powering components in the system.

Procedure

1. Shut down the system and turn Off the power.

2. Rotate the power in disconnect switch counterclockwise to the Off position.

• If access to the electrical panel is required, turn and remove the key from the disconnect box, then insert it into the access door lock and turn key to open.

Note: The key is on a retractable cord to prevent its removal from the printer.

• Once the key is removed from the disconnect box, the Power disconnect switch cannot be rotated to an ON position. Since the key is still in the vicinity as it is attached proceed to step 3 below to lockout the printer’s power.

Note: The key cannot be removed from the electrical panel unless both doors are shut correctly and locked.

Note: Printers with serial number < L1000 do not include a key. Make sure that the power-in disconnect is rotated to the OFF position and locked out if access to the electrical panel is required.

13

Key

Lockout Bar

3. Flip the lockout bar to the locked position. Note that the circuit breakers cannot be returned to the

ON position when the lockout bar is in the locked position.

4. Secure the lockout bar with an external lock. The lockout bar will not stay in the locked position without an external lock.

• Each person servicing the system should have a personal lock.

• Never remove someone else’s lock from the lockout.

14

OPERATING ENVIRONMENT

• The Fortus 900mc is for indoor use only.

• Operating temperature: 60°F (15.5°C) to 85°F (29°C).

• Humidity: 20-80% non-condensing.

HEAT OUTPUT

Heat output is material dependent due to the various temperatures maintained in the build oven.

Material Type

PPSF

PC

M30

Heat Load BTU/hr

26,000 heat load BTU/hr

18,000 heat load BTU/hr

12,000 heat load BTU/hr

ELECTRICAL REQUIREMENTS

The facility power is required to meet the following power quality and nominal voltage requirements:

• Rating of system is 13.5KVA

• 230VAC nominal 3-phase service with 5% regulation

Note: 230VAC as measured phase-to-phase at the input connection to the printer. Facilities wiring should be designed to meet the + or - 5% voltage tolerance requirement at the printer under all operating currents ranging up to 34 Amps.

• 50 Hz or 60 Hz

• 40 Amp circuit

• 34 Amp full load current on all three phases

• Maximum inrush current ~570 Amps for 2ms

• Three wire plus ground electrical connection

Operation of the system outside this range is not recommended and degradation of the system performance and shortened component life expectancy will be experienced. The system is to be operated on a 3-phase service meeting the recommendations for power quality given in IEEE Standard 141-1976. Facilities who are unsure of their power quality should contact their service provider.

COMPRESSED AIR REQUIREMENTS

The system has an onboard pressure regulator, onboard particle filtration, water, and oil separation.

• Supply pressure at the system: 90-120 psi with a minimum flow of 14 CFM

• Less than 95°F (35°C)

• Non-lubricated

• Non-condensing

• DIN ISO 8573-1 Quality Class 5 or better is recommended to improve onboard filter life

• Connection: Dimensional standard A-A-59439

LAN REQUIREMENTS

A LAN connection is required for communication and file transfer functions.

• Category 5 or better

• 10/100 Base T Ethernet

• RJ45 connector

Note: The Fortus 900mc will function in both DHCP or Static IP configurations.

• Use a standard Ethernet patch cable when connecting to a facility network (included in the start-up installation kit). If connecting directly to a workstation an Ethernet cross over cable is required (not supplied in the start-up kit).

15

TOOLS

START-UP KIT CONTENTS

The printer’s Start-Up Kit contains the Welcome Insert document, software CD, the common tools you will need to maintain the printer, and a variety of replacement parts. Use the following tables to identify the contents of the

Start-Up Kit.

Start-Up Kit Contents

Welcome Insert Document Contains instructions for downloading the 900mc User Guide (this document).

RJ45 Cable This cable is used to establish a network connection between the 900mc and your

Ethernet network. Job files are transfered to the printer via this connection.

Leather Safety Gloves

Protective Arm Sleeve

Printer components may be extremely hot. To prevent burns or other injuries, these gloves should be worn any time you see the gloves safety sign.

To prevent burns or other injuries, these sleeves should be worn in addition to the leather safety gloves.

Magnetic Handle

Pick Set

Hex Ball

End

Driver

(9/64)

10x

Lighted Magnifier

Occasionally, you may need to use these picks to aid in the removal of breakaway supports or clearing debris which have accumulated on the head and/or tips.

This is used throughout the process of changing the printer’s tips.

This tool is included to aid you with performing an XYZ Tip Offset Calibration which requires you to view small toolpath relationships. Batteries for this item (2 C batteries) are not included.

5” Cutters

Needle Nose Pliers (7

1

/

8

)

These are used to cut a canister’s filament when unloading and removing materials from the printer.

Occasionally, you may need to use pliers to aid in the removal of breakaway supports or clearing debris which have accumulated on the head and/or tips.

Angled Tweezers

#2 Phillips Screwdriver

Platen Dusting

Brush

Scraper

Utility Knife

Insight CD

This tool can be used for multiple general maintenance applications.

This tool can be used for multiple general maintenance applications.

This tool is used to brush away material debris when cleaning the platen. Always ensure that the platen is clean before starting a build, as debris on the platen will affect vacuum quality.

This tool is used to remove parts or debris from the build sheet.

This tool can be used for multiple general maintenance applications.

This CD is used to load Insight software (as well as FDM Control Center software) onto your workstation PC. Insight is the software used to process files and then transfer them to the printer to be built.

16

SAFETY INFORMATION

The following basic safety tips are given to ensure safe installation, operation, and maintenance of Stratasys equipment and are not to be considered as comprehensive on matters of safety. The Fortus 900mc printer is designed to be a safe and reliable rapid prototyping printer. Access to areas of the printer are potentially dangerous.

HAZARD TYPES

Stratasys recommends that all services be performed by qualified personnel. All personnel working on or around this printer should be knowledgeable of what the following hazard classifications mean throughout this guide.

• Warnings and Cautions precede the paragraph to which they pertain.

Warning: Indicates a potentially hazardous situation which, if not avoided, may result in injury or death.

Caution: Indicates a situation which, if not avoided, could result in damage to equipment.

Note: Indicates additional information relative to the current topic.

SAFETY SYMBOLS

Note: Always read and adhere to safety statements, and be aware of the following safety signs when you see them on the printer.

We make every effort to ensure that our printers are safe and reliable at all times. However, there will be times when you must access areas of the printer where potentially high voltages, hot temperatures, and/or moving mechanical components could cause severe injury.

Personal Injury: The personal injury sign indicates mechanical parts, and severe personal injury is possible. Always use extra care. Do not wear ties, loose clothing, or dangling jewelry. Keep long hair tied up and away from any moving parts.

High Voltage: The high voltage sign indicates the presence of high voltages. Always stay away from any exposed electrical circuitry. It is recommended that all jewelry be removed.

Hot Surface: The hot surface sign indicates the presence of devices with high temperatures.

Always use extra care when working around heated components. Always wear the safety gloves provided in the Welcome Kit.

17

Gloves: The gloves sign indicates that if you enter the area specified by the symbol you must wear safety gloves (provided in the Welcome Kit) which have been approved for high temperatures.

Sharp Object: The sharp object sign indicates the presence of sharp objects. Do not touch sharp objects as they may cause a loss of body parts.

Crushed Hand: The crushed hand sign indicates that a crushing hazard exists between two objects.

Do Not Enter Oven: This signs warns you to never enter the oven with your entire body.

when working on or near electrical circuits.

ESD: Use standard electrostatic discharge (ESD) precautions

18

SAFETY PRECAUTIONS

The following components and areas of the printer are potential safety hazards. Take adequate precautions when using and maintaining the printer.

OVEN

Warning: Always wear safety gloves and long sleeves when working inside the oven. Components are hot.

The oven temperature is extremely hot. The oven temperature is controlled by a safety thermostat that shuts the printer off when temperatures reach 260°C

(500°F).

Note: Opening the oven door removes power to the oven heaters.

GANTRY

Warning: Never wear a tie, loose clothing or dangling jewelry when working around moving components of the system. Beneath the top cover of the system is the XY Gantry. This area houses the mechanical drive components of the X and Y axes. Use extreme caution whenever accessing this area of the system.

The servo drive system is extremely powerful so care must be taken. The servo motors are disabled when the oven door or top covers are opened. The XY pinch hazard between the timing belts and pulleys is minimized by locking the hood while building and disabling the motors when the top hood is open.

Z STAGE

Warning: Never wear a tie, loose clothing or dangling jewelry when working around moving components of the system. The Z-Stage and Z-Stage servo motor can cause severe injury. The Z-Stage crushing hazard is minimized by locking the door during Z-Stage movement and disables the Z-Motor when the door is open.

GUARD DOOR INTERLOCKS

Interlock switches are used to communicate the status of the oven door and the two top slide covers. For safety reasons, the oven door and the slide covers must be closed before the X, Y, and Z motors will operate.

19

STABILITY WEDGE BLOCKS

Back Wedge Block Placement

Adjacent to the outside of the skid angle iron mount point

Wedge Block

(2X)

1. Place the Wedge Blocks in position and then snug up the wedge to a gap of 0.25 inch (0.6 cm) between the system frame and the edge of the wedge.

2. Use a wrench to tighten the wedges until the top of the wedges are flush with the frame

System

Frame

Flush

Snug Fit Before Tightening

0.25 in.

(0.6 cm)

After Tightening

20

Front Wedge Block Placement

Only Wedge Block placed inside System

Approximately

1.0 in. (2.5 cm)

Note: Only the front left Wedge Block is placed on the inside of the system. This is done so the adjuster of the wedge block will not be visible after the front left kick panel is installed.

Note: The Wedge Blocks are not intended to lift the system off the floor. They are used only to stabilize the system in position. Do not adjust such that any caster actually leaves the floor.

GENERAL SAFETY PRACTICES

Abide by these general safety practices when working with this system.

High Voltage: High voltage is present in the system when powered off and unplugged because of the Uninterruptible Power supply (UPS).

Warning: Only use an OSHA or CE approved step stool when accessing the area under the top slide covers (located at the top of the system).

Always wear safety gloves and long sleeves when working in the oven, with the head, or liquefier tips. These components are very hot.

21

BASIC USER OPERATIONS

The Operator Touchscreen is located on the front of the system. Icons are displayed on the screen that are universal and intuitive to use.

Power On

Button

Power Off

Button

Operator

Touchsceen

The Operator Touchscreen allows you to:

• Access material loading and unloading functions along with access to calibration.

• Monitor system status.

• Monitor material status (type loaded and amount).

• Monitor job status (number of hours completed, number of hours total, current build height and total build height, and the name of job currently being built).

• Initiates a system power ON or a power OFF.

• Access network configuration.

• Access the job queue.

• Access the sample job queue.

22

POWERING ON THE SYSTEM

To turn the system ON:

1. Press the flashing green button ( Figure ).

2. If there is a completed part in the system, remove the part from the system and install a new build sheet and close the door.

3. Press the Materials/Tools icon from the touchscreen and then press the XYZ icon to auto home the platen.

• The system will find the home position for the X, Y, and Z axes. This must be done before any part can be built.

4. If the system has been powered down long enough for the oven to cool, allow the oven to heat and stabilize for at least four hours before performing system calibrations or part build.

POWERING OFF THE SYSTEM

Warning: Due to the UPS, high voltage is present in the system when the power cord is unplugged.

Caution: Do not turn the blowers off prior to the five minute time-out or damage to the system may occur.

To power down the system, press the red button ( Figure ).

• The screen will show: It is now safe to turn off your system .

• After a few minutes, the green light on the panel will flash.

Note: If power to the system is removed, the head blower will continue to operate with power supplied from the UPS. The UPS will supply power for approximately five minutes while shutting down the system.

Always wait until the green button starts to flash indicating that the system is ready to be turned on again.

23

USER INTERFACE

The following figure depicts the navigation buttons and status indicators of the Fortus 900mc touchscreen:

Back Build Pause Stop Light Door

Material

Tools

Help Login

Previous Job

Selected Job

Next Job

Queue Window

System Log

Health Monitor System State

MATERIALS/TOOLS DISPLAY

This window displays the current status of the modeler and support filament, canister status, and tip size and setpoint and the actual temperature of the tips. The color of the tips will turn blue (for model) and brown (for support) when material is fully loaded. A variety of messages will be temporarily displayed under the canister icon to show the current activity of the canister/filament.

Temperature

Set Point

Tip Size Odometer Reading Temperature

Model Canister

Support

Canister

Canister

State

24

QUEUE WINDOW

The Queue menu contains files downloaded from the Insight application on your PC workstation.

• Job Queue displays current jobs that are waiting in the queue.

• A list of stored sample jobs can be displayed by pressing the Sample Queue icon.

Note: The jobs listed in either queue can be arranged by pressing any of the categories (i.e., Job Name, Materials, Tips, or Build Time).

25

TIP OFFSET MENU

This menu allows the user to adjust the XYZ calibration offsets. The thickness of the support material can also be adjusted. After adjustment, the user can press the Build Calibrations Box to verify the calibration.

PART PLACEMENT MENU

The Part Placement window allows the user to move the part manually to a position on the build sheet. The part is moved by touching the black box outline of the part and dragging it to the desired location. Shadows of previous builds appear as grey boxes. These can be cleared by pressing the “Clear” button. The part outline cannot be dragged outside the currently installed build sheet.

26

SYSTEM DEFAULT VALUES

System defaults can be changed from the System Default menu.

DISPLAY UNITS

Select Display Units.

• Inches or metric can be selected (factory setting is in English).

USER PLACEMENT

The part build location can be viewed or changed from the User Placement button.

1. If User Placement is set to Off (default), the part will build in the center of the platen.

2. If User Placement is set to On, the position of the part can be position on the platen by the user.

The part can be position by dragging and dropping the part using the Operator Touchscreen. The part cannot be outside the limits of the build sheet.

AUTO COOL OVEN

If the Auto Cool Oven is set to on, the oven will cool to the standby temperature.

ENABLE SECURITY

Planned for future development.

CAMERA ENABLE

Allows you to turn the printer’s camera On and Off for remote job monitoring purposes.

27

BUILDING SCREEN

The Building Screen displays the progress of the part being built. Oven temperature is displayed as well as platen vacuum for large and small build sheets. The icon will turn green when vacuum is present. Pressing the

Platen Vacuum button turns off the platen vacuum so a build sheet can be removed. When off, the button displays a Ø symbol. Vacuum is restored by closing the oven door.

Build Progress

Set Point Temperature

Actual Temperature

Platen Vacuum

Material Name

Odometer

Amount of Material

28

LOADING/UNLOADING MATERIAL

LOADING MATERIAL TO THE LIQUEFIER TIPS

Note: Loading filament to the liquefiers is done in the Idle or Paused mode only, not while building.

Caution: If the material type is changed, the tips must be changed.

Perform the following steps to load material to the liquefier tips:

1. Make sure the system is in the Pause or Idle mode.

2. From the Main Menu, select Operator Tools and the following screen will appear.

Load

3. Select the material to be loaded and press the Load icon.

Note: Model and support materials must be compatible. If a selected material is incompatible with a loaded material, a material mis-match load error will occur.

The selected material will not be loaded.

• The head warms up to the material operating temperature (Automatic - based on SmartSpool data). This step also sets the oven temperature to the correct value for the material being loaded.

• The canister drive motor starts to push the filament to the liquefier tips.

• For some materials (i.e., SR-20) the order of steps A and B is reversed.

• When the filament reaches the head (takes 2 to 4 minutes), it enters the liquefier tip, and the tip purges a small amount of material.

• A successful load is indicated by a steady green LED. A complete load and purge cycle should take less than five minutes.

29

UNLOADING MATERIAL FROM THE LIQUEFIER TIPS

Note: Unloading filament from the liquefiers is done in the Idle mode only, not while building or in a paused state.

Perform the following steps to unload material from the liquefier tips:

1. Make sure the system is in the Pause or Idle mode.

2. From the Main Menu, select Operator Tools and the following screen will appear.

Unload

3. Select the material to be unloaded and press the Unload icon.

• The head warms up to the unload temperature, and the canister LED rapidly flashes green.

• The head drive motors and canister drive motor turn in reverse. The material is pulled back from the head about 4-6 inches (10-15 cm).

Note: For some materials (i.e., SR-20), a tip purge is performed before the material is unloaded from the liquefier.

• The head temperature lowers to standby temperature and the canister LED turns to a slower flashing green (same flash rate as used to indicate canister Ready condition).

• The display will show At Head for the unloaded material.

4. Replace the canister.

30

CHANGING TIPS OR MATERIAL TYPE

Note: If you are changing tips, or changing to a different material type, the user interface has a menu selection that guides you through the process.

Caution: If the material type is changed, the tips must be changed.

Perform the following steps to change tips an/or material type:

1. Clean the oven and the tip wipe assembly.

2. Empty waste material from the purge bucket.

Note: Residue from lower temperature materials can melt and drip onto higher temperature parts if cleaning is neglected.

3. Inspect the tip wipe assembly.

4. From the Main Menu select the Materials/Tools icon and then select the Tips/Materials

Change icon .

Tips/Materials Change

5. The Tips/Materials Change menu is designed to guide you through the steps necessary to complete a material type change or a tip replacement procedure.

6. If the liquefier tips are to be changed:

Warning: Always use an approved ladder or step stool when working with components under the top slide covers.

A. Open the left top slide cover.

31

B. Place the head in the head maintenance bracket.

Warning: Surfaces of the liquefier tips and heater block can be very hot.

C. Loosen the two captive screws that clamp each liquefier tip in place. Remove the tips.

Liquefier

Clamp Screws

D. Place the new liquefier tips in the head. Tighten the clamp screws.

Note: Make sure the tips are fully inserted into heater block before tightening the clamp screws.

Make sure the tip is fully inserted into the block .

E. Remove the head from the maintenance bracket and place it back in the gantry. Tighten the two captive screws that hold the head in place.

Note: Make sure the filament tubes, umbilical cable, and air hose are not tangled and are routed correctly.

32

AUTOMATIC CALIBRATIONS

After tips are changed the user menu will prompt you to perform a series of automatic calibrations: Autocal Tips

Calibration, Autohome XYZ, and Auto Z Calibration.

Note: Perform an Autohome XYZ before initiating automatic calibration.

Operator interaction is not required for Auto Z Stage Zero calibration.

XY and Z Tip Offset requires that the operator analyze a calibration part and supply the system with correction values.

START AUTO Z ZERO CALIBRATION

Start Auto Z Zero Calibration sets the model liquefier tip to the Z zero location on the build sheet.

No operator interaction is required. This is also performed automatically before each job build.

START AUTO TIP CALIBRATION

Start Auto Tip Calibration allows the user to calibrate the tip-to-tip offsets in the Z direction. No operator interaction is required.

1. The system automatically performs this calibration as part of the tip change wizard actions.

2. Proper calibration allows the system to toggle material tips and place the current tip at the precise coordinate necessary to continue accurate part build.

33

ADJUST XYZ CALIBRATION OFFSETS

Adjust XYZ Calibration registers the support tip relative to the model tip.

1. The system automatically builds the calibration model when the Build Calibration Box button is pressed.

2. Remove the build sheet from the platen and allow it to cool.

3. Determine the XY Offset Adjustment.

A. View the relationship between the support calibration toolpath and the alignment indicators to determine the X and Y Axis calibration.

• Use a magnifier.

• Hold the build sheet up to the light, a light-colored wall, or a light-colored piece of paper.

B. Determine where on each axis the support toolpath is most centered between the X-Y alignment path.

C. Read the Offset Adjustment Value closest to the centered location for each location.

• This value represents the adjustment value to be entered into the system - increments of 0.002 of an inch or 0.05 mm.

• If the value is 0, then the system is calibrated for that axis - an entry is not required.

D. Slide the arrow on the screen to match where the support is most centered. Only move arrows on two of the four sides of the calibration part.

E. Press OK . The screen will pop up asking if you want to apply these values. Press OK . When

X and Y are both at 0, proceed to adjusting the Z.

F. If an adjustment entry for either axis is required, re-run the calibration model on a clean build sheet.

G. Continue to check and adjust for XY offset until the calibration toolpath is centered at 0 for the X and Y axis.

34

Calibration Model

English Units

- Y Tip Offset Adjustment Indicators

X - Y Support Calibration

Toolpath

Example: Best

Centered Position

- X

X - Y Alignment

Indicators

+ X

Z Calibration Box

+ Y

This example requires an adjustment to

Y of -.002 in. The X axis requires no adjustment.

H. After the adjustments are made, a new calibration box can be run from this menu by pressing Build Calibration Box .

- Y Tip Offset Adjustment Indicators

Calibration Model

Metric Units

X - Y Support

Calibration Toolpath

Example: Best

Centered Position

X - Y Alignment

Indicators

- X

+ X

Z Calibration Box

This example requires an adjustment to

Y of -.05 mm. The X axis requires no adjustment.

+ Y

4. Determine the Z Adjustment.

Note: Do not measure for Z adjustment until the Calibration Model shows the XY

Offset to be less than 0.002 inch (0.05 mm) for the X and Y axis.

A. Peel the Support layer from the Z Calibration box.

B. Measure the thickness of the Support layer with a caliper or micrometer.

• If the measured value is within ±0.0005 inch (0.01 mm) of Model Tip slice height, no adjustment is necessary.

• Enter the value that is read from the caliber in the “Support Thickness” field.

C. If an adjustment entry is required, re-run the calibration model on a clean build sheet.

D. Continue to check for Z Calibration until the Support layer matches the Model Tip slice height

±0.0005 inch (0.01 mm).

35

AUTOHOME XYZ

When the AutoHome icon is pressed, the system will perform the following exercise with no operator interaction required:

Note: AutoHome is used to move away from a limit switch.

1. Finds the Z home limit switch.

2. Finds the X home limit switch.

3. Finds the Y home limit switch.

4. Returns to the head parked position.

36

BASIC JOB BUILD TASKS

BEFORE A BUILD

To build a job, you must send the job file to the system from the Insight application installed on your workstation.

Jobs are sent in a CMB format and placed in the job queue (stored on the system hard drive). The header of the

CMB file contains the processed job’s basic information (material type, approximate material amount required for build, tip size, etc.). This information is used to verify job compatibility with the system setup.

1. Prepare the system:

A. Power up the system. (Stabilization of the system takes approximately four hours.)

B. Install a new build sheet by doing the following;

Warning: Wear proper safety equipment when handling items inside the oven.

Surfaces in the build chamber can be very hot.

i. If applicable, remove the plastic wrap from both sides of a new build sheet.

Note: Always use a new build sheet when building a job. The build sheet is intended for one-time use. Do not turn a build sheet over and place it on the platen. Material residue on the sheet can adhere to the platen or interfere with the build sheet vacuum.

Using build sheets not provided by Stratasys may impact part quality and system reliability.

ABS, ASA and PC parts use a clear build sheet.

PPSF and ULTEM parts use an amber-colored build sheet.

Nylon parts use a green tinted build sheet.

ii. Set the build sheet on the platen.

• The Fortus 900mc can accommodate two sizes of build sheets. Make sure the build sheet that is used is centered on the platen.

• If the oven is hot, the build sheet will curl when placed on the platen. As the build sheet warms up, it will flatten and adhere to the platen. Some adjustment of the sheet may be necessary to seal it against the platen. (Turning the platen vacuum off and on will help this final adjustment to a warm build sheet.)

• If there is a curvature set to the build sheet, place the build sheet onto the platen in the concave orientation.

Platen

37

iii. Make sure the active model and support canister bays have filament loaded to the head (steady green

LED).

iv. Make sure the loaded filament match the material requirements of the CMB file. Change material type if necessary.

v. The touchscreen warns if there is a material mis-match.

vi. Make sure that the tip cleaning brush and tips are clean.

vii. Empty the purge bucket.

viii. If using Auto-Cool Down, or if the material type has changed, allow the oven to heat and stabilize for at least four hours.

2. Modify System Defaults:

A. Display units - choose inches or metric.

B. User Placement on Platen - allows you to choose the part build location.

SELECT A JOB TO BUILD

From the Building screen, select one of the following job build options:

Build

Previous Job

Selected Job

Next Job

Queue

Window

1. Next Job

• Selects the first job in the job queue for build.

2. Previous Job - builds the last job completed.

• The previous job built by the system will be selected for build.

• If a previous job does not exist, the screen will show No Previous Job .

3. Queue Window

• The job queue is displayed.

• Select a specific job in the queue.

4. If the User Placement option is set to on, the following screen will appear.

38

Position Part

Build

5. Using the touchscreen, position the part on the displayed platen.

6. Press the Build icon to initiate the building of the selected part.

BUILD JOB WARNINGS

If the system detects an issue that may affect a job build, the system displays one of the following warnings:

A. Head has been changed. Consider tip calibration.

• Indicates a new head has been installed.

• Run and verify a calibration part before building jobs.

B. Change Model (or Support) canister to ABS (or other material).

• Indicates a mis-match between loaded material and material for which the part (CMB) file was processed.

• Replace the flagged material canister with proper type.

39

C. Need More Model (or Support) Material.

• The total available material is less than the estimated amount for the part (CMB file).

• If the system runs out of material before part completion, system will pause the build until material is added.

• Replace flagged material canister.

D. Need both (or 4 for 4-bay system) canisters present.

• Indicates that at least one operating canister bay does not have material loaded to the Ready mode

(flashing green LED)

• System operation will not be significantly compromised by this condition. The air-dryer circuit performs more efficiently when all operable bays are Ready.

• Install canisters to the Ready mode for all operating canister bays.

E. Replace Model (or Support) tip with T12.

• Indicates a mis-match between installed tip and tip for which the part (CMB) file was processed.

• Install the correct.

F. Replace Worn Model (or Support) tip.

• The system tracks the amount of material extruded through a tip. You will receive this prompt when tip performance may start to become compromised. (Tip-life prediction is an estimated value. Many factors contribute to actual tip-life aside from amount of material extruded. Actual tip-life may differ from predicted tip-life.)

• Replace the flagged tip.

G. Model / Support Material Incompatibility.

• Model and support materials are not of compatible types.

• Load correct material.

H. Vacuum not present. Check the build sheet

• Vacuum is below minimum for system operation.

• Correct condition - often the result of a poorly positioned build sheet.

I. Continue.

• You can choose to ignore the warning and ‘Continue’ the build, but part build quality will be unpredictable.

Note: A warning generated from a mis-match of model/support compatibility or from low vacuum cannot be bypassed.

40

WORKING WITH THE JOB QUEUES

There are two queues available on the Fortus 900mc - the Job Queue and the Sample Job Queue. Use the Job

Queue and Sample Queue buttons within the Operator Touchscreen to toggle between the two queues.

The Job Queue menu contains files downloaded from the Insight application on your PC workstation.

• Side Bar - Use the slide bar to scroll the display up or down through the available jobs.

• Heading Bar - Press any column in the heading bar to change the order of the column listing.

The Sample Queue menu contains files that are helpful for testing the system. The Fortus 900mc comes with several sample job files permanently installed on the system.

• Use the slide bar to scroll the display up or down through the available sample jobs.

Heading

Bar

Slide Bar

PAUSING OR STOPPING A JOB

During a part build, the system can pause automatically (when a canister runs out of material, failure detected, etc.) or can be put into a paused state using the Pause icon on the Operator Touchscreen.

Note: If an automatic pause occurs, the issue will appear in the System Log

Button on the bottom of the screen.

When the system is directed to pause, the following actions take place:

1. The current tool path is completed.

2. The Z Stage is lowered slightly.

3. The head is parked.

4. The user display will change to indicate the paused condition.

From the pause mode you can make the following selections:

1. Resume Build - the system resumes building the part.

2. Modeler Status - View the Job Status and Canister Status.

41

3. Operator Control - Unlock the oven door and top slide covers, clean tips, change materials

(including load/unload and canister removal/installation), move the head, or move the Z Stage.

4. Stop Job - Stops the current job.

42

AFTER A JOB BUILD

Warning: Wear proper safety equipment when handling items inside the oven.

Surfaces in the build chamber can be very hot.

After a job build is complete, the system performs the following actions:

• The Z Stage is lowered and the head is parked.

• The touchscreen will displays the following Build Complete message :

Perform the following steps after the completion of a job build:

1. Press OK and then remove the part from the system.

Note: If Auto Cool Oven is active, allow the oven to cool to the standby temperature before removing the part.

2. Turn off the vacuum with the button on the Operator Touchscreen.

Caution: Do not attempt to remove a part from the build sheet while the build sheet is on the platen. Damage to the platen or the platen level may occur.

3. Open the oven door and remove the build sheet from the platen.

Caution: Use extreme care when cleaning the platen. If using a brush, brush away from the vacuum port in the center of the platform. If debris falls into the vacuum port, it can cause a loss of vacuum, resulting in poor adhesion of the build sheet during building.

4. Use a vacuum cleaner or a soft brush to remove debris that may have fallen onto the platen.

43

5. Carefully peel the part from the build sheet.

• If the part does not peel easily, use the metal scraper included in your Startup Kit to carefully pry the part from the sheet.

• The build sheet is intended for one-time use. Do not turn a build sheet over and place it on the platen. Material residue on the sheet can adhere to the platen or interfere with the build sheet vacuum.

6. Remove supports from the completed part.

44

USER MAINTENANCE

Maintenance tasks must be performed on a regular basis in order to maintain optimal system operation. The following table outlines the general maintenance schedule. Detailed instructions for each task make up the rest of this chapter. Please note that the testing of interlock/protective circuits is not applicable to the Fortus 900mc.

Warning: always wear proper heat protective clothing when working inside the oven.

Daily

X

X

Weekly Quarterly As Needed Maintenance Task

X

X

X

X

X

X

X

Clean the Platen.

Empty the Purge Bucket.

Vacuum the Build Envelope.

Clean/Inspect the Tip Wipe Assembly.

Clean the Tip Sensor Plunger.

Clean the Liquefier Tips.

Clean the Cabinet.

Clean Plastic Components.

Clean the Oven Door, Camera/Lamp and Touchscreen

Display.

45

DAILY MAINTENANCE

CLEAN THE PLATEN

The platen is the surface on which the build sheet is placed for modeling. If debris collects on the platen, it can adversely affect the vacuum which secures the build sheet to the platen.

1. Remove the build sheet from the platen.

• Lift a corner of the build sheet to break the vacuum holding it to the platen or turn off vacuum using the button on the touch screen.

• Slide the build sheet from the platen.

2. Carefully remove debris that has fallen into the channels of the platen.Use a vacuum or use a soft brush.

• If a brush is used, brush away from the vacuum port in the center of the platen.

• If debris falls into the vacuum ports, it can cause a loss of vacuum, resulting in poor adhesion of the build sheet to the platen during part build.

Note: Do not attempt to remove the vacuum port screens. They are not a customer replaceable items.

Vacuum Ports and Debris Screens

46

EMPTY THE PURGE BUCKET

The purge bucket is located inside the oven. It catches the material that has been purged or wiped from the liquefiers and liquefier tips. The purge bucket should be emptied daily.

Warning: Always wear safety gloves and long sleeves when working inside the oven. Components are hot!

1. Open the Oven door. Use caution because the oven is hot.

2. Make sure the build platen is at the bottom of the envelope area.

3. Lift the purge bucket straight up from the purge bucket bracket and remove from the oven bay.

4. Empty the waste material from the purge bucket. There is a waste door at the bottom of the bucket.

5. Install the purge bucket on the purge bucket bracket.

Purge

Bucket

Purge Bucket

Bracket

Waste Door

47

WEEKLY MAINTENANCE

VACUUM THE BUILD ENVELOPE

Vacuum the build envelope to remove build material waste, debris, and dust.

CLEAN/INSPECT TIP WIPE ASSEMBLY

Inspect the Tip Wipe Assembly once a week. Replace parts as necessary when wear is detected. The brush and flicker are replaced as an assembly.

1. Remove the Tip Wipe Assembly by lifting straight up.

Purge Ledge

Tip Wipe

Assembly (2X)

2. Remove the Purge Ledge assembly by lifting it straight up.

3. Use a cleaning brush (in the system start-up kit) to remove debris from around the Tip Wipe and

Purge Ledge area.

4. Clean and inspect the surface around the locating pins - make sure that the Tip Wipe Assemblies and Purge Ledge can sit flush on the surface.

5. Inspect the Kapton tape around the upper funnel chute. Replace the Kapton tape if wear or tears are evident.

• The Kapton tape is secured to the upper funnel chute with self-adhesive material. To replace the tape, peel the tape from the chute.

• Clean the area around the top of the upper funnel chute with Isopropyl alcohol and a clean, lintfree cloth.

• Peel the backing material from the new Kapton tape and carefully position the shield in place on the upper funnel chute - the top edge of the adhesive area should be even with the top of the chute.

• Press the Kapton tape in place to secure.

6. Inspect the Purge Ledge assembly:

• The purge surface should be free from pock marks or surface irregularities.

• Install a new purge ledge assembly if necessary. Use a PPSF purge ledge assembly when using

PPSF or ULTEM material.

48

For PPSF and

ULTEM Material

Only

Standard

Purge Ledge

7. Inspect the flicker/brush assemblies.

8. The top edge of the flicker should be straight. Replace the flicker if it is notched or bent - a small amount of wear is acceptable. The flicker can be replaced individually if the brush is acceptable for reuse.

Unacceptable

Acceptable - some wear is allowed.

• The brush bristles must not show evidence of wear from the tip - no notches in the bristle pattern.

• Frayed bristles are acceptable as long as the top edge is even across all of the bristles.

• Replace the flicker/brush assembly if the brush does not meet inspection requirements.

9. Install the flicker/brush assemblies by placing them over the locating pins.

10. Install the purge ledge assembly by placing it over the locating pins.

Brush Flicker

Remove Screw

49

QUARTERLY MAINTENANCE

CLEAN THE TIP SENSOR PLUNGER

1. Remove the plunger - gently pull up and out.

2. Remove material residue on the top of the plunger with a razor blade.

3. Replace the plunger in the sensor bracket making sure the flat surface is up.

Tip Sensor Plunger

Tip Sensor Bracket

50

AS NEEDED MAINTENANCE

CLEANING THE LIQUEFIER TIPS

The system automatically cleans the tips before and during each part build - using the tip cleaning assembly.

However, occasionally, material may build up on the tips that cannot be removed during the auto-cleaning process. Remove excess material manually using a brass, wooden-handled brush (included in the Startup Kit).

CLEANING THE CABINET

Use a soft cloth moistened with mild soap and water to wipe down the outside of the cabinet. Do not use abrasive or high alkaline cleaners on the system. Vacuum all air vents of dirt and debris that would block airflow through the system.

CLEANING PLASTIC COMPONENTS

Clean the oven door and all plastic components on the outside of the system using mild soap and water.

Commercially available products made for cleaning plastic are also acceptable. Do not use abrasive or high alkaline cleaners on the system. Avoid streaks by rinsing with clear water and then drying with a soft cloth.

In addition to the above noted user maintenance tasks, Stratasys recommends all 900mc systems go through a

1 year PM which addresses lubing and the replacement of wear components and filters, which if not replaced, may contribute to diminished component life. In addition, Stratasys recommends a 6 month PM on systems with serial numbers lower than L0140 AND serial numbers listed L0148 through L0151. The 6 month PM primarily involves lubing of all the moving XYZ axis components.

Please contact Stratasys Customer Support if you are interested in receiving a quote for these services or would like additional information. Failure to adhere to this schedule could lead to reduced life of XYZ components such as lead screws and bearings.

CLEANING THE OVEN DOOR, CAMERA/LAMP, AND TOUCHSCREEN DISPLAY

Commercial glass cleaner can be used on the outer surfaces of the oven door and touchscreen bezel because these items have an anti-scratch coating applied.

Note: Never apply a glass cleaning product to the high temperature glass inside the oven because discoloration may occur at elevated temperatures.

Use only a 50-50 mix of isopropyl alcohol and water to clean the high temperature glass windows of the oven door and camera/lamp assemblies.

Use the following guidelines for cleaning the polycarbonate oven door window insert:

• Do not use abrasives or high alkaline products.

• Do not apply cleaners in direct sunlight or at elevated temperatures.

• Do not use scrapers, squeegees, razor blades or other sharp instruments.

• Do not clean with gasoline, acetone or carbon tetrachloride.

• If scratching should occur, minor abrasions can be removed or minimized using a mild automotive polish.

• The glass on the oven door should only be cleaned with isopropyl alcohol. This prevents the glass from producing a film at high temperatures.

51

SUPPLEMENTAL INFORMATION

ELECTRICAL PANEL COMPONENTS (GEN 2 ONLY,

SERIAL NUMBER > 1030)

The electrical panel is located in the back of the system and accessed from behind two hinged access panels.

These can be either opened or removed by a service representative when they are servicing the system.

Virtually all system communication, interface and control takes place or originates from within electrical panel of the Fortus 900mc system. The electrical panel is not intended for customer/user access because potentially deadly electrical power sources are present. Safe electrical practices must be followed when performing service within this enclosure.

Electrical panel components include the following:

• Motor Amplifiers

• 120V DC Power Supply (3X)

• Computer

• AC Filters

• 24V DC Power Supply

• AC Distribution Bus

• UPS

• Oven Thermal Breaker

• Heater Solid State Relay

Amp, Programmed X

Amp, Programmed Y Amp, Programmed Z

Power Supply

(24V, 250W)

Filter, Motor EMI

CCA, MAC

Board

CCA, Auxiliary

120VDC P.S.

Din Rail Assy.

SOK SATA

Computer Assy.

Filter, AC Line

Line Reactor

UPS

CCA Differential

Line Filter

SSR, Oven

Heaters

Block,

Heater

Terminal

Power

Supply

LED

52

Breaker, Thermal

Oven

Din Rail Detailed View (Gen II only, Serial Number > 1030)

Y MOTOR

Z MOTOR

T3

SAFETY RELAY

SAFETY

CONTACTOR

SAFETY

CONTACTOR

MOTOR

CONTROL

OVEN

BLOWER

EX FAN

FANS EB

HEATER

MAC MN

T2

MAIN

MAC LINE

T1

OVEN

LIGHTS

53

AUXILIARY PANEL (GEN 2 ONLY, SERIAL NUMBER >

1030)

The auxiliary panel is located on the right side of the system and accessed from the access panels. With the

MAC board interface and control, the auxiliary panel provides two primary functions; vacuum generation and air drying. These functions are performed using an external compressed air source (non-lubricated) at 90-120 psi).

Because of the large build area offered by the Fortus 900mc, two separate vacuum zones on the vacuum platen are provided. The zones are identified as the “inner” and “outer” and permit use of either large or small build sheets. Dried air is supplied to the filament feed path of the system making sure that material delivered to the head does not become contaminated by moisture that could cause part quality issues.

Auxiliary Panel Components:

• Relief Valve

• Solenoid Air Valve

• Input Regulator and Filter

• Coalescing Water and Oil Filter

• Input Manifold and Dual Pressure Sensor

• Vacuum Generators

• Air Dryer

• Dry Air Filter

• Output Manifold and Gauges

Dry Air Filter

Solenoid Air Valve

(on reverse side of panel)

Vacuum Generators

Coalescing Water and Oil Filter

Pressure Regulator and Filter

Output

Manifold,

Gauges and

Airflow

Orifice

Air Dryer

54

Input Manifold and

Dual Pressure Sensor

CONNECTION TO ELECTRICAL SUPPLY

Caution: A licensed electrician must perform all wiring from service connection to the system - including all connectors, cables, and proper strain relief.

Comply with all applicable local and national electric codes.

1. Remove 10 screws that attach the Left Back Access Plate to the system, This provides access to the electrical junction box.

Caution: Make sure to replace the back panel after the system is wired.

2. Wiring is to be routed from the top of the system to the fuse blocks.

Compressed Air RJ45 Connector

Junction Box

Top View

Note: Wiring is to be Routed from the

Top of the System.

Left Back

Access Plate

Screws

(10X)

55

3. Connect the system to the electrical service as follows:

Warning: HIGH LEAKAGE CURRENT. Earth connection essential before connecting supply.

• Line 1 connects to fuse block L1.

• Line 2 connects to fuse block L2.

• Line 3 connects to fuse block L3.

• Ground wire connects to the grounding block (minimum 10 mm

2

, 7AWG cu).

Note: A licensed electrician must perform all wiring from service connect and system including connectors, cables, and proper strain relief. Consult a licensed electrician to comply with all applicable local and national electric codes.

L1 L2 L3 Fuse Block (3X)

Grounding Block

(Position of bock may vary from that shown.)

L1

L2

230 Volts

230 Volts

230 Volts

L3

56

120VDC PO

120VDC PO

120VDC PO

SAFETY INTERLOCK SUMMARY (GEN 2 ONLY, SERIAL NUMBER > 1030)

• The one oven door and two top cover interlock sensor switches each utilize three contactor sets.

One set is used to provide open/closed status to the system software. The other two sets of each sensor report status to the safety control relay.

• The oven door and top cover interlock sensor switches interface their switch status to the safety control relay via cables 402194 and 402195.

• Power (+24VDC) to the safety control relay and dual contactors is provided by cable 402170.

• Power (230VAC) to the dual contactors is provided by cable 402174.

• One contact set of each dual contactors utilize +24VDC to feedback contactor status to the safety control relay.

• No calibration or periodic testing of the interlock relays is required.

63

HEADQUARTERS

7665 Commerce Way, Eden Prairie, MN 55344

+1 888 480 3548 (US Toll Free)

+1 952 937 3000 (Intl)

+1 952 937 0070 (Fax)

2 Holtzman St., Science Park, PO Box 2496

Rehovot 76124, Israel

+972 74 745-4000

+972 74 745 5000 (Fax)

ISO 9001:2008 Certified

For more information about Stratasys systems, materials, and applications contact your Stratasys representative or visit www.stratasys.com

.

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. We greatly value your comments, review all of them, and use them to improve subsequent releases of the documentation. In your email message please include the document title, part number (located on the front cover), and page number.

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