Stratasys Dimension 768/Elite Service Manual
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Stratasys Dimension 768/Elite Service Manual

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Table of Contents

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Dimension
768/Elite
®
3D Printer
Service Manual
Part No. 209009-0001, Rev A

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Summary of Contents for Stratasys Dimension 768/Elite

  • Page 1 Dimension 768/Elite ® 3D Printer Service Manual Part No. 209009-0001, Rev A...
  • Page 2 Notice The information in this document is subject to change without notice. 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. 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.
  • Page 3 About This Guide This service guide is designed to help you easily find the information you need to successfully service Dimension BST and SST systems. This guide is arranged in chapters with tabs for easy reference. When viewing the electronic PDF version, you can easily hyperlink to specific headings or chapters using the following methods: •...

  • Page 4: Table Of Contents

    Table of Contents Safety Hazard Classifications....................... 1-1 Product Safety Symbols ....................1-1 Safety Devices........................1-1 Electronics Overview Dimension 768 and Elite Specifications ................ 2-3 What Happens When......................2-4 Powering Up..........................2-4 Powering Down ........................2-4 Loading Material........................2-4 Making a Part ..........................2-5 A System Error Occurs......................
  • Page 5 Troubleshooting Troubleshooting a System Malfunction ............... 4-3 Overview ............................4-3 Testing the 186 processor board:..................4-3 Testing the Hard Drive and SBC:..................4-4 Final Test: ..........................4-4 Fault determination codes....................4-6 Cycling power........................4-6 Diagnosing loss of extrusion ................... 4-7 Clogged tip.......................... 4-8 Service Troubleshooting ....................4-9 Code Errors........................
  • Page 6 Service Procedures Exterior Components......................5-9 Rear Door............................5-9 Side Panels..........................5-11 Front Bezel..........................5-13 Display Panel ...........................5-21 Door Solenoid ..........................5-24 Door Sensor ..........................5-26 Gen 3 Electrical Components ..................5-28 Power Distribution Board (PDB)...................5-28 Controller Board ........................5-38 Single Board Computer (SBC) ....................5-43 Hard Drive..........................5-50 Electronics Bay Cooling Fan ....................5-56 24 VDC Power Supply ......................5-58 120 VDC Power Supply (SST only)..................5-63...
  • Page 7 Head Components ......................5-184 Head Cooling Fan........................5-184 Head Temperature Snap Switch ..................5-188 BST Swivel Head ........................5-192 SST Swivel Head........................5-197 TC Amp Board ........................5-203 Umbilical Cable........................5-209 Z Foam Level Sensor......................5-222 Z Foam Level Assembly .......................5-224 Chamber Thermal Snap Switch...................5-226 XY Table Cable Drive Components ................5-231 X EOT (End of Travel) Limit Switch...................5-231 X BOT (Home) Sensor......................5-233 Y EOT (End of Travel) Limit Switch...................5-236...
  • Page 8 Z Stage Components (1 Lead Screw)................5-423 Chamber Thermocouple (1 Lead Screw) ................5-423 Chamber Fans (1 Lead Screw) .....................5-426 Chamber Heaters (1 Lead Screw)..................5-432 Z Jam Sensor (1 Lead Screw) ....................5-438 Z Sensors (1 Lead Screw)......................5-442 Z Motor Belt (1 Lead Screw) ....................5-447 Z Motor (1 Lead Screw) ......................5-451 Z Stage Assembly - 1 LS .......................5-454 Receiver Components ....................
  • Page 9 Appendix 120/240 VAC Jumper Configuration ............Appendix-15 Fuse Specifications ..................Appendix-16 Device Voltages....................Appendix-17 Hard Drive Installation Checklist ..............Appendix-18 XY Table Installation Checklist ..............Appendix-19 Head Installation Checklist ................Appendix-20 Pre-Installation Checklist................Appendix-21 System Installation Checklist................ Appendix-22 Training Checklist ................... Appendix-23 Required Tool List...................

  • Page 10: Safety

    Safety Dimension 768 and Elite printers are designed to be safe and reliable rapid prototyping systems. However, as an installer and service engineer for this equipment, it will be required that you access areas of the machine that are potentially dangerous. This chapter includes the hazard classifications that are listed throughout this guide.
  • Page 11 Safety...

  • Page 12: Electronics Overview

    Electronics Overview In this chapter you will learn about the main components of the system. The contents and page numbers of this chapter are as follows: Dimension 768 and Elite Specifications ................3 What Happens When......................4 Powering Up..........................4 Powering Down ..........................4 Loading Material...........................4 Making a Part ..........................5 A System Error Occurs.........................5...
  • Page 13 Filament Motor Control ....................... 18 Temperature Control ......................18 Liquefier Temperature Control ................... 18 Actuators, Switches & Optical Sensors ................20 Safety Devices ........................20 Controller Board Layout ...................... 20 Reset Button ........................... 21 Dip Switches .......................... 21 Memory ..........................22 LEDs ............................

  • Page 14: Dimension 768 And Elite Specifications

    Dimension 768 and Elite Specifications Build Size Parts can be built up to 203 x 203 x 305 mm (8 x 8 x 12 in.) Material Parts are built of tough, durable ABS plastic in white (standard), blue, black, red, or green. Custom colors are available. Material Supply Two autoload cartridges with 0.95 kg (2.1 lbs) material per system (1 model and 1 support).

  • Page 15: What Happens When

    What Happens When... Powering Up When power is supplied to the system, the fans run continuously until power is shut off. Like any PC compatible computer, the SBC executes a built-in test and then goes out the HDD and loads the Linux Operating System. The OS and controller software are loaded and the Linux drivers are initialized.

  • Page 16: Making A Part

    Once the filament is detected in the head, the loading motors stop, and the head moves to the right rear location over the purge bucket. At this time, the filament motors are driven forward, loading the liquefier, causing it to purge. You will be asked to verify that the purge has occurred. Making a Part Once the printer is in , the...

  • Page 17: Gen 1 Electronics

    Gen 1 Electronics 186 Processor Board 186 Microprocessor Overview The 186 board provides all of the low level hardware control and sensing for the system. The software that runs on the 186 CPU and is E-prom resident (rather than on the HDD as with the SBC).

  • Page 18: Filament Motor Control

    Filament Motor Control The 186 cpu takes the flow rate information from the SBC and sends it to a 629 servo motor controller. The 629 uses this information along with the encoder signals from the filament motors to generate an output signal to drive this servo motor in the head assembly. There are two filament motors and two 629 servo motor controllers.

  • Page 19: Actuators, Switches & Optical Sensors

    Actual power to the liquefier heater is supplied by the power distribution board which is controlled by the 186 processor. The heater is turned off and on 1000 times a second (pulses). The duration of the 120 VDC pulse determines the average power being supplied to keep the liquefier at temperature.

  • Page 20: 186 Board Layout

    186 Board Layout Figure 3 below shows the layout of the 186 board connectors with labels indicating where each of the functions described previously are connected. In addition to those functions, the figure shows a reset button, a set of dip switches, and the LEDs (D3 –D11). Figure 3: 186 processor board detail To Z jam sensor, Y To door sensor, Y...

  • Page 21: Memory

    DANGER: Take extreme caution when accessing this area. It is very dangerous since there is no safety mechanism if anything, such as a body part, gets caught in the system. • Switch 5 will print out through the hyperterminal the temperature and power settings of both the liquefier and the chamber.

  • Page 22: Single Board Computer

    Single Board Computer The single board computer (SBC) is the main processor in the system. It is a complete “PC compatible computer” on a single board. See Figure 4. The TCP/IP network interface connects directly to the RJ-45 connector on the SBC. The network interface supports both 10baseT and 100baseT operation.
  • Page 23 Figure 5: Old Ampro SBC detail Manufacturer name AMPRO To Power Down Switch and LCD To hard drive (ribbon cable) To LCD (ribbon cable) +5 and +12 VDC input RJ-45 Network connection Ampro SBC Figure 6: Nova 600 SBC detail Manufacturer name To hard drive (ribbon cable)

  • Page 24: Power Distribution Board (Pdb)

    Power Distribution Board (PDB) This board provides all the various power levels required to run the system. AC line voltage comes into the PDB, as well as 24 VDC from the main power supply. AC line voltage comes into the PDB, see Figure 7.
  • Page 25 Figure 7: Power distribution board detail 2-14 Electronics Overview...

  • Page 26: Motor Driver Board

    Motor Driver Board Overview The motor driver board supplies current amplification for the X, Y and Z stepper motors. Control signals from the PMD chips (186 board) are sent via ribbon cables to the motor driver board. These signals are then amplified and sent to the X, Y and Z stepper motors. The board contains three identical and separate amplifying circuits, one for each of the three stepper motors.
  • Page 27 Figure 8: Motor driver board detail 24VDC power in Output to X axis X driver circuits stepper motor X axis motor input from 186 Output to Y axis stepper motor Y driver circuits Y axis motor input from 186 Output to Z axis stepper motor Z driver circuits Z axis motor input...

  • Page 28: Gen 2 Electronics

    Gen 2 Electronics Electronics Overview Figure 9: Gen 2 electronics detail Controller Board +24 VDC +120 VDC +5 and +12 power power VDC Power supply supply Supply AC Input 120-240 VAC 120-240 VAC in 2-17...

  • Page 29: Controller Board

    Controller Board Overview The controller board in BST/SST provides all of the low level hardware control and sensing for the system. The software runs on the controller cpu and is flash resident (rather than on the HDD as with the SBC). Voltage Generation •...
  • Page 30 signal from the T/C is amplified by the head distribution. It is then sent down the umbilical cable to the PDB, and then to the controller board. An A to D converter in the ColdFire chip converts the analog signal to digital. In order to improve temperature resolution, this signal is biased.

  • Page 31: Actuators, Switches & Optical Sensors

    Actuators, Switches & Optical Sensors The input and output signals are passed through the PDB and then processed by the controller board. The non-motor actuators on a BST/SST system are 24 volt solenoids. The 24 volt power is supplied by the PDB which in turn is controlled by the controller board. The following is a list of actuators: •...

  • Page 32: Reset Button

    Figure 11: Controller board detail DIP switches SW2 SW5 SW6 Z axis PMD chip To PDB PMD 3410 (Pilot) D6-D13 XY axis PMD chip and To PDB head drive motor PMD 2840 PMD chip (Navigator) Serial port for HT PMD Dual Port Memory To PDB SDRAM...

  • Page 33: Memory

    Number (in Description Setting Default black) PMD pilot baud rate 57600 1-2 off, 3 on Pilot parity bits None Pilot stop bits Pilot protocol Point to point Unused Unused Number (in Description Default white) 16-24 Unused Number (in Description Default white) 8-15 Unused...

  • Page 34: Leds

    LEDs There are 11 LEDs located on the controller board. A grouping of three (D1-D3) are located on the lower left side. The other group of eight (D6-D13) are located on the upper right side. D1-D3 are lit when their associated voltage, as shown in table below, is present. The 3.3 VDC supply is generated on the controller board, +5 and +12 VDC come from the PDB.

  • Page 35: Power Distribution Board (Pdb)

    Power Distribution Board (PDB) Figure 12: Power distribution board detail J16 - To LCD display (ribbon) J21 - Not used J13 - Chamber thermocouple connector J24 - To external UPS dry contact (768 Only) J14 - To controller (ribbon cable) J7 - To receiver J9 - Head umbilical II (X motor, filament motors,...

  • Page 36: Chamber Temperature Control

    series, or 120 VAC in parallel. The solid state relay is controlled by the controller board, and turns the heater on/off to regulate the chamber temperature. A second solid state relay provides AC line voltage to the system. It is controlled by the controller board and safely shuts down the system when the power down switch is turned off.
  • Page 37 System Component Test Point Description TP26 Power fail signal from external UPS +5V REF Head T/C service reference Door Switch TP12 State of the door (open or closed) On/Off Request TP20 State of power down switch Power Enable TP24 Enables power to circuitry (normally high) Dual Thermocouple TP23 SST: High, T/C board jumper present...
  • Page 38 System Component Test Point Description +12 VDC SW TP32 +12 VDC switched (off when power enable is off, when powering up, and during download) +24 VDC TP31 +24 VDC +24 VDC SW TP30 +24 VDC switched (off when power enable is off, when powering up, and during download) AC On/Off Drive signal to power down relay...
  • Page 39 System Description Component Chamber Heater On or off +120 VDC Model +120 VDC on Model Heater PWM Indicates duty cycle of model PWM Support Heater PWM Indicates duty cycle of support PWM 2-28 Electronics Overview...

  • Page 40: Gen 3 Electronics

    Gen 3 Electronics Electronics Overview Figure 13: Electronics overview detail Controller Board +24 VDC +120 VDC +5 and +12 power power VDC Power supply supply Supply AC Input 120-240 VAC 120-240 VAC in 2-29...

  • Page 41: Controller Board

    Controller Board Overview The controller board in BST/SST provides all of the low level hardware control and sensing for the system. The software runs on the controller cpu and is flash resident (rather than on the HDD as with the SBC). Voltage Generation •...
  • Page 42 signal from the T/C is amplified by the head distribution. It is then sent down the umbilical cable to the PDB, and then to the controller board. An A to D converter in the ColdFire chip converts the analog signal to digital. In order to improve temperature resolution, this signal is biased.

  • Page 43: Actuators, Switches & Optical Sensors

    Actuators, Switches & Optical Sensors The input and output signals are passed through the PDB and then processed by the controller board. The non-motor actuators on a BST/SST system are 24 volt solenoids. The 24 volt power is supplied by the PDB which in turn is controlled by the controller board. The following is a list of actuators: •...

  • Page 44: Reset Button

    Figure 15: Controller board connection detail Reset Button Located on the lower right side of the board, the reset button will do a hard reset of the controller board. Before continuing with normal operation after resetting the board, system power must be cycled before building.

  • Page 45: Memory

    Number (in Description Default white) 16-24 Unused Number (in Description Default white) 8-15 Unused Number (in Description Default white) Run built-in self test (BIST) Load Firmware (turn on when using SNDBIN.EXE) Disable door latching Unused Don’t reset controller when in command is issued Off Disable WatchDog timer Enable use of dc commands Unused...

  • Page 46: Single Board Computer

    Single Board Computer The single board computer (SBC) is the main processor in the system. It is a complete “PC compatible computer” on a single board. See Figure 16. The TCP/IP network interface connects directly to the RJ-45 connector on the SBC. The network interface supports both 10baseT and 100baseT operation.

  • Page 47: Power Distribution Board (Pdb)

    Power Distribution Board (PDB) Figure 17: Power Distribution Board detail AC power in To power switch and main thermal cutoff fuse To chamber heaters (AC) 24VDC in Mid unit harness 2 5/12 VDC in Receiver cable To controller - ribbon cable Head umbilical 2 J10 Head umbilical I J11 Head heater...

  • Page 48: Chamber Temperature Control

    • The 24 VDC powers the stepper motors, solenoids, fans, and chamber lights. • The 120 VDC circuit powers the model heater. For SST only, a separate 120 VDC supply powers the support heater. There are two fuses on the power distribution board. See Figure 17.
  • Page 49 System Component Test Point Description On/Off Request DL13 TP14 State of power down switch Power Enable DL25 Enables power to circuitry (normally high) Dual Thermocouple DL28 TP40 SST: High, T/C board jumper present BST: Low, T/C board jumper removed Model Toggle TP17 Not used Ground...
  • Page 50 Lit LEDs do not imply accurate voltage. Verify voltage levels using a meter. Figure 18: LED and test point detail System Description Component +5 V DL27 +5 VDC present +12 V DL19 +12 VDC present +12 V SW DL22 +12 VDC switched (power enabled) +24 V DL20...
  • Page 51 2-40 Electronics Overview...

  • Page 52: Software

    Software In this chapter you will learn about the software that is used in the system. The contents and page numbers of this chapter are as follows: Software Architecture......................2 DataStat ........................... 4 CatalystEX Help........................5 Maraca Help ........................... 7 System Software ........................

  • Page 53: Software Architecture

    Software Architecture Figure 1 shows the major software components that control the system. The software that runs on the 186 board is EPROM based. The software that runs on the SBC is stored on the HDD and loaded during power up. Like all PC compatible computers, the SBC runs a brief self-test on power up and then loads the operating system followed by the system’s application components.
  • Page 54 System Manager The system manager software provides the overall control and decision making functions that are used by the system during all operations. User requests are received from the Display Driver (in response to button pushes). The requests are processed and commands sent to the 186 board to activate the appropriate hardware.

  • Page 55: Datastat

    DataStat DataStat is a “condensed” version of Maraca. It was developed to: • Aid in troubleshooting system problems by allowing the customer to view and report spe- cific system information. • Allow the customer to adjust tip depth into foam (Z offset). Using DataStat allows you to: •...

  • Page 56: Catalystex Help

    CatalystEX Help CatalystEX Overview CatalystEX is an intuitive, user-friendly application designed to interface with Dimension 3D printers. It allows you to quickly and easily open a 3D drawing of a part, prepare the drawing for print, and send the print command to create the part. CatalystEX provides 'Help' information in two ways - through a Conventional Help file and through a Dynamic Help system.
  • Page 57 The main screen is divided into several sections. The main menu and a toolbar are along the upper part of the screen. CatalystEX reports information and problems in the system-message area beneath the geometry window. The STL model, boundary curves, and toolpaths are displayed in the geometry window. The View Sphere allows you to dynamically pan and rotate your view of the geometry using the mouse button to make selections.

  • Page 58: Maraca Help

    Maraca Help Overview Maraca is a program used for machine configuration and troubleshooting. It is intended for use by trained service personnel only. Caution: It is possible, using this program, to damage the controller software and make the machine non-functional. Using Maraca you can select a modeler to work with, modify machine-specific configuration parameters, download new calibration file data, download new test parts, and test the machine's operation.
  • Page 59 Modeler Setup In order to use Maraca on a network modeler, you must first create a modeler definition. You can create modeler definitions by clicking the + button in the main window. A modeler definition is made complete by specifying the following: •...
  • Page 60 Versions The current version number for the complete software release Product Version The build number for current SBC software Build Version The current version for the 186 controller software Firmware Version The current version of the programmable logic devices on the 186. PLD Version The serial number of the complete system.
  • Page 61 P400 - is a standard modeling material P400R - is a standard release material. P400SR - is a standard soluble release material. This is a lot code used by Stratasys to control the manufacturing pro- Manufacturing Lot cess. This is the date that the cartridge was manufactured.
  • Page 62 Temperatures The temperature control dialog allows you to adjust the set points for the head and chamber temperatures, for both modeling and at standby. Temperature Limits Temperature Min. Head Support Chamber Outputs The outputs dialog contains toggle buttons to control solenoids and motors that can not be directly controlled on the Control Panel Display.
  • Page 63 calibration floppy that ships in the electronics pan for systems with a build number greater than or equal to 1132. This file contains all the factory calibration information, including, but not limited to: Tip Offset, Tip Depth, Y Lash, X Correction, and the table calibration DAT file. When the button is pressed, a file selection dialog is presented allowing the assignment of a file name and the selection of a storage location.

  • Page 64: System Software

    System Software Required Tools • Dimension controller software and CatalystEX. • Crossover cable or network connection • Notebook computer or workstation. Installing system software: 1. System should be powered on and MUST be in mode. Idle 2. Select from the display menu. Maintenance 3.
  • Page 65 3-14 Software...

  • Page 66: Troubleshooting

    Troubleshooting In this chapter you will learn how to troubleshoot the system. The contents of this chapter are as follows: Troubleshooting a System Malfunction................3 Overview............................3 Testing the 186 processor board: ...................3 Testing the Hard Drive and SBC: ..................4 Final Test:..........................4 Fault determination codes ....................
  • Page 67 What happens during Power Up / Boot................. 32 Power UP / Boot ........................33 "Can't Find Home - Check Modeling Base" displayed on LCD........... 34 Power Down..........................35 Power UP / Boot ........................33 System VERY slow to reach temperature ................35 Calibration Issues ........................

  • Page 68: Troubleshooting A System Malfunction

    Troubleshooting a System Malfunction Overview How to troubleshoot system malfunction and narrow down the possible cause of a system malfunction to either the 186, SBC or hard drive. Parts and Tools Required • Null modem cable (Laplink cable) • SBC to monitor cable •...

  • Page 69: Testing The Hard Drive And Sbc

    Connect a monitor and monitor cable to J5 of the Ampro SBC. See Figure 1. b. Connect a monitor and monitor cable to CN9 of the Nova 600 SBC. See Figure 1. Contact Stratasys technical support for monitor cable. Figure 1: SBC detail Ampro NOVA-600 3.
  • Page 70 Figure 2: Troubleshooting sequence...

  • Page 71: Fault Determination Codes

    Fault determination codes If a fault occurs which would prevent the printer from executing an operator request, the printer will begin to shut down and cool. The panel will display an error code. An error-code list (with the filename “error.txt”) can be found on the DVD-ROM for the printer firmware. (Because this list may change with each new software version, be sure to check the error.txt attachment when you download new firmware upgrades.) After the printer has finished cooling, the only option displayed is...

  • Page 72: Diagnosing Loss Of Extrusion

    Diagnosing loss of extrusion Occasionally, the printer’s head may experience loss of extrusion. This will be evident by observing one of the following: • The head is moving with no material coming out of either tip • The height of the model and support materials are not equal •...

  • Page 73: Clogged Tip

    Clogged tip Occasionally, a tip may clog with material. This will often result in a loss of extrusion (LOE). A clogged tip will prohibit material load and part building. 1. From the display panel, press Maintenance 2. Press Machine 3. Press Head 4.

  • Page 74: Service Troubleshooting

    4. If you have any suggestions, additions or changes that need to be made to this guide please e-mail prodigyTSguideteam@stratasys.com. A. Verify that the machine is plugged directly into a wall outlet. Do not use an extension cord or power strip.

  • Page 75: Code Errors

    Code Errors Major Codes These codes are displayed on the system LCD Display. Code Error Definition/Recommendation Unknown Error No data on what error occurred. Cycle power. PUC Error Path, utilities and controller development library (Used for software testing). Cycle power. No Display Process that runs LCD display generated error.

  • Page 76: Major Codes With Minor Codes

    Code Error Definition/Recommendation Controller Initializa- Controller failed to reboot or start. See detailed 19 error code section below. tion Failed Door Latch Com- See detailed non-error code section of this guide. mand Failed Ldrool Failed Cycle power Controller Commu- Not used. nications Failed Universal Device Cycle power...
  • Page 77 Code Description Corrective Actions 14,02 Report: Attempt to raise mod- Cycle power eling base sensor failed Replace Substrate. Check for obstructions preventing X or Y movement Check the Z foam sensor bar is not damaged. If so, replace bar. Gen 1 - Check connector J7 on 186 board for loose pins. Gen 2 - Check connector J10 (pin 19) on the PDB for loose pins.
  • Page 78 Code Description Corrective Actions 14,11 Abort : Door opened while axis Check to see if door latch is activating using using Maraca/LED's/test in motion points Gen 2- Check signal at TP12 Gen 3- Check signal at J5 -pin 1 Look at LCD display, should show "Door Open" when machine is idle and door is open.
  • Page 79 Code Description Corrective Actions 14,23 Report: Begin curve parame- Communication error between 186/Controller Board & SBC - Cycle ters not in sequence. power Re-seat the 186/Controller Board into SBC. Replace 186/Controller Board and/or SBC. 14,24 Abort : X axis command error Cycle power.
  • Page 80 Code Description Corrective Actions 14,36 Report: Modeling material not Gen 1 electronics moving in head. Cycle power. 14,37 Report: Support material not If error continues, replace the 186/Controller Board. moving in head. Gen 2/3 electronics Cycle power. Check/re-seat J9 on PDB. If error continues, replace the Controller Board.
  • Page 81 Code Description Corrective Actions 14,41 Abort : Motion command Cycle power. while door open. Check to see if door solenoid is operating properly. Toggle solenoid 14,42 Abort : Load cartridge while using MaracaEX. door open. Look at LCD display, should read "Door Open" when machine is idle 14,43 Abort : Modeling command and door is open.
  • Page 82 Code Description Corrective Actions 14,57 Abort : Find home failed, X Move the head away from the sensors and cycle power. home timeout If chatter in motor, check motor and/or motor cable for Y, umbilical 14,58 Abort : Find home failed, Y cable for X.
  • Page 83 Code Description Corrective Actions 14,67 Abort : Head temperature too Verify the TC and Liquefier Heaters are plugged in properly. high Verify umbilical cable is connected properly. TC Amp board is bad. Replace TC Amp board. Head Board is bad Replace head board. Replace the umbilical cable.
  • Page 84 Code Description Corrective Actions 14,87 Resource already in use Cycle power. 14,88 The dual-port memory is cor- Cycle power. rupted 14,89 No valid ISR callback routine Cycle power. 14,90 An internal queue has over- Cycle power. flowed 14,91 Address not properly aligned Cycle power.
  • Page 85 Code Description Corrective Actions 14,100 Find home failed, Z HOME Move Z stage away from sensors and cycle power. (BOT) not tripped Check for objects/parts on Z stage and around lead screw. 14,101 Find home failed, Z EOT not Check for purge material around lead screws. Remove material, clean tripped and lube.
  • Page 86 Code Description Corrective Actions 14,113 Door not latched Inspect solenoid and wiring. Check for 24VDC on the upper harness at the solenoid power connec- tion. Replace solenoid. Replace PDB. 14,114 Thermocouple snap switch Using a meter, check if head or chamber thermostat are open. If they tripped are open, press the reset button.
  • Page 87 Code Description Corrective Actions 14,132 UPS low power UPS is shutting down. Check UPS and AC power. 14,133 Head liquefier is not heating Liquefier heater is open (infinite resistance). Liquefier T/C may be crushed. Test using meter. If crushed, reading will be 0 Ohms between pin 1 and ground. Check for 120 VDC at head board, if OK heater is bad.

  • Page 88: Starting Up Failed Minor Errors (15.Xx)

    Starting Up Failed Minor Errors (15.XX) Code Description Corrective Actions 15,01 Startup state activation failed Software use only 15,02 Timeout period expired while See CFG file for additional error details. starting up Replacement Controller or Hard Drive is gendered incorrectly. If printer is in Dynamic Mode: a.

  • Page 89: Temperature Failed To Regulate Minor Errors (18.Xx)

    Temperature Failed to Regulate Minor Errors (18.XX) Code Description Corrective Actions 18,01 Temperature not chang- Status-Details: Check to see if current envelope temperature is above ing fast enough. 72C before starting a model. Chamber is slow to heat Status--Details: Check to see if envelope temperature set point is 77C. If not, toggle power switch.

  • Page 90: Controller Initialization Failed Minor Errors (19.Xx)

    Controller Initialization Failed Minor Errors (19.XX) Code Description Corrective Actions 19,01 IN_COMMAND Rejected by Software use only Controller. 19,02 IN_COMMAND Timeout. Cycle power. Replace 186/controller board. Replace Hard Drive. Door Unlatch Failed (20.XX) Code Description Corrective Actions 20,01 Unlatch command rejected. Check door latch solenoid wiring.

  • Page 91: Non-Code Errors

    Non-Code Errors "Build Error" displayed on LCD Tip depth is incorrect "Corrupted Upgrade" Displayed on LCD "Cartridge Invalid or Empty" Displayed on LCD Door Latch "Door Open" Displayed on LCD Download Loss of Extrusion (LOE) Lights Material/Unload Error Network Communication Pauses During Build Power UP / Boot "Can't Find Home - Check Modeling Base"...

  • Page 92: Build Error" Displayed On Lcd

    A. "Build Error" displayed on LCD Part stops building before complete. Partial or bad model file sent to unit. - Check and reprocess the STL and re-download B. Tip depth is incorrect Tip Depth is wrong (too deep or above the mod- Replace the substrate.

  • Page 93: Door Open" Displayed On Lcd

    F. "Door Open" Displayed on LCD Door doesn’t latch/unlatch. The door is open. Close the door. Verify the magnet mounted to door frame is not misaligned or missing. Door switch is bad, replace door switch. Check for door delamination or warping. If present, replace door. G.

  • Page 94: Lights

    H. Loss of Extrusion (LOE) Material missing at drive wheel Drive wheel or mushroom jam. Refer to loss of extrusion section. “Diagnos- - Material tube disconnected ing loss of extrusion” on page 7. - Material pulled back Material jammed in cartridge. Replace cartridge. Material motor connector is bad.

  • Page 95: Network Communication

    J. Material/Unload Error (Continued) Cartridge will not load (no move- Verify cartridge inserted completely and latched. ment) after pressing load. Move Z stage away from sensors and cycle power. E-prom has failed. Replace cartridge. Receiver encryption board has failed, replace cartridge. Pogo pins bent or failed, replace receiver.

  • Page 96: Pauses During Build

    L. Pauses During Build Chamber won't heat up to at Verify top and side panels and insulation are installed. least - 70 degrees Verify chamber fans are operating. Gen 1 - PDB strapped for wrong power. Jumper PDB to proper AC input voltage. re-seat heater connections - Gen 1 - J7 on 186 board.

  • Page 97: What Happens During Power Up / Boot

    What happens during Power Up / Boot Power Switch turned to ON Chamber lights (dim mode), display backlight and fans turn on. Material bay drive homes. See M - 4 Controller Performs Power On Self Test (POST). BIOS starts and loads the OS POST looks at voltages, checksum (operating system) from the and memory, etc.

  • Page 98: Power Up / Boot

    M. Power UP / Boot Chamber wont heat up to at Heater bad. Check heater resistance - should be 36 +/- 5 ohms. If out of toler- least: ance, replace heater. BST - 50 degrees Gen 1 - PDB strapped for wrong power. Jumper PDB to proper AC input voltage. SST - 65 degrees Replace PDB.

  • Page 99: Can't Find Home - Check Modeling Base" Displayed On Lcd

    M. Power UP / Boot (Continued) System reaching temp, does Substrate sensor broken. System is attempting to retract sensor. Replace the sen- not go to "Idle" screen and sor. head hits into the right side of the machine System displays “Copyright” Cycle Power at the Circuit Breaker.

  • Page 100: Power Down

    O. Power Down Fails to shutdown. Toggle the power switch again. Wait 5 minutes Shut system off at the breaker. Display indicates "Recovery AC power was interrupted. Check customer AC power. after uncontrolled shut- Bad power switch cable. down" UPS malfunctioned, replace UPS. Display indicates "Recovery AC power was interrupted.
  • Page 101 R. Z Calibration Failure (Continued) First layer tip too high off modeling base Add -.010 to Z offset value Diagnostic details: Left square (SS) Upper layers - Missing or barely stuck to modeling base 1st layer - Missing or barely stuck to modeling base Right square (model) Upper layers - Missing or barely stuck to modeling base...

  • Page 102: Noise

    R. Z Calibration Failure (Continued) Model filament not loaded Load material Diagnostic details: Left square (SS) Upper layers - Built OK 1st layer - OK Right square (model) Upper layers - Missing or barely stuck to modeling base. 1st layer - Missing. No evidence of ABS extrusion Support filament not loaded Load material Diagnostic details:...

  • Page 103: Part Quality Troubleshooting

    Part Quality Troubleshooting Embedded support strands in model Characteristics: Strands of support materail embedded in model. Problem corrected after re-orientation Example of embedded support Corrective actions: 1. Change the part orientation. Rotate part 90 degrees - see example above. 2. Build the part using the “Minimal” support option. 3.

  • Page 104: Brown Streaks (Burn Marks)

    Brown streaks (burn marks) Characteristics: Brown streaks in parts. Corrective actions: 1. Part geometry’s are such that the model tip sits idle for an extended period of time. Change the part orientation. 2. Worn tip shrouds, replace tip shrouds. 3. Material build-up behind the tips, remove excess material. 4.

  • Page 105: Loss Of Extrusion (Loe)

    Loss of Extrusion (LOE) Characteristics: Material strands inside build envelope and/or partially built parts. Either the model or support material has failed to extrude from swivel head or toggle plate assembly. Can also be caused by a part falling over or a part shift. Here the support material has had a loss of extrusion, causing the model material to continue to extrude without support material under it.

  • Page 106: Model Embedded In To Support

    Model embedded in to support Characteristics: Difficult to remove the support material. Corrective actions: 1. Run Z and Offset Calibrations 2. Check for loose tip screws. Tighten screws if required. 3. Check for loose modeling base. Use a new modeling base. 4-41...

  • Page 107: Moisture In Material

    Moisture in material Characteristics: Material will appear to rough or stringy. Rough Stringy Corrective actions: 1. Material is older than one year. Replace with newer material. 2. Moisture in material. Replace using new material spool. 4-42 Troubleshooting...

  • Page 108: Open Seams

    Open seams Characteristics: Visible gap in the model material. Corrective actions: 1. Check the height of the brush and flicker. 2. Verify wall thickness is greater than: 0.040” for 0.010” slice. 3. Reprocess the part using the latest version of CatalystEX and check STL report for errors. 4.

  • Page 109: Part Curling

    Part curling Characteristics: Top surface appears rough. Model and support will separate or support and substrate will separate. Corrective actions: 1. The part is too dense, try using the “Sparse Fill” option in CatalystEX. 2. Modeling base has been re-used or is defective. Replace with unused modeling base. 3.

  • Page 110: Part Fell Over

    Part fell over Characteristics: A part falls over and separates at the support base or substrate. Material will continue to extrude causing strands of material to build up in the envelope. Corrective actions: 1. Substrate has been re-used or is defective. Replace the substrate. 2.

  • Page 111: Part Shifting

    Part shifting Characteristics: Model shifts in X or Y axis, this may cause unexpected contact errors with X or Y sensors. Corrective actions: 1. The modeling base is defective or is not latched tightly. Replace modeling base and latch properly. 2.

  • Page 112: Rough Surface Quality

    Rough surface quality Characteristics: Sides of part are rough or over filled, with little or no part shift. Corrective actions: 1. STL wall thickness is too thin. Verify proper wall thickness. 2. Reprocess the part using the latest version of CatalystEX software and check STL report for errors.

  • Page 113: Rough Quality All Over

    Rough quality all over Characteristics: The part sides, top and bottom are very rough. Corrective actions: 1. Moisture in material, replace with new cartridge. 2. Reprocess the part using the latest version of CatalystEX software. 3. Check for STL errors with CAD software. 4.

  • Page 114: Model Strands On Parts

    Model strands on parts Characteristics: Model material strands appear outside the normal model build. Corrective actions: 1. Check for material build up on tips, brush and flicker. Remove excess material. 2. Verify brush/flicker height. Adjust if required. 3. Run Z and Offset Calibrations. 4.

  • Page 115: Wavy Surface

    Wavy surface Characteristics: One side of the model will have wavy build. Wavy Normal Corrective actions: 1. Run Z and Offset calibrations. 2. Reprocess the part using the latest version of CatalystEX and check STL report for errors. 3. Check for STL errors in CAD software. 4.

  • Page 116: Wavy Parts

    Wavy parts Characteristics: Parts will shift in X and Y, giving the appearance of waves. Corrective actions: 1. Verify X and Y guide rods are securely fastened. 2. Check and adjust X, Y and Z belt tensions. 3. Verify the Z stage is properly leveled. 4.

  • Page 117: Under Fill

    Under fill Characteristics: Open seam between start and stop of toolpaths. Corrective actions: 1. Verify wall thickness is greater than: 0.040” for 0.010” slice. 2. Reprocess the part using the latest version of CatalystEX software. 3. Check for material build up around head and tips. 4.

  • Page 118: Material Sagging On Curved Parts

    Material sagging on curved parts Characteristics: Surface finish not smooth. Corrective actions: 1. Reprocess the part using the latest version of CatalystEX software. 2. Reprocess part with CAD software. 3. Check for bad bearings in X/Y table. Replace XY table if needed. 4.

  • Page 119: Fused Layers

    Fused layers Characteristics: Layers appear to be fused together. Corrective actions: 1. Check Z stage: A. Check connections to Z motor. B. If head is digging in to the part, check Z motor belt tension. C. Check to see if Z stage is jamming. D.

  • Page 120: Z Layers Inconsistent

    Z layers inconsistent Characteristics: Z layers not bonding properly. Corrective actions: 1. Check Z stage: A. Verify Z motor is tightly secured. B. Verify Z stage is level. C. Replace the Z motor. D. Replace the Z stage if substrate is lower in the back (failed to find home). 2.

  • Page 121: Hyperterminal

    Hyperterminal Using Hyperterminal (HT) When using these commands, there is a high risk of damage to the machine because the printer does not recognize the location of any other components in the machine that may be in the way. This means if you use the command to move the Z-Stage, you will have to make sure that the Head is moved out of the way.
  • Page 122 B. Type a name for the new connection and click OK. C. Select the appropriate COM Port.and click OK, see Figure 4. Figure 4: COM Port D. Set the Port settings to match the figure below and click OK, see Figure 5.
  • Page 123 E. Now you should be able to communicate with the machine, if not, here are a couple of things that you can try: If it failed to establish communication, check to see if the appropriate COM Port is selected. Click on configuration to see if the settings for the COM Port are correct.
  • Page 124 G. Select the Settings Tab, see Figure 7. Figure 7: Settings 4-59...
  • Page 125 H. Select the ASCII button, see Figure 8. Figure 8: ASCII Setup 4-60 Troubleshooting...
  • Page 126 Under ASCII receiving, check "Append line feeds to incoming line ends" and "Wrap lines that exceed terminal width", see Figure 9. Figure 9: ASCII Setup Select OK twice to exit setting window. K. In the HT window enter - trace c commandDetails on. This will enable details to be shown in the HT window.
  • Page 127 Hyperterminal Commands Hyperterminal is an easy way to check and troubleshoot the hardware of a machine. Here are a couple of helpful commands which can be used to operate the machine through HyperTerminal. All values, which are displayed in Hyperterminal, are in inches. For some commands, the machine must find Home position before you can enter commands.
  • Page 128 2. fz = Find Z home This command determines the Z axis home position. This position is determined by the modeling base that is installed in the system. The find home command must be executed before this command will work. Example: fz The values, which are displayed, are explained below, see Figure 11.
  • Page 129 3. mz = Move Z The MZ command moves the Z-Stage relative to the current position. A positive value moves the Z-Stage down. A negative value moves the Z-Stage up. Example: mz 4.0 This command will move the Z-Stage 4 inch down. 4.
  • Page 130 Figure 12: TZ command Z BOT Zoffset: This value is the expected position of the Z BOT sensor. Z EOT Z offset: This value is the expected position of the Z EOT sensor. Z BOT delta : This value is the actual position - expected position of the Z BOT sensor. Z EOT delta : This value is the actual position - expected position of the Z EOT sensor.
  • Page 131 5. xt=Test XY Limits Tests the XY axis by moving from corner to corner, stopping at each corner and measuring the offset against the actual position as indicated by the limit switches. The command can be used for testing the Z-Stage. To do so, repeat the tz command at least 2 times and compare the X BOT delta values, X EOT delta values, Y BOT delta values and the Y EOT delta values.
  • Page 132 6. ss=Switch Status The ss diagnostic message stands for send status. The controller outputs a report on optical and mechanical switches to the terminal window. Use this command to look for the Gender of the system and the Software version. Figure 14: Switch status 4-67...
  • Page 133 7. gp = get POST. Displays power on self test results Use this command to check if the controller board passes the self test and to see the reason for the last reset. Figure 15: Get POST 4-68 Troubleshooting...
  • Page 134 8. rt = repeat This command will tell the machine to repeat the previous command. The command line takes a repeat count, and flags whether or not to ignore errors. It will also flags wether or not to show the command line of the command to be run. The command line consists of one or more commands separated by semicolons.
  • Page 135 9. le = load exception log This command prints the contents of the exception log located in non-volatile memory. This exception log contains a record of the most recent exceptions that occurred within the controller. The exceptions are printed in chronological order. Use this command to get the History of systems errors printed on the screen.
  • Page 136 11. my = move y This command moves the head in the y axis. Parameters: Float Position: This is the position it moves to, in inches, when the command is sent from the Con- sole and in device units when the command is sent through the DPM. Example: my 3.0 (moves the Y-Axis 3 inches away from the Y-Home sensor) 12.
  • Page 137 Figure 17: Monitor temperatures This is what the set temperature is regulated to. This is either the set point or the setback temperature depending on whether temperature setback is active. The TS field shows whether temperature setback is active. The TS fields are displayed as 0 or 1 depending on whether they disabled/enabled or off/on respectively.
  • Page 138 Service Procedures This chapter describes removal and replacement procedures for Dimension, 768 and Elite printers. Exterior Components......................5-9 Rear Door ............................5-9 Removing the Rear Door: ......................5-9 Installing the Rear Door:......................5-10 Side Panels ............................5-11 Removing the Side Panels for serial numbers less than P04746: ........5-11 Installing the Side Panels for serial numbers less than P04746:........
  • Page 139 Hard Drive ............................5-50 Removing the IDE Hard Drive:.....................5-50 Installing the IDE Hard Drive: ....................5-52 Removing the SATA Hard Drive: ..................5-53 Installing the SATA Hard Drive:...................5-54 Electronics Bay Cooling Fan ......................5-56 Removing the Electronics Bay Cooling Fan: ...............5-56 Installing the Electronics Bay Cooling Fan: .................5-57 24 VDC Power Supply........................5-58 Removing the 24 VDC Power Supply: .................5-58 Installing the 24 VDC Power Supply:...................5-61...
  • Page 140 120 VDC Power Supply (SST only).....................5-108 Removing the 120 VDC Power Supply: ................5-108 Installing the 120 VDC Power Supply:................5-110 5/12 VDC Power Supply ......................5-111 Removing the 5/12 VDC Power Supply:................5-111 Installing the 5/12 VDC Power Supply: ................5-113 Line Filter Board..........................5-114 Removing the Line Filter Board: ..................5-114 Installing the Line Filter Board:...................5-116 AC Input ............................5-117...
  • Page 141 Line Filter ............................5-173 Removing the Line Filter:.....................5-173 Installing the Line Filter: ......................5-176 AC Input ............................5-177 Removing the AC Input: ......................5-177 Installing the AC Input: ......................5-180 Circuit Breaker..........................5-181 Removing the Circuit Breaker: ....................5-181 Installing the Circuit Breaker:....................5-183 Head Components ......................5-184 Head Cooling Fan .........................5-184 Removing the Head Cooling Fan:..................5-184 Installing the Head Cooling Fan: ..................5-187...
  • Page 142 Installing the X EOT Switch: ....................5-232 X BOT (Home) Sensor........................5-233 Removing the X BOT Sensor:....................5-233 Installing the X BOT Sensor: ....................5-235 Y EOT (End of Travel) Limit Switch...................5-236 Removing the Y EOT Switch: ....................5-236 Installing the Y EOT Switch: ....................5-238 Y BOT (Beginning of Travel) Sensor ..................5-239 Removing the Y BOT Sensor:....................5-239 Installing the Y BOT Sensor: ....................5-241...
  • Page 143 Installing the Left Side Y Drive Belt:...................5-305 Y Pulley (Belt Drive) ........................5-309 Removing the Right Side Y Pulley:..................5-309 Installing the Right Side Y Pulley: ..................5-312 Removing the Left Side Y Pulley:..................5-315 Installing the Left Side Y Pulley: ..................5-318 Y Drive Assembly (Belt Drive) ....................5-322 Removing the Y Drive Assembly:..................5-322 Installing the Y Drive Assembly: ..................5-328 XY Table Assembly (Belt Drive)....................5-334...
  • Page 144 Installing the Z Stage Bearings: ...................5-413 Z Foam Retainers ..........................5-421 Removing the Z Foam Retainers:..................5-421 Installing the Z Foam Retainers: ..................5-421 Z Stage Components (1 Lead Screw) ................5-423 Chamber Thermocouple (1 Lead Screw) ...................5-423 Removing the Chamber Thermocouple:................5-423 Installing the Chamber Thermocouple: ................5-425 Chamber Fans (1 Lead Screw).....................5-426 Removing the Left Side Chamber Fans:................5-426 Installing the Left Side Chamber Fans: ................5-428...
  • Page 145 Should you have any questions about Dimension BST/SST replacement procedures, contact Stratasys Customer Support at 1-800-801-6491 for further information or assistance. Read these warnings before performing any service on this machine! Warning: Ensure the printer is not powered on when performing any of the assembly instructions in this chapter.

  • Page 146: Exterior Components

    Exterior Components Rear Door Required Tools • Phillips screwdriver Removing the Rear Door: 1. Using a phillips screwdriver, loosen the 3 self retaining screws. See Figure 1. Figure 1: Self retaining screw locations 3 Self retaining phillips screws 2. Open the door and lift upwards to remove from hinges. Set door aside. See Figure 2.

  • Page 147: Installing The Rear Door

    Figure 2: Removing rear door Installing the Rear Door: 1. Align the door with the hinges and set into place. 2. Close the door and use a phillips screwdriver to tighten the 3 self retaining screws. 5-10...

  • Page 148: Side Panels

    Side Panels Printers with a serial number less than P04746 will have white panels. Printers with a serial number greater than P04746 will have gray panels. Required Tools • ⁄ ” allen wrench • ⁄ ” nut driver or standard screwdriver Removing the Side Panels for serial numbers less than P04746: 1.

  • Page 149: Installing The Side Panels For Serial Numbers Less Than P04746

    Installing the Side Panels for serial numbers less than P04746: 1. Align the panels with the printer. 2. Using a ⁄ ” allen wrench, reinstall the 7 mounting screws. 3. Reinstall the rear door. See “Installing the Rear Door:” on page 5-10. Removing the Side Panels for serial numbers greater than P04746: 1.

  • Page 150: Front Bezel

    Front Bezel Required Tools • ⁄ ” allen wrench • ⁄ ” nut driver or standard screwdriver • ⁄ ” nut driver or box wrench • ⁄ ” nut driver or box wrench Removing the Front Bezel: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position.
  • Page 151 6. Remove the foam insert from behind the left side of the bezel. See Figure 6. Figure 6: Left side foam insert location Foam insert 7. Using a ⁄ ” nut driver or standard screwdriver, remove the ground wire screw from the frame.
  • Page 152 Figure 7: Ground screw location Ground screw 8. Un-clip the 4 wire clips from behind the bezel on the right side. See Figure 8. 5-15...
  • Page 153 Figure 8: Wire clip locations 4 wire clips 9. Disconnect the DRSOL cable by pressing the tab and pulling apart. See Figure 9. 10. Disconnect the DRSW COM (green) and ON (yellow) by pulling apart. See Figure 9. Mark the DRSW cables for easy reinstallation 5-16...
  • Page 154 Figure 9: Door cable locations DRSOL DRSW 11. Using a ⁄ ” allen wrench, remove the 3 left side bezel mounting screws. See Figure 10. Figure 10: Bezel left side mounting screw locations Upper mounting screw 2 lower mounting screws 5-17...
  • Page 155 12. Using a ⁄ ” allen wrench, remove the 2 lower right side bezel mounting screws. See Figure Figure 11: Bezel right side lower mounting screw locations 2 lower mounting screws 13. Using a ⁄ ” allen wrench, loosen but do not remove the upper right side bezel mounting screw.
  • Page 156 14. Hold the front bezel so it will not fall and use a ⁄ ” allen wrench to remove the upper right side bezel mounting screw. See Figure 13. Figure 13: Removing the upper bezel mounting screw Hold bezel from falling Remove upper mounting screw...

  • Page 157: Installing The Front Bezel

    Installing the Front Bezel: 1. Reinstall the door sensor. See “Installing the Door Sensor:” on page 5-27. 2. Reinstall the door solenoid. See “Installing the Door Solenoid:” on page 5-25. 3. Reinstall the display panel. See “Installing the Display Panel:” on page 5-23. 4.

  • Page 158: Display Panel

    Display Panel Required Tools • ⁄ ” nut driver or box wrench Removing the Display Panel: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position. 2. Unplug the AC power cord, RJ-45 network cable and UPS cable (if used) from the rear of the printer.
  • Page 159 Figure 15: Display panel cable access hatch location Cable access hatch 8. Disconnect the J404 ribbon cable from the display panel by pressing the tabs out and pull- ing outwards. See Figure 16. 9. Disconnect the J405 cable from the display panel by pressing the tab and pulling outwards. Figure 16.

  • Page 160: Installing The Display Panel

    Installing the Display Panel: 1. Reconnect the J405 cable by pushing into place. 2. Reconnect the J404 ribbon cable by pushing into place. 3. Align the 2 display panel mounting screws with the mounting holes and push into place. Be sure to feed all wires through the display panel access hatch. 4.

  • Page 161: Door Solenoid

    Door Solenoid Required Tools • ⁄ ” nut driver or box wrench Removing the Door Solenoid: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position. 2. Unplug the AC power cord, RJ-45 network cable and UPS cable (if used) from the rear of the printer.

  • Page 162: Installing The Door Solenoid

    Installing the Door Solenoid: 1. Align the door solenoid bracket with the mounting holes and slide the solenoid pin through the hole in the front bezel. See Figure 18. Figure 18: Door solenoid mounting location 2 mounting holes Solenoid pin hole 2.

  • Page 163: Door Sensor

    Door Sensor Required Tools • ⁄ ” box wrench • Light colored marker Removing the Door Sensor: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position. 2.

  • Page 164: Installing The Door Sensor

    Figure 20: Mark the door sensor Mark sensor at jam nut Installing the Door Sensor: 1. Line up the door sensors and mark the new door sensor at the same place as the old door sensor. 2. Tighten jam nuts to mark on door sensor. 3.

  • Page 165: Gen 3 Electrical Components

    Gen 3 Electrical Components Gen 3 electronics will be installed on printers with serial numbers greater than P09000. Power Distribution Board (PDB) Required Tools • Standard screwdriver • Phillips screwdriver • Grounding wrist strap Figure 21: Power distribution board details AC power in To power switch and main thermal cutoff fuse...

  • Page 166: Removing The Power Distribution Board

    Removing the Power Distribution Board: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position. 2. Unplug the AC power cord, RJ-45 network cable and UPS cable (if used) from the rear of the printer.
  • Page 167 Figure 23: Chamber thermocouple location Chamber thermocouple 8. Disconnect the J14, J17 and J18 ribbon cables from the power distribution board by pressing the tabs and pulling outwards. See Figure 24. Figure 24: Power distribution board ribbon cable locations 5-30...
  • Page 168 9. Disconnect the J19 fan cable by pulling outwards. See Figure 25. 10. Disconnect the J15 ribbon cable by pressing the tabs and pulling outwards. See Figure 25. 11. Using a standard screwdriver, loosen the J2 DB-9 cable mounting screws and pull outwards to remove.
  • Page 169 Figure 26: Power distribution board cable locations 14. Disconnect J22 from the power distribution board by pressing the tab in and pulling out- wards. See Figure 27. 15. Disconnect J1 from the power distribution board by pressing the tab in and pulling out- wards.
  • Page 170 Figure 27: Power distribution board cable locations 16. At the back side of the power distribution board, disconnect the J16 ribbon cable by pulling outwards. See Figure 28. Figure 28: J16 ribbon cable location 5-33...
  • Page 171 17. Disconnect the J10, J21, J12, J7, J3 and J2 cables from the back side of the power distribution board by pressing the tabs in and pulling outwards. See Figure 29. Figure 29: Rear power distribution board cables 18. Disconnect the J9, J11, J5 and J8 cables from the back side of the power distribution board by pressing the tabs in and pulling outwards.
  • Page 172 Figure 30: Rear power distribution board cables 19. Using a phillips screwdriver, remove the 11 power distribution board mounting screws. Figure 31. 5-35...
  • Page 173 Figure 31: Power distribution board mounting screw locations Locking tab Locking tab 20. Gently pull the power distribution board away from the mounting posts. 5-36...

  • Page 174: Installing The Power Distribution Board

    14. Reconnect the AC power cord, RJ-45 network cable and UPS cable (if used). 15. Power on the system. The system should reach Idle with no displayed errors. 16. Run a small test part and monitor system operation during build. 17. Send the bad power distribution board back to Stratasys, Inc. 5-37...

  • Page 175: Controller Board

    Controller Board Required Tools • Standard screwdriver • Phillips screwdriver • Grounding wrist strap Figure 32: Controller board detail 5-38...

  • Page 176: Removing The Controller Board

    Removing the Controller Board: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position. 2. Unplug the AC power cord, RJ-45 network cable and UPS cable (if used) from the rear of the printer.
  • Page 177 Figure 34: Ribbon cable locations 7. Using a standard screwdriver, loosen the J15 DB-9 connector and pull outwards to discon- nect. See Figure 35. Figure 35: J15 location 2 mounting screws 5-40...
  • Page 178 8. Using a Phillips screwdriver, remove the 6 controller board mounting screws. See Figure Figure 36: Controller board mounting screw locations 9. Gently pull the controller board at the P104 connector on the single board computer to remove. See Figure 37: P104 location P104 5-41...

  • Page 179: Installing The Controller Board

    14. Navigate CatalystEX to the CD drive and select the proper .UPG file for the printer. 15. When finished downloading, verifying and installing, reboot the printer. 16. Run a small test part and monitor system operation during build. 17. Send the bad controller board back to Stratasys, Inc. 5-42...

  • Page 180: Single Board Computer (Sbc)

    Single Board Computer (SBC) Required Tools • Standard screwdriver • Phillips screwdriver • Grounding wrist strap Figure 38: Single board computer detail 5-43...

  • Page 181: Removing The Ide Single Board Computer

    Removing the IDE Single Board Computer: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position. 2. Unplug the AC power cord, RJ-45 network cable and UPS cable (if used) from the rear of the printer.
  • Page 182 Figure 40: IDE ribbon cable and power input cable locations IDE ribbon cable Power input cable 9. Disconnect the RJ-45 network cable by pressing the tab in and pulling outwards. See Figure 10. Using a standard screwdriver, loosen the 2 CN 20 DB-9 connector mounting screws and then pull outwards to remove.

  • Page 183: Installing The Ide Single Board Computer

    9. Reconnect the AC power cord, RJ-45 network cable and UPS cable (if used). 10. Power up the printer. 11. Run a small test part and monitor system operation during build. 12. Send the bad single board computer back to Stratasys, Inc. 5-46...

  • Page 184: Removing The Sata Single Board Computer

    Removing the SATA Single Board Computer: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position. 2. Unplug the AC power cord, RJ-45 network cable and UPS cable (if used) from the rear of the printer.
  • Page 185 Figure 44: SATA cable and power input cable locations SATA cable Power input cable 9. Disconnect the RJ-45 network cable by pressing the tab in and pulling outwards. See Figure 10. Using a standard screwdriver, loosen the 2 CN 20 DB-9 connector mounting screws and then pull outwards to remove.

  • Page 186: Installing The Sata Single Board Computer

    9. Reconnect the AC power cord, RJ-45 network cable and UPS cable (if used). 10. Power up the printer. 11. Run a small test part and monitor system operation during build. 1. Send the bad single board computer back to Stratasys, Inc. 5-49...

  • Page 187: Hard Drive

    Hard Drive Required Tools • Phillips screwdriver • Grounding wrist strap Removing the IDE Hard Drive: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position. 2. Unplug the AC power cord, RJ-45 network cable and UPS cable (if used) from the rear of the printer.
  • Page 188 6. Disconnect the power input cable by pulling outwards. See Figure 48. 7. Disconnect the IDE ribbon cable by pulling outwards. See Figure 48. 8. Using a phillips screwdriver, remove the 2 hard drive mounting screws. See Figure 48. Figure 48: Hard drive connector locations IDE ribbon Power input 2 mounting...

  • Page 189: Installing The Ide Hard Drive

    14. Navigate CatalystEX to the CD drive and select the proper .UPG file for the printer. 15. When finished downloading, verifying and installing, reboot the printer. 16. Run a small test part and monitor system operation during build. 17. Send the bad hard drive back to Stratasys, Inc. 5-52...

  • Page 190: Removing The Sata Hard Drive

    Removing the SATA Hard Drive: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position. 2. Unplug the AC power cord, RJ-45 network cable and UPS cable (if used) from the rear of the printer.

  • Page 191: Installing The Sata Hard Drive

    Figure 51: Hard drive connector locations Power input cable SATA 2 mounting cable screws 9. Remove the hard drive from the electronics bay. Installing the SATA Hard Drive: 1. Wear a grounding wrist strap and connect the end to the electronics bay pan. 2.
  • Page 192 14. Navigate CatalystEX to the CD drive and select the proper .UPG file for the printer. 15. When finished downloading, verifying and installing, reboot the printer. 16. Run a small test part and monitor system operation during build. 17. Send the bad hard drive back to Stratasys, Inc. 5-55...

  • Page 193: Electronics Bay Cooling Fan

    Electronics Bay Cooling Fan Required Tools • ⁄ ” allen wrench • Grounding wrist strap Removing the Electronics Bay Cooling Fan: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position. 2.

  • Page 194: Installing The Electronics Bay Cooling Fan

    6. Disconnect the electronics bay cooling fan cable by pressing the tab in and pulling out- wards. See Figure 54. 7. Using a ⁄ ” allen wrench, remove the lower 2 electronics bay cooling fan mounting screws. See Figure 54. Figure 54: Electronics bay cooling fan connector location Fan cable connector 2 lower mounting screws...

  • Page 195: 24 Vdc Power Supply

    24 VDC Power Supply Required Tools • Phillips screwdriver • Grounding wrist strap Removing the 24 VDC Power Supply: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position. 2.
  • Page 196 6. Remove the electronics bay cooling fan. See “Removing the Electronics Bay Cooling Fan:” on page 5-56. 7. Disconnect the power input cable by pulling outwards. See Figure 56. Figure 56: 24 VDC power supply cable locations Power input cable 8. Using a phillips screwdriver, loosen but do not remove the J1, J2, J3 and J4 output wire ter- minals and remove the wires from the terminal.
  • Page 197 9. Using a phillips screwdriver, remove the 24 VDC power supply mounting screws. See Fig- ure 58. Figure 58: 24 VDC power supply mounting screw locations 2 mounting screws 10. Lift the 24 VDC power supply upwards and angle out of the electronics bay. 11.

  • Page 198: Installing The 24 Vdc Power Supply

    Installing the 24 VDC Power Supply: 1. Wear a grounding wrist strap and connect the end to the electronics bay pan. 2. Align the 24 VDC power supply with the mounting bracket and use a phillips screwdriver to reinstall the 2 mounting screws. 3.
  • Page 199 6. Reconnect the power input cable to the 24 VDC power supply. 7. Reinstall the electronics bay cooling fan. See “Installing the Electronics Bay Cooling Fan:” on page 5-102. 8. Reinstall the rear door. See “Installing the Rear Door:” on page 5-10. 9.

  • Page 200: Vdc Power Supply (Sst Only)

    120 VDC Power Supply (SST only) Required Tools • Phillips screwdriver • Grounding wrist strap Removing the 120 VDC Power Supply: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position. 2.
  • Page 201 6. Remove the electronics bay cooling fan. See “Removing the Electronics Bay Cooling Fan:” on page 5-101. 7. Disconnect the J601 cable by pulling outward. See Figure 63. Figure 63: J601 cable location J601 8. Using a phillips screwdriver, remove the 3 mounting screws. See Figure 64.

  • Page 202: Installing The 120 Vdc Power Supply

    Figure 64: 120 VDC power supply mounting screw locations Locking tab Mounting screws Locking tab Mounting screw Installing the 120 VDC Power Supply: 1. Wear a grounding wrist strap and connect the end to the electronics bay pan. 2. Align the 120 VDC power supply with the mounting holes and use a phillips screwdriver to reinstall the 3 mounting screws.

  • Page 203: 5/12 Vdc Power Supply

    5/12 VDC Power Supply Required Tools • Phillips screwdriver • Grounding wrist strap Removing the 5/12 VDC Power Supply: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position. 2.
  • Page 204 6. Disconnect the J4 cable by pulling outwards. See Figure 66. 7. Disconnect the power input cable by pulling outwards. See Figure 66. 8. Disconnect the G2 ground wire by pulling outwards. See Figure 66. Figure 66: J4 cable location Power input cable 9.

  • Page 205: Installing The 5/12 Vdc Power Supply

    Figure 67: 5/12 VDC power supply mounting screw locations 2 mounting screws Installing the 5/12 VDC Power Supply: 1. Wear a grounding wrist strap and connect the end to the electronics bay pan. 2. Align the 5/12 VDC power supply with the mounting holes and use a phillips screwdriver to reinstall the 2 mounting screws.

  • Page 206: Line Filter Board

    Line Filter Board Required Tools • Phillips screwdriver • Grounding wrist strap Removing the Line Filter Board: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position. 2.
  • Page 207 6. Using a phillips screwdriver, remove the 3 input box mounting screws. See Figure 69. Figure 69: Input box mounting screw locations 3 mounting screws 7. Disconnect L2-1 (black) and N2-1 (white) from the front of the line filter board. See Figure 8.

  • Page 208: Installing The Line Filter Board

    9. Using a phillips screwdriver, remove the 4 mounting screws. See Figure 71. Figure 71: Line filter mounting screw locations 4 mounting screws Installing the Line Filter Board: 1. Wear a grounding wrist strap and connect the end to the electronics bay pan. 2.

  • Page 209: Ac Input

    AC Input Required Tools • Phillips screwdriver • Grounding wrist strap Removing the AC Input: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position. 2. Unplug the AC power cord, RJ-45 network cable and UPS cable (if used) from the rear of the printer.
  • Page 210 6. Using a phillips screwdriver, remove the 2 AC input mounting screws. See Figure 73. Figure 73: AC input mounting screw locations 2 mounting screws 7. Using a phillips screwdriver, remove the 3 input box mounting screws. See Figure 74. Figure 74: Input box mounting screw locations 3 mounting screws 5-73...

  • Page 211: Installing The Ac Input

    8. Disconnect LF-P (black) from the bottom right side of the AC input by pulling outwards. Figure 75. 9. Disconnect LF-N (white) from the upper right side of the AC input by pulling outwards. Figure 75. 10. Disconnect LF-G (green) from the left side of the AC input by pulling outwards. See Figure Figure 75: AC input connection locations LF-P...

  • Page 212: Circuit Breaker

    Circuit Breaker Required Tools • Phillips screwdriver • Grounding wrist strap Removing the Circuit Breaker: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position. 2. Unplug the AC power cord, RJ-45 network cable and UPS cable (if used) from the rear of the printer.
  • Page 213 6. Using a phillips screwdriver, remove the 3 input box mounting screws. See Figure 77. Figure 77: Input box mounting screw locations 3 mounting screws 7. Disconnect CB1 (black) from the upper left side of the circuit breaker by pulling outward. Figure 78.
  • Page 214 Figure 78: Circuit breaker connection locations 11. Press the 2 tabs in and push the circuit breaker outwards to remove. See Figure 79. Figure 79: Circuit breaker tab locations Upper tab Lower tab 5-77...

  • Page 215: Installing The Circuit Breaker

    Installing the Circuit Breaker: 1. Wear a grounding wrist strap and connect the end to the electronics bay pan. 2. Push the circuit breaker into the input box until it locks in place. 3. Reconnect CB1 (black) to the upper left side of the circuit breaker. 4.

  • Page 216: Gen 2 Electrical Components

    Gen 2 Electrical Components Gen 2 electronics will be installed on printers with serial numbers between P4000 and P08999 Power Distribution Board (PDB) Required Tools • Phillips screwdriver • Small standard screwdriver • Grounding wrist strap Figure 80: Gen 2 power distribution board detail J16 - To LCD display (ribbon) J21 - Not used J13 - Chamber thermocouple connector...

  • Page 217: Removing The Power Distribution Board

    Removing the Power Distribution Board: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position. 2. Unplug the AC power cord, RJ-45 network cable and UPS cable (if used) from the rear of the printer.
  • Page 218 Figure 82: Chamber thermocouple location Chamber thermocouple 8. Using a standard screwdriver, loosen the J24 DB-9 connector on the power distribution board and pull outward to disconnect. See Figure 83. Figure 83: J24 location J24 mounting screws 5-81...
  • Page 219 9. Disconnect the J14, J17 and J19 ribbon cables from the power distribution board by pressing the tabs in and pulling outwards. See Figure 84. Figure 84: Power distribution board ribbon cable locations 10. Disconnect the J15 ribbon cable by pressing the tabs in and pulling outward. See Figure 85.
  • Page 220 11. Disconnect the J4, J6 and J23 cables by pressing the tabs in and pulling outwards. See Figure Figure 86: Power distribution board cable locations 12. Disconnect the J1 and J22 cables by pressing the tabs in and pulling outwards. See Figure Figure 87: Power distribution board cable locations 5-83...
  • Page 221 13. At the back side of the power distribution board, disconnect the J16 ribbon cable by pulling outwards. See Figure 88. Figure 88: J16 cable location 14. At the back side of the power distribution board, disconnect the J7, J10, J12, J8, J3 and J2 cables by pressing the tabs in and pulling outwards.
  • Page 222 15. At the back side of the power distribution board, disconnect the J5, J9 and J11 cables by pressing the tabs in and pulling outwards. See Figure 90. Figure 90: Power distribution board rear cable locations 16. Using a phillips screwdriver, remove the 11 power distribution board mounting screws. Figure 91.
  • Page 223 Figure 91: Power distribution board mounting screw locations Locking tab Locking tab 17. Gently pull the power distribution board away from the mounting posts. 5-86...

  • Page 224: Installing The Power Distribution Board

    15. Reconnect the AC power cord, RJ-45 network cable and UPS cable (if used). 16. Power on the system. The system should reach Idle with no displayed errors. 17. Run a small test part and monitor system operation during build. 18. Send the bad power distribution board back to Stratasys, Inc. 5-87...

  • Page 225: Controller Board

    Controller Board Required Tools • Phillips screwdriver • Small standard screwdriver • Grounding wrist strap Figure 92: Controller board detail DIP switches Z axis PMD chip To PDB XY axis PMD chip and To PDB head drive motor PMD chip Serial port for HT To PDB Battery...

  • Page 226: Removing The Controller Board

    Removing the Controller Board: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position. 2. Unplug the AC power cord, RJ-45 network cable and UPS cable (if used) from the rear of the printer.
  • Page 227 Figure 94: Controller board ribbon cable locations 7. Using a small standard screwdriver, loosen the 2 J15 DB-9 ribbon cable mounting screws and disconnect by pulling outwards. See Figure 95. Figure 95: J15 DB-9 cable location 2 mounting screws 5-90...
  • Page 228 8. Using a phillips screwdriver, remove the 5 controller board mounting screws. See Figure Figure 96: Controller board mounting screw locations Locking 9. Gently pull the controller board at the P104 connector on the single board computer to remove. See Figure 97.

  • Page 229: Installing The Controller Board

    14. Navigate CatalystEX to the CD drive and select the proper .UPG file for the printer. 15. When finished downloading, verifying and installing, reboot the printer. 16. Run a small test part and monitor system operation during build. 17. Send the bad controller board back to Stratasys, Inc. 5-92...

  • Page 230: Single Board Computer (Sbc)

    Single Board Computer (SBC) Required Tools • Phillips screwdriver • Small standard screwdriver • Grounding wrist strap Figure 98: Single board computer details AMPRO 2 SBC Powe To hard drive (ribbon To LCD (ribbon cable) +5/12 VDC input RJ-45 network NOVA-600 (manufacturer To hard drive (ribbon To power...

  • Page 231: Removing The Single Board Computer

    Removing the Single Board Computer: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position. 2. Unplug the AC power cord, RJ-45 network cable and UPS cable (if used) from the rear of the printer.
  • Page 232 Figure 100: RJ-45 network cable location RJ-45 network cable 8. Disconnect the J11 ribbon cable (for Ampro SBC’s, CN7 for Nova SBC’s) by pulling out- ward. See Figure 101. 9. Disconnect the J24 ribbon cable by pulling outward. See Figure 101. 5-95...
  • Page 233 Figure 101: J11 and J24 ribbon cable locations 10. Disconnect the power J100 cable by pulling outward. See Figure 102. Figure 102: J100 cable location J100 5-96...

  • Page 234: Installing The Single Board Computer

    9. Reconnect the AC power cord, RJ-45 network cable and UPS cable (if used). 10. Power up the printer. 11. Run a small test part and monitor system operation during build. 12. Send the bad single board computer back to Stratasys, Inc. 5-97...

  • Page 235: Hard Drive

    Hard Drive Required Tools • Phillips screwdriver • Grounding wrist strap Removing the Hard Drive: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position. 2. Unplug the AC power cord, RJ-45 network cable and UPS cable (if used) from the rear of the printer.
  • Page 236 6. Disconnect the power input cable by pulling outwards. See Figure 105. 7. Disconnect the IDE ribbon cable by pulling outwards. See Figure 105. 8. Using a phillips screwdriver, remove the 2 hard drive mounting screws. See Figure 105. Figure 105: Hard drive cable and mounting screw locations IDE ribbon cable Power input cable 2 mounting screws...

  • Page 237: Installing The Hard Drive

    14. Navigate CatalystEX to the CD drive and select the proper .UPG file for the printer. 15. When finished downloading, verifying and installing, reboot the printer. 16. Run a small test part and monitor system operation during build. 17. Send the bad hard drive back to Stratasys, Inc. 5-100...

  • Page 238: Electronics Bay Cooling Fan

    Electronics Bay Cooling Fan Required Tools • ⁄ ” allen wrench • Grounding wrist strap Removing the Electronics Bay Cooling Fan: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position. 2.

  • Page 239: Installing The Electronics Bay Cooling Fan

    6. Disconnect the electronics bay cooling fan cable by pressing the tab in and pulling out- wards. See Figure 108. 7. Using a ⁄ ” allen wrench, remove the lower 2 electronics bay cooling fan mounting screws. See Figure 108. Figure 108: Electronics bay cooling fan connector location Fan cable connector 2 lower mounting screws...

  • Page 240: 24 Vdc Power Supply

    24 VDC Power Supply Required Tools • Phillips screwdriver • Grounding wrist strap Removing the 24 VDC Power Supply: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position. 2.
  • Page 241 6. Remove the electronics bay cooling fan. See “Removing the Electronics Bay Cooling Fan:” on page 5-101. 7. Disconnect the 24 VDC power input cable by pulling outward. See Figure 110. Figure 110: 24 VDC power input cable location Power input cable 8.
  • Page 242 Figure 111: J4 location 9. Using a phillips screwdriver, remove the 2 mounting screws. See Figure 112. Figure 112: 24 VDC mounting screw locations 2 mounting screws 5-105...
  • Page 243 10. Lift the power supply up and angle outwards to remove from the electronics bay. 11. Using a phillips screwdriver, remove the 24V (red) cable and RTN (black) cable from the 24 VDC power supply. See Figure 113. Figure 113: 24 VDC output cable locations 12.
  • Page 244 Installing the 24 VDC Power Supply: 1. Wear a grounding wrist strap and connect the end to the electronics bay pan. 2. Align the 24 VDC power supply with the mounting bracket and use a phillips screwdriver to reinstall the 2 mounting screws. 3.

  • Page 245: Vdc Power Supply (Sst Only)

    120 VDC Power Supply (SST only) Required Tools • Phillips screwdriver • Grounding wrist strap Removing the 120 VDC Power Supply: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position. 2.
  • Page 246 6. Remove the electronics bay cooling fan. See “Removing the Electronics Bay Cooling Fan:” on page 5-101. 7. Disconnect the J601 cable by pulling outward. See Figure 117. Figure 117: J601 cable location J601 8. Using a phillips screwdriver, remove the 3 mounting screws. See Figure 118.
  • Page 247 Figure 118: 120 VDC power supply mounting screw locations Locking tab Mounting screws Locking tab Mounting screw Installing the 120 VDC Power Supply: 1. Wear a grounding wrist strap and connect the end to the electronics bay pan. 2. Align the 120 VDC power supply with the mounting holes and use a phillips screwdriver to reinstall the 3 mounting screws.

  • Page 248: 5/12 Vdc Power Supply

    5/12 VDC Power Supply Required Tools • Phillips screwdriver • Grounding wrist strap Removing the 5/12 VDC Power Supply: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position. 2.
  • Page 249 6. Disconnect the J4 cable by pulling outwards. See Figure 120. 7. Disconnect the power input cable by pulling outwards. See Figure 120. 8. Disconnect the G2 ground wire by pulling outwards. See Figure 120. Figure 120: J4 cable location Power input cable 9.
  • Page 250 Figure 121: 5/12 VDC power supply mounting screw locations 2 mounting screws Installing the 5/12 VDC Power Supply: 1. Wear a grounding wrist strap and connect the end to the electronics bay pan. 2. Align the 5/12 VDC power supply with the mounting holes and use a phillips screwdriver to reinstall the 2 mounting screws.

  • Page 251: Line Filter Board

    Line Filter Board Required Tools • Phillips screwdriver • Grounding wrist strap Removing the Line Filter Board: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position. 2.
  • Page 252 6. Using a phillips screwdriver, remove the 3 input box mounting screws. See Figure 123. Figure 123: Input box mounting screw locations 3 mounting screws 7. Disconnect L2-1 (black) and N2-1 (white) from the front of the line filter board. See Figure 124.
  • Page 253 9. Using a phillips screwdriver, remove the 4 mounting screws. See Figure 125. Figure 125: Line filter mounting screw locations 4 mounting screws Installing the Line Filter Board: 1. Wear a grounding wrist strap and connect the end to the electronics bay pan. 2.

  • Page 254: Ac Input

    AC Input Required Tools • Phillips screwdriver • Grounding wrist strap Removing the AC Input: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position. 2. Unplug the AC power cord, RJ-45 network cable and UPS cable (if used) from the rear of the printer.
  • Page 255 6. Using a phillips screwdriver, remove the 2 AC input mounting screws. See Figure 127. Figure 127: AC input mounting screw locations 2 mounting screws 7. Using a phillips screwdriver, remove the 3 input box mounting screws. See Figure 128. Figure 128: Input box mounting screw locations 3 mounting screws 5-118...
  • Page 256 8. Disconnect LF-P (black) from the bottom right side of the AC input by pulling outwards. Figure 129. 9. Disconnect LF-N (white) from the upper right side of the AC input by pulling outwards. Figure 129. 10. Disconnect LF-G (green) from the left side of the AC input by pulling outwards. See Figure 129.

  • Page 257: Circuit Breaker

    Circuit Breaker Required Tools • Phillips screwdriver • Grounding wrist strap Removing the Circuit Breaker: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position. 2. Unplug the AC power cord, RJ-45 network cable and UPS cable (if used) from the rear of the printer.
  • Page 258 6. Using a phillips screwdriver, remove the 4 circuit breaker mounting screws. See Figure 131. Figure 131: AC input mounting screw locations 4 mounting screws 7. Using a phillips screwdriver, remove the 3 input box mounting screws. See Figure 132. Figure 132: Input box mounting screw locations 3 mounting screws 5-121...
  • Page 259 8. Disconnect CB1 (black) from the upper left side of the circuit breaker by pulling outward. Figure 133. 9. Disconnect CB2 (white) from the upper right side of the circuit breaker by pulling outward. Figure 133. 10. Disconnect CB1 (black) from the lower left side of the circuit breaker by pulling outward. Figure 133.
  • Page 260 Installing the Circuit Breaker: 1. Wear a grounding wrist strap and connect the end to the electronics bay pan. 2. Reconnect CB1 (black) to the upper left side of the circuit breaker. 3. Reconnect CB2 (white) to the upper right side of the circuit breaker. 4.

  • Page 261: Gen 1 Electrical Components

    Gen 1 Electrical Components Power Distribution Board (PDB) Required Tools • Phillips screwdriver • ⁄ ” nut driver or standard screwdriver • Grounding wrist strap Removing the Power Distribution Board: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position.
  • Page 262 6. Disconnect the 14 cables on the power distribution board. See Figure 135. Carefully note the location and orientation of the connectors. If necessary, mark cable orientation and location to guarantee correct re- connection. Figure 135: Power distribution board details 120 VDC to 24 VDC to MDB and 120 VDC to...
  • Page 263 7. Using a ⁄ ” nut driver or standard screwdriver, remove the 2 screws holding the board and heat sink to the electronics bay Figure 136. Figure 136: PDB mounting screw locations 2 Mounting screws 8. Lift upward on the board and pull outwards to remove. 5-126...
  • Page 264 6. Reconnect the AC power cord, RJ-45 network cable and UPS cable (if used). 7. Power on the system. The system should reach Idle with no displayed errors. 8. Run a small test part and monitor system operation during build. 9. Send the bad PDB back to Stratasys, Inc. 5-127...

  • Page 265: 186 Processor Board

    186 Processor Board Required Tools • Phillips screwdriver • Grounding wrist strap • Cutters Removing the 186 processor board: 1. Power down the system using the power-down switch. Once the system is powered down, turn the breaker off. 2. Unplug the AC power cord, RJ-45 network cable and UPS cable (if used) from the rear of the printer.
  • Page 266 Figure 139: Diagnostics cable location Cut the 2 wire ties 7. Disconnect the 12 connectors from the 186 board. See Figure 140. Carefully note the location and orientation of the connectors. If necessary, mark cable orientation and location to guarantee correct re- connection.
  • Page 267 Figure 140: 186 processor board details To door sensor, Y-EOT To Z jam sensor and Y sensor, Z limit switches home sensor (upper and lower) Not used To X-EOT, Z foam sensor, X home sensor, Head T/ To chamber To filament (head) thermocouple motors and encoders To receiver motors...
  • Page 268 Figure 141: 186 processor board mounting screw locations 9. Carefully remove the 186 processor board from the P104 connector on the Single Board Computer (SBC) by pulling outward until the 186 processor board is free of the SBC. The lower portion of the 186 processor board is connected to the top of the SBC via an array of pins.
  • Page 269 13. Navigate CatalystEX to the CD drive and select the proper .UPG file for the printer. 14. When finished downloading, verifying and installing, reboot the printer. 15. Run a small test part and monitor system operation during build. 16. Send the bad 186 processor board back to Stratasys, Inc. 5-132...

  • Page 270: Single Board Computer (Sbc)

    Single Board Computer (SBC) Required Tools • Phillips screwdriver • Grounding wrist strap Removing the Single Board Computer: 1. Power down the system using the power-down switch. Once the system is powered down, turn the breaker off. 2. Unplug the AC power cord, RJ-45 network cable and UPS cable (if used) from the rear of the printer.
  • Page 271 Figure 144: Single board computer details AMPRO To hard drive (ribbon cable) To power down switch and LCD To LCD (ribbon cable) +5/12 VDC input RJ-45 network AMPRO 2 SBC Powe To hard drive (ribbon To LCD (ribbon cable) +5/12 VDC input RJ-45 network NOVA-600 (manufacturer To hard drive (ribbon...
  • Page 272 8. Reconnect the AC cord and the RJ-45 network cable. 9. Power on the system. The system should reach Idle without displaying an error. 10. Run a small test part and monitor system operation during build. 11. Send the bad SBC back to Stratasys, Inc. 5-135...

  • Page 273: Vdc Piggyback Power Supply

    5 VDC Piggyback Power Supply Due to availability, printers will now use two different manufacturers of Single Board Computers: Nova and Ampro. The Nova SBC has a higher 5 VDC current rating, therefore an additional 5 VDC supply must be added when a Nova board is installed. If a Nova SBC is installed the additional 5 VDC supply must be present.
  • Page 274 6. Using a phillips screwdriver, remove the upper mounting screw from the L bracket. See Figure 147. 7. Using a ⁄ ” nut driver or standard screwdriver, remove the lower mounting screw from the L bracket. See Figure 147. Figure 147: L Bracket mounting screw locations Upper mounting screw Lower mounting screw 8.
  • Page 275 10. Connect the J5 connector from the 5 VDC supply to J5 on the PDB. 11. If not already disconnected, disconnect the P-SBC connector from the SBC and plug it into the top of the 5 VDC board. 12. Connect the SBC power cable from the 5 VDC board into the SBC. See Figure 149.
  • Page 276 Removing the 5 VDC piggyback power supply: 1. Power down the system using the power-down switch. Once the system is powered down, turn the breaker off. 2. Unplug the AC power cord, RJ-45 network cable and UPS cable (if used) from the rear of the printer.
  • Page 277 Figure 151: 5 VDC piggyback power supply connections J5 on the PDB To J10 on the Ampro To CN4 on the Nova SBC only SBC only (inner connector on (outer connector on P-SBC J5 to the 5 VDC power 9. Using a phillips screwdriver, remove the 4 piggyback power supply mounting screws. See Figure 152.
  • Page 278 Figure 152: 5 VDC piggyback power supply mounting screw locations 10. Remove the 5 VDC piggyback power supply and discard. 5-141...
  • Page 279 Installing the 5 VDC piggyback power supply: 1. Wear a grounding wrist strap and connect the end to the electronics bay pan. 2. Align the 5 VDC piggyback power supply with the mounting bracket. 3. Using a phillips screwdriver, reinstall the 4 mounting screws. 4.

  • Page 280: 24 Vdc Power Supply

    24 VDC Power Supply Required Tools • Phillips screwdriver • ⁄ ” nut driver or standard screwdriver • ⁄ ” allen wrench • Grounding wrist strap Removing the 24 VDC Power Supply 1. Power down the system using the power-down switch. Once the system is powered down, turn the breaker off.
  • Page 281 6. Disconnect the lower electronics bay cooling fan cable by pressing the tab in and pulling the connector apart. See Figure 155. 7. Using a ⁄ ” allen wrench, remove the 3 lower electronics bay cooling fan and fan guard mounting screws.
  • Page 282 Figure 156: 5 VDC piggyback power supply and PDB connections J5 on the PDB To J10 on the Ampro To CN4 on the Nova SBC only SBC only (inner connector on (outer connector on SBC) SBC) P-SBC J5 to the 5 VDC power 4.
  • Page 283 Figure 157: L bracket mounting screw locations 24 VDC power supply with 5 VDC piggy back power supply installed 2 mounting screws 5. Move the power supply forward about 6” or enough to access the left side of the supply. 6.
  • Page 284 Figure 159: 24 VDC output cable locations 24V1 RTN2 RTN1 24V2 8. Rotate supply to gain access to the right side of the supply. 9. Using a phillips screwdriver, loosen but do not remove the 3 AC input wire mounting screws.
  • Page 285 10. Remove power supply. 11. Using a phillips screwdriver, remove the L bracket mounting screw and the 5 VDC piggy- back power supply bracket mounting screw. See Figure 161. Figure 161: Bracket mounting screw locations If the 5 VDC piggyback power supply is NOT installed: 1.
  • Page 286 2. Using a ⁄ ” nut driver or standard screwdriver, remove the 2 mounting screws holding the 24 VDC power supply L brackets to the electronics bay. See Figure 163. Figure 163: L bracket mounting screw locations 24 VDC power supply without 5 VDC piggy back power supply installed 2 mounting screws 3.
  • Page 287 Figure 165: 24 VDC output wire locations 24V1 RTN2 RTN1 24V2 6. Rotate supply to gain access to the right side of the supply. 7. Using a phillips screwdriver, loosen but do not remove the 3 AC input wire mounting screws.
  • Page 288 8. Remove power supply. 9. Using a phillips screwdriver, remove the two L bracket mounting screws. See Figure 167. Figure 167: L bracket mounting screw locations Installing the 24 VDC Power Supply: 1. Wear a grounding wrist strap and connect the end to the electronics bay pan. If 5 VDC piggyback power supply is NOT installed: If the 5 VDC piggyback power supply is installed proceed to “If the 5...
  • Page 289 3. Using a phillips screwdriver, reinstall the 4 output wires. See Figure 169. Figure 169: 24 VDC output wire locations 24V1 RTN2 RTN1 24V2 4. Align the 24 VDC power supply with the mounting holes. 5. Using a ⁄ ” nut driver or standard screwdriver, secure the L brackets to the electronics bay. 6.
  • Page 290 If the 5 VDC piggyback power supply is installed: 1. Using a phillips screwdriver, reinstall the L bracket and 5 VDC piggyback power supply bracket to the 24 VDC power supply. 2. Using a phillips screwdriver, reconnect the 3 AC input wires. See Figure 170.
  • Page 291 4. Align the 24 VDC power supply with the mounting holes. 5. Using a ⁄ ” nut driver or standard screwdriver, secure the L bracket and 5 VDC piggyback power supply bracket to the electronics bay. 6. Reconnect the P-SBC and J5 cables to the piggyback power supply. See Figure 172.
  • Page 292 Airflow direction arrows are embossed on side of fan. Fan must be replaced with the correct direction of airflow. 11. Reconnect the lower electronics bay fan cable. 12. Reinstall the rear door. See “Installing the Rear Door:” on page 5-10. 13. Reconnect the AC power cord, RJ-45 network cable and UPS cable (if used). 14.

  • Page 293: Dual 48 Vdc Power Supplies (Sst Only)

    Dual 48 VDC Power Supplies (SST only) Required Tools • Phillips screwdriver • ⁄ ” nut driver or standard screwdriver • ⁄ ” allen wrench • Grounding wrist strap Removing the Dual 48 VDC Power Supplies: 1. Power down the system using the power-down switch. Once the system is powered down, turn the breaker off.
  • Page 294 6. Disconnect the upper electronics bay cooling fan cable by pressing the tab in and pulling the connector apart. See Figure 174. 7. Using a ⁄ ” allen wrench, remove the 3 upper electronics bay cooling fan mounting screws. See Figure 174.
  • Page 295 Figure 175: Dual 48 VDC power supplies location Dual 48 VDC power supplies 9. Disconnect C63 from the power distribution board by pulling outward and remove the cable from the wire clip. See Figure 176. Figure 176: C63 connector location Wire clip connector 5-158...
  • Page 296 10. Using a ⁄ ” nut driver or standard screwdriver, remove the dual 48 VDC mounting bracket mounting screw. See Figure 177. Figure 177: Dual 48 VDC mounting bracket location Mounting bracket screw 11. Remove the assembly by pulling forward until it is free from the mounting slot. 12.
  • Page 297 14. Disconnect the J2 cable from both power supplies. See Figure 179. Figure 179: J2 connector location connector connector 15. Using phillips screwdriver, remove the 4 mounting screws from each power supply. See Figure 180. Figure 180: Dual 48 VDC power supplies mounting screw locations 5-160...
  • Page 298 Installing the Dual 48 VDC Power Supplies: 1. Wear a grounding wrist strap and connect the end to the electronics bay pan. 2. Align the new 48 VDC power supplies with the mounting standoffs on the mounting bracket. 3. Using a phillips screwdriver reinstall the 4 mounting screws for each power supply. 4.

  • Page 299: Motor Driver Board (Mdb)

    Motor Driver Board (MDB) Required Tools • Phillips screwdriver • ⁄ ” nut driver or standard screwdriver • Grounding wrist strap Removing the Motor Driver Board: 1. Power down the system using the power-down switch. Once the system is powered down, turn the breaker off.
  • Page 300 6. Disconnect the P301, P306 and P310 ribbon cables from the motor driver board and 186 pro- cessor board by pulling outward. See Figure 182. Figure 182: MDB ribbon connector locations P301 P306 P310 7. Disconnect the J302, J305 and J308 connectors from the motor driver board by pressing the tabs in and pulling out ward.
  • Page 301 Figure 183: MDB cable locations Chamber thermocouple J302 J305 J308 9. Disconnect the J3, J7 and J11 cables from the motor diver board. See Figure 184. 5-164...
  • Page 302 Figure 184: MDB cable locations J11 (back), J7 (center) and J3 (front) 10. Using a ⁄ ” nut driver or standard screwdriver, remove the 2 motor driver board mounting screws. See Figure 185. 11. Remove the motor driver board and heat sink. 5-165...
  • Page 303 7. Reconnect the AC power cord, RJ-45 network cable and UPS cable (if used). 8. Power up the printer. 9. Run a small test part and monitor system operation during build. 10. Send the bad motor driver board back to Stratasys, Inc. 5-166...

  • Page 304: Hard Drive

    Hard Drive Required Tools • Phillips screwdriver • ⁄ ” nut driver or standard screwdriver • Grounding wrist strap • Notebook computer or Workstation running CatalystEX • System Software CD Removing the Hard Drive: 1. Power down the system using the power-down switch. Once the system is powered down, turn the breaker off.
  • Page 305 6. Using a phillips screwdriver, remove the upper 5 VDC piggyback power supply mounting screw. See Figure 187. 7. Using a ⁄ ” nut driver or standard screwdriver, remove the lower 5 VDC piggyback power supply mounting screw. See Figure 187. Figure 187: 5 VDC piggyback power supply mounting screw locations 2 mounting screws...
  • Page 306 Figure 189: Ribbon cable ferrite location Slide ribbon cable out Insert standard screwdriver 10. Disconnect the hard drive IDE ribbon cable by pulling outward. See Figure 190. 11. Disconnect the hard drive power input cable by pulling outward. See Figure 190. Figure 190: Hard drive cable locations Power input IDE ribbon...
  • Page 307 Figure 191: Hard drive mounting screw locations 2 shorter mounting screws 2 longer mounting screws 13. Slide the hard drive down and pull it outwards to remove. See Figure 192. Figure 192: Removing the hard drive 5-170...
  • Page 308 14. Using a ⁄ ” nut driver or standard screwdriver, remove the 2 hard drive mounting bracket mounting screws. See Figure 193. The orientation of the mounting bracket on the hard drive for reinstallation. Figure 193: Hard drive mounting bracket mounting screw locations 2 mounting screws Installing the Hard Drive: 1.
  • Page 309 21. Run a small test part and monitor system operation during build. 22. Follow the steps in the Hard Drive Installation Checklist. See “Hard Drive Installation Checklist” on page Appendix-18. 23. Send the bad hard drive back to Stratasys, Inc. 5-172...

  • Page 310: Line Filter

    Line Filter Required Tools • ⁄ ” nut driver or standard screwdriver • Grounding wrist strap Removing the Line Filter: 1. Power down the system using the power-down switch. Once the system is powered down, turn the breaker off. 2. Unplug the AC power cord, RJ-45 network cable and UPS cable (if used) from the rear of the printer.
  • Page 311 6. Using a ⁄ ” nut driver or standard screwdriver, remove the 3 input box cover mounting screws and set the input box cover aside. See Figure 196. Figure 196: Input box cover mounting screw locations 3 mounting screws 7. Using a ⁄...
  • Page 312 8. Disconnect LF1 (black), LF2 (white) and LF3 (green) from the front of the line filter by pull- ing outward. See Figure 198. Figure 198: Line filter front connection locations 9. Disconnect LF4 (black) and LF5 (white) from the rear of the line filter by pulling outward. Figure 199.

  • Page 313: Installing The Line Filter

    10. Using a ⁄ ” nut driver or standard screwdriver, remove the 4 line filter mounting screws and remove the line filter. See Figure 200. Figure 200: Line filter mounting screw locations 4 mounting screws Installing the Line Filter: 1. Wear a grounding wrist strap and connect the end to the electronics bay pan. 2.

  • Page 314: Ac Input

    AC Input Required Tools • ⁄ ” nut driver or standard screwdriver • Grounding wrist strap Removing the AC Input: 1. Power down the system using the power-down switch. Once the system is powered down, turn the breaker off. 2. Unplug the AC power cord, RJ-45 network cable and UPS cable (if used) from the rear of the printer.
  • Page 315 6. Using a ⁄ ” nut driver or standard screwdriver, remove the 3 input box cover mounting screws and set the input box cover aside. See Figure 202. Figure 202: Input box cover mounting screw locations 3 mounting screws 7. Using a ⁄...
  • Page 316 8. Disconnect CB1 (black) from the upper right and CB2 (white) from the upper left of the cir- cuit breaker. See Figure 204. Figure 204: Circuit breaker connection locations 9. Using a ⁄ ” nut driver, remove the grounding post nut. See Figure 205.

  • Page 317: Installing The Ac Input

    Installing the AC Input: 1. Wear a grounding wrist strap and connect the end to the electronics bay pan. 2. Slide the AC input through the mounting hole on the input box. 3. Reconnect G1 to the grounding post. 4. Using a ⁄...

  • Page 318: Circuit Breaker

    Circuit Breaker Required Tools • ⁄ ” nut driver or standard screwdriver • Grounding wrist strap Removing the Circuit Breaker: 1. Power down the system using the power-down switch. Once the system is powered down, turn the breaker off. 2. Unplug the AC power cord, RJ-45 network cable and UPS cable (if used) from the rear of the printer.
  • Page 319 6. Using a ⁄ ” nut driver or standard screwdriver, remove the 3 input box cover mounting screws and set the input box cover aside. See Figure 207. Figure 207: Input box cover mounting screw locations 3 mounting screws 7. Disconnect CB1 (black) from the upper right and CB2 (white) from the upper left of the cir- cuit breaker by pulling outwards.

  • Page 320: Installing The Circuit Breaker

    9. Using a ⁄ ” nut driver or standard screwdriver, remove the 4 circuit breaker mounting screws. See Figure 209. Figure 209: Circuit breaker mounting screw locations 4 mounting screws 10. Push the circuit breaker through the back of the input box, remove and discard. Installing the Circuit Breaker: 1.

  • Page 321: Head Components

    Head Components Head Cooling Fan Required Tools • ⁄ ” nut driver or standard screwdriver • ⁄ ” allen wrench • ⁄ ” allen wrench • ⁄ ” allen wrench Removing the Head Cooling Fan: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position.
  • Page 322 6. Disconnect the fan cable by pressing the tab in and pulling apart. See Figure 211. Figure 211: Fan cable location Head cooling fan cable 7. Depending on which bracket style you have, complete the following: a. Using a ⁄ ”...
  • Page 323 8. Using a ⁄ ” nut driver or standard screwdriver, remove the 4 hose collar mounting screws. Figure 213. Figure 213: Hose collar mounting screw locations 2 mounting screws behind 2 mounting frame screws 9. Slide the fan down and out the back of the machine. 5-186...

  • Page 324: Installing The Head Cooling Fan

    Installing the Head Cooling Fan: 1. Using a ⁄ ” allen wrench, attach the head cooling fan adapter plate to the hose collar using the screws provided in the kit. See Figure 214. Figure 214: Head cooling fan adapter plate Head fan adapter Install screws up through...

  • Page 325: Head Temperature Snap Switch

    Head Temperature Snap Switch Required Tools • ⁄ ” allen wrench Removing the Head Temperature Snap Switch: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position. 2.
  • Page 326 7. Remove the two female spade connectors from the head temperature snap switch by pull- ing away from the spades. See Figure 216. Figure 216: Head temperature snap switch connections Spade connectors 8. Using a ⁄ ” allen wrench, remove the 2 mounting screws. See If necessary, turn the head temperature snap switch to access the mounting screws.

  • Page 327: Installing The Head Temperature Snap Switch

    Installing the Head Temperature Snap Switch: 1. Align the head temperature snap switch with the mounting holes and use a ⁄ ” allen wrench to reinstall the 2 mounting screws. 2. Reconnect both spade connectors by pushing them onto the spades. 3.
  • Page 328 5-191...

  • Page 329: Bst Swivel Head

    BST Swivel Head Required Tools • Phillips screwdriver • ⁄ ” allen wrench • ⁄ ” nut driver or standard screwdriver Removing the BST Swivel Head: 1. Unload both model and support material from the head. 2. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position.
  • Page 330 Figure 219: Model thermocouple location Model thermocouple 8. Using a phillips screwdriver, loosen the 2 self retaining screws from the left side of the head and open the head by pulling outward. See Figure 220. Figure 220: Head self retaining screw locations 2 self retaining screws 9.
  • Page 331 12. Disconnect the model liquefier connector by pressing the tab in and pulling outwards. See Figure 221. 13. Pull the model and support thermocouple wires through the access slot on the translator. Figure 221. Figure 221: Head connector detail Access slot Model liquefier connector Support motor...
  • Page 332 Figure 222: Head hinge pin set screw location Hinge pin set screw 15. Remove the head hinge pin by lifting upwards. See Figure 223. Figure 223: Removing the head hinge pin 16. Remove the head from the printer. 5-195...

  • Page 333: Installing The Bst Swivel Head

    “Tip Offset Calibration” on page 6-8. 19. Follow the Head Installation Checklist. See “Head Installation Checklist” on page Appen- dix-20. 20. Run a small test part and monitor system operation during build. 21. Send bad SST head back to Stratasys, Inc. 5-196...

  • Page 334: Sst Swivel Head

    SST Swivel Head Required Tools • Phillips screwdriver • ⁄ ” allen wrench • ⁄ ” nut driver or standard screwdriver Removing the SST Swivel Head: 1. Unload both model and support material from the head. 2. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position.
  • Page 335 8. Disconnect J303 from the TC Amp board by pulling outwards. See Figure 225. Note the location of the model and support thermocouples for reinstallation Figure 225: Model and support thermocouple locations J303 Model thermocouple Support thermocouple 9. Using a phillips screwdriver, loosen the 2 self retaining screws from the left side of the head and open the head by pulling outward.
  • Page 336 11. Disconnect the support motor connector by pressing the tab in and pulling outwards. See Figure 227. 12. Pull the support motor wire clip from the translator. See Figure 227. 13. Disconnect the model liquefier connector by pressing the tab in and pulling outwards. See Figure 227.
  • Page 337 Figure 228: Translator access slot location Pull model and support thermocouples through slot 16. Using a ⁄ ” allen wrench, remove the head hinge pin set screw. See Figure 229. Be careful not to lose the head hinge pin set screw. Figure 229: Head hinge pin set screw location Hinge pin set screw 17.
  • Page 338 Figure 230: Removing the head hinge pin 18. Remove the head from the printer. 5-201...

  • Page 339: Installing The Sst Swivel Head

    “Tip Offset Calibration” on page 6-8. 20. Follow the Head Installation Checklist. See “Head Installation Checklist” on page Appen- dix-20. 21. Run a small test part and monitor system operation during build. 22. Send bad SST head back to Stratasys, Inc. 5-202...

  • Page 340: Tc Amp Board

    TC Amp Board Required Tools • ⁄ ” nut driver or standard screwdriver • Grounding wrist strap Removing the TC Amp Board for SST: 1. Lower the Z stage at least ⁄ way down its travel. 2. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position.
  • Page 341 10. Disconnect the model (upper) and support (lower) thermocouples by pulling outwards. Figure 232. Note the location of the model and support thermocouples for reinstallation Figure 232: TC Amp Board Detail J303 connector Model thermocouple Support thermocouple J301 connector 11. Using a ⁄...
  • Page 342 Figure 233: Mounting screw locations Ground wire 4 mounting screws 12. Remove the 2 jumpers from the TC Amp board. See Figure 234. Figure 234: Jumper locations 2 Jumpers 13. Discard the TC Amp board. 5-205...

  • Page 343: Installing The Tc Amp Board For Sst

    Installing the TC Amp Board for SST: 1. Install the 2 jumpers removed from the bad TC Amp board on the replacement TC Amp board. 2. Align the TC Amp board with the mounting holes and reinstall the ground wire and 4 mounting screws using a ⁄...
  • Page 344 Figure 235: TC Amp board location TC Amp Board 8. Disconnect the umbilical cable by pressing the tab in and pulling outwards. See Figure 236. 9. Disconnect the power input cable by pressing the tab in and pulling outwards. See Figure 236.
  • Page 345 11. Using a ⁄ ” nut driver or standard screwdriver, remove the 4 mounting screws. See Figure 237. Note the location of the ground wire. Figure 237: Mounting screw locations Ground wire 4 mounting screws 12. Discard the TC Amp board. Installing the TC Amp Board for BST: 1.

  • Page 346: Umbilical Cable

    Umbilical Cable Required Tools • ⁄ ” nut driver or standard screwdriver • Phillips screwdriver • Cutters • Wire ties • Grounding wrist strap Removing the Umbilical Cable: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position.
  • Page 347 9. Disconnect the model liquefier connector by pressing the tab in and pulling outwards. See Figure 239. 10. Disconnect the support liquefier connector by pressing the tab in and pulling outwards. See Figure 239. Figure 239: Head connector detail Support liquefier Model liquefier connector connector...
  • Page 348 12. Using a cutters, cut and remove the wire tie from the X motor connector. Disconnect the X motor cable by pressing the tab in and pulling apart. See Figure 241. Figure 241: X motor wire tie location Wire tie X motor connector 13.
  • Page 349 Figure 243: X BOT (Home) sensor connector location X BOT connector 15. Disconnect the X EOT (End of travel) sensor by pressing the tab in and pulling apart. See Figure 244. Figure 244: X EOT (End of travel) sensor connector location X EOT connector 16.
  • Page 350 Figure 245: Model and support thermocouple connector locations Model thermocouple Support thermocouple 17. Disconnect the head thermal snap switch by pulling the 2 wires away from the spade con- nectors. See Figure 246. Figure 246: Thermal snap switch connector locations 2 Spade connectors 18.
  • Page 351 19. Using a ⁄ ” nut driver or standard screwdriver, remove the ground wire from the TC Amp board. See Figure 247. Figure 247: TC Amp board connections Ground wire mounting screw J301 20. Using a cutters, cut the wire tie from the umbilical hose mount. See Figure 248.
  • Page 352 21. Using a large pliers or crescent wrench, remove the umbilical cable strain relief at the head. Figure 249. 22. Remove the umbilical cable from the strain relief mount by lifting up and out through the slot. See Figure 249. Figure 249: Umbilical cable strain relief removal Lift wires through slot Remove strain relief...
  • Page 353 25. Using a cutters, cut and remove the wire tie from the umbilical hose. See Figure 251. Figure 251: Umbilical cable and hose wire tie location Wire tie 26. Disconnect the following: a. For Gen 1 electronics: Using a ⁄ ”...
  • Page 354 ii. Disconnect J302 from the motor driver board. See Figure 253. Figure 253: J302 location J302 iii. Disconnect J101 and J10 from the power distribution board. See Figure 254. Figure 254: Power distribution board connections J101 5-217...
  • Page 355 iv. Disconnect J14 and J7 from the 186 board. See Figure 255. Figure 255: 186 connections v. Pull the wires through the access hole at the back of the electronics bay. See Figure 256. Figure 256: Electronics bay access hole Pull umbilical cable wires through access hole 5-218...
  • Page 356 b. For Gen 2 electronics: Un-clip the 4 wire ties at the back of the electronics bay. See Figure 257. Figure 257: Wire tie locations 4 wire ties ii. Disconnect J9, J10 and J11 from the power distribution board by pressing the tabs in and pulling outwards.
  • Page 357 c. For Gen 3 electronics: Un-clip the 4 wire ties at the back of the electronics bay. See Figure 259. Figure 259: Wire tie locations 4 wire ties ii. Disconnect J9, J10, J11 and J21 from the power distribution board by pressing the tabs in and pulling outwards.

  • Page 358: Installing The Umbilical Cable

    Installing the Umbilical Cable: 1. Lay the new cable out and loosen the bushings on each of the strain relief assemblies using a large pliers or crescent wrench. 2. Remove the strain relief mounting nuts from each strain relief. It is not necessary to pull the nuts all the way off the cable.

  • Page 359: Z Foam Level Sensor

    Z Foam Level Sensor Required Tools • ⁄ ” allen wrench • Cutters • Wire ties Removing the Z Foam Level Sensor: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position. 2.

  • Page 360: Installing The Z Foam Level Sensor

    7. Disconnect the Z foam level sensor connector by pressing the tab in and pulling apart. See Figure 262. 8. Using a ⁄ ” allen wrench, remove the 2 Z foam level sensor mounting screws and washers. Figure 262. Be careful not to lose the washers. Figure 262: Z foam level sensor wire tie location Z foam level sensor connector and...

  • Page 361: Z Foam Level Assembly

    Z Foam Level Assembly Required Tools • ⁄ ” allen wrench Removing the Z Foam Level Assembly: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position. 2.

  • Page 362: Installing The Z Foam Level Assembly

    Figure 264: Z foam level assembly mounting screw locations 4 mounting screws 8. Remove the Z foam level assembly and discard. Installing the Z Foam Level Assembly: 1. Remove the Z foam level bar from the assembly by pushing the actuator into the housing and pulling the bar to the right.

  • Page 363: Chamber Thermal Snap Switch

    Chamber Thermal Snap Switch Required Tools • ⁄ ” nut driver • ⁄ ” nut driver • Standard screw driver • ⁄ ” allen wrench Removing the Chamber Thermal Snap Switch for Cable Drive XY Table: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position.

  • Page 364: Installing The Chamber Thermal Snap Switch For Cable Drive Xy Table

    Figure 266: Chamber thermal snap switch detail 2 mounting screws 8. Discard the chamber thermal snap switch. Installing the Chamber Thermal Snap Switch for Cable Drive XY Table: 1. Align the chamber thermal snap switch with the mounting holes and use a ⁄...

  • Page 365: Removing The Chamber Thermal Snap Switch For Belt Drive Xy Table

    Removing the Chamber Thermal Snap Switch for Belt Drive XY Table: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position. 2. Unplug the AC power cord, RJ-45 network cable and UPS cable (if used) from the rear of the printer.
  • Page 366 Figure 268: Rear frame bracket mounting screw locations 4 mounting screws 7. Disconnect the chamber thermal snap switch wires buy pulling the spade connectors away from the switch. See Figure 269. 8. Using a ⁄ ” allen wrench, remove the 2 chamber thermal snap switch mounting screws. Figure 269.

  • Page 367: Installing The Chamber Thermal Snap Switch For Belt Drive Xy Table

    Installing the Chamber Thermal Snap Switch for Belt Drive XY Table: 1. Align the chamber thermal snap switch with the mounting holes and use a ⁄ ” allen wrench to reinstall the 2 mounting screws. 2. Reconnect the chamber thermal snap switch wires by pushing onto the spade connectors. 3.

  • Page 368: Xy Table Cable Drive Components

    XY Table Cable Drive Components X EOT (End of Travel) Limit Switch Required Tools • Small standard screwdriver Removing the X EOT Switch: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position. 2.

  • Page 369: Installing The X Eot Switch

    Figure 271: X EOT switch detail X EOT connector X EOT switch X EOT switch mounting screw 8. Remove the X EOT switch and discard. Installing the X EOT Switch: 1. Align the X EOT switch with the mounting hole. 2.

  • Page 370: Bot (Home) Sensor

    X BOT (Home) Sensor Required Tools • ⁄ ” allen wrench • Cutters • Wire ties Removing the X BOT Sensor: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position. 2.
  • Page 371 Figure 274: Wire tie location X BOT sensor Wire tie 7. Disconnect the X BOT cable by pressing the tab in and pulling the connectors apart. See Figure 275. Figure 275: X BOT connector location X BOT connector 8. Using a ⁄...

  • Page 372: Installing The X Bot Sensor

    Installing the X BOT Sensor: 1. ALign the X BOT sensor with the mounting hole and use a ⁄ ” allen wrench to reinstall the mounting screw. 2. Reconnect the X BOT sensor cable by pushing the connectors together. 3. Reinstall a wire tie around the X BOT sensor cable and X motor cable connector. 4.

  • Page 373: Y Eot (End Of Travel) Limit Switch

    Y EOT (End of Travel) Limit Switch Required Tools • Allen wrench set • Standard screwdriver • Phillips screwdriver Removing the Y EOT Switch: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position. 2.
  • Page 374 Figure 277: Y EOT switch connector locations COM connector NC connector 7. Using a standard screwdriver, remove the 2 mounting screws from the Y EOT switch. See Figure 278: Y EOT switch mounting screw locations 2 mounting screws 8. Remove the Y EOT switch and discard. 5-237...

  • Page 375: Installing The Y Eot Switch

    Installing the Y EOT Switch: 1. Align the Y EOT switch with the mounting holes and use a standard screwdriver to reinstall the 2 mounting screws. See Figure 279. 2. Reconnect the NC (yellow) wire and COM (green) wire to the Y EOT switch by pushing the connector onto the spade.

  • Page 376: Y Bot (Beginning Of Travel) Sensor

    Y BOT (Beginning of Travel) Sensor Required Tools • Standard screwdriver • Wire ties • Cutters Removing the Y BOT Sensor: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position. 2.
  • Page 377 Figure 281: Wire tie and Y BOT connector locations 3 wire ties Y BOT sensor connector and wire tie 9. Using a standard screwdriver, remove the 3 Y BOT sensor mounting screws. See Figure 282. Figure 282: Y BOT mounting screw locations 2 mounting screws 10.

  • Page 378: Installing The Y Bot Sensor

    Installing the Y BOT Sensor: 1. Align the Y BOT sensor with the mounting holes and use a standard screwdriver to reinstall the 2 mounting screws. 2. Reconnect the Y BOT sensor cable by pushing the connectors together. 3. Reinstall the 3 wire ties around the Y BOT sensor cable. 4.

  • Page 379: Xy Table Assembly (Cable Drive)

    XY Table Assembly (Cable Drive) Required Tools • Standard screwdriver • ⁄ ” allen wrench • ⁄ ” nut driver • ⁄ ” nut driver • Cutters • Wire ties Removing the XY Table Assembly: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position.
  • Page 380 Figure 284: X EOT switch detail X EOT connector X EOT wire tie 8. Locate the X BOT sensor. See Figure 285. Figure 285: X BOT location X BOT sensor 9. Cut and remove the wire tie holding the X motor connector to the head. See Figure 286.
  • Page 381 Figure 286: Wire tie location X motor connector Wire tie 11. Disconnect the X BOT cable by pressing the tab in and pulling the connectors apart. See Figure 287. Figure 287: X BOT connector location X BOT connector 12. Locate the Y EOT limit switch. See Figure 288.
  • Page 382 Figure 288: Y EOT switch location Y EOT switch 13. Disconnect the NC (yellow) and COM (green) spade connectors from the switch by pulling outwards. See Figure 289. Note the location of the NC (yellow) and COM (green) wires for easy reinstallation.
  • Page 383 Figure 290: Y BOT location Y BOT sensor Y BOT sensor connector 15. Using a cutters, cut and remove the wire tie from the Y BOT connector. See Figure 291. 16. Disconnect the Y BOT sensor connector by pressing the tab in and pulling outwards. See Figure 291.
  • Page 384 Figure 292: Y motor cable location Y motor connector and wire tie 18. Locate the chamber thermal snap switch and disconnect by pulling the spade connectors apart. See Figure 293. Figure 293: Chamber thermal snap switch location 2 spade connectors 19.
  • Page 385 Figure 294: Wire location Pull cables through hole 20. Using a ⁄ ” nut driver or standard screwdriver, remove the 4 TC Amp board mounting screws and let TC Amp board hang to the side. See Figure 295. Figure 295: TC Amp board mounting screw locations 21.
  • Page 386 Figure 296: Head mounting screw locations 2 left side mounting screws 2 right side mounting screws 22. Gently lower the head. 23. Using a ⁄ ” nut driver or standard screwdriver, remove the 4 XY table mounting screws and shims. See Figure 297.

  • Page 387: Installing The Xy Table Assembly

    Installing the XY Table Assembly: 1. Lift and align the XY table with the mounting posts. 2. Reinstall the shims for each corner of the XY table. 3. Using a ⁄ ” nut driver or standard screwdriver, reinstall the 4 XY table mounting screws. 4.
  • Page 388 15. Using a ⁄ ” allen wrench, remove the 2 head cooling fan mounting screws. Set the fan off to the side. See Figure 299. Figure 299: Head fan mounting screw locations 2 mounting screws 16. Using a ⁄ ” allen wrench, remove the dial indicator mounting screw from the head bracket. Figure 300.
  • Page 389 Figure 301: Dial indicator installation 18. Using a light colored marker, mark the Z platen in the rear left, rear right, front left and front right corners. See Figure 302. Figure 302: Z platen mark locations 5-252...
  • Page 390 19. Align the head bracket and dial indicator with the head fan mounting holes and use a ⁄ ” allen wrench to install the 2 mounting screws. Position the head fan behind the head bracket. See Figure 303. Figure 303: Head bracket and dial indicator installation 20.
  • Page 391 Figure 304: Zero the dial indicator Set screw 24. Move indicator to the remaining 3 corners and record the height at each. The LOWER the XY table is, the GREATER the indicator reading will 25. Each 0.010 shim will cause the head to raise approximately 0.004” at each corner. As an example: If a corner of the XY is low 0.012 (indicator reads +0.012) it will take three shims to raise it to the correct height.
  • Page 392 Figure 305: Shim calculation One shim: Indicator reads +0.006 One shim: Indicator reads +0.004 Three shims: Highest corner: 0 Indicator reads +0.012 27. Once the number of shims has been determined, loosen all four of the XY table mounting screws using a ⁄...
  • Page 393 “Part Based Calibration” on page 6-12. 52. Run a small test part and monitor system operation during build. 53. Follow the XY Table checklist. See “XY Table Installation Checklist” on page Appendix-19. 54. Send bad cable XY table back to Stratasys, Inc. 5-256...

  • Page 394: Xy Table Belt Drive Components

    XY Table Belt Drive Components X BOT (Home) Sensor (Belt Drive) Required Tools • ⁄ ” allen wrench • Cutters Removing the X BOT Sensor: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position.
  • Page 395 6. Using a cutters, cut and remove the wire tie securing the X BOT sensor wire. See Figure 308. 7. Disconnect the X BOT sensor by pressing the tab in and pulling apart. See Figure 308. Figure 308: X BOT sensor connector location X BOT sensor Wire tie X BOT sensor...

  • Page 396: Installing The X Bot Sensor

    Installing the X BOT Sensor: 1. Align the X BOT sensor with the mounting holes. 2. Using a ⁄ ” allen wrench, reinstall the 2 mounting screws. 3. Reconnect the X BOT sensor wire by pushing into the connector. 4. Reinstall a wire tie around the X BOT Sensor wire. 5.

  • Page 397: Eot (End Of Travel) Sensor (Belt Drive)

    X EOT (End of Travel) Sensor (Belt Drive) Required Tools • ⁄ ” allen wrench • Phillips screwdriver • Cutters Removing the X EOT Sensor: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position.
  • Page 398 Figure 311: X EOT sensor connector location X motor connector Wire tie X EOT sensor connector 9. Using a ⁄ ” allen wrench, remove the 2 X EOT sensor mounting bracket mounting screws. Figure 312. Figure 312: X EOT sensor mounting bracket mounting screw locations 2 mounting screws 5-261...

  • Page 399: Installing The X Eot Sensor

    10. Using a phillips screwdriver, remove the X EOT sensor mounting screw. See Figure 313. Figure 313: X EOT sensor mounting screw location Mounting screw 11. Remove the X EOT sensor and discard. Installing the X EOT Sensor: 1. Align the X EOT sensor with the mounting bracket and use a phillips screwdriver to reinstall the mounting screw.

  • Page 400: Motor (Belt Drive)

    X Motor (Belt Drive) Required Tools • ⁄ ” allen wrench • Belt tension tool Removing the X Motor: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position. 2.
  • Page 401 Figure 315: X motor connector location X motor connector 7. Using a ⁄ ” allen wrench, remove the 3 X motor mounting screws. See Figure 316. Figure 316: X motor mounting screw locations 3 mounting screws 8. Slide the motor to the left and remove the X motor belt from the X motor pulley and remove the X motor.

  • Page 402: Installing The X Motor

    Installing the X Motor: 1. Align the X motor with the mounting holes and use a ⁄ ” allen wrench to loosely reinstall the 3 X motor mounting screws. Make sure the X motor cable is on the right side of the X motor when reinstalling.

  • Page 403: Motor Belt (Belt Drive)

    X Motor Belt (Belt Drive) Required Tools • ⁄ ” allen wrench • ⁄ ” allen wrench • ⁄ ” nut driver or box wrench • Small standard screwdriver • XY motor belt tensioning tool • Belt tension gauge • Dial Indicator Removing the X Motor Belt: 1.
  • Page 404 6. Loosen, but do not remove, the 3 X motor mounting screws using a ⁄ ” allen wrench. See Figure 319. Figure 319: X motor mounting screw locations 3 mounting screws 7. Loosen the X motor belt by sliding the X motor to the right and remove the X motor belt from the X motor pulley.
  • Page 405 8. Using a ⁄ ” nut driver or box wrench, loosen the X drive belt by turning the X drive belt tensioning nut counter clockwise. See Figure 321. The X drive belt will need to be very loose to allow removal of the X motor belt.
  • Page 406 10. Push shaft out of the pulley and set aside. See Figure 323. Figure 323: X drive pulley shaft removal 11. Roll the X drive pulley down to the right, remove the X motor belt and discard. See Figure 324. Figure 324: Removing the X motor belt 5-269...

  • Page 407: Installing The X Motor Belt

    Installing the X Motor Belt: 1. Place the X belt over the X drive pulley. 2. Slide the X drive pulley back into position. 3. Reinstall the X drive pulley shaft and retaining rings. 4. Loop the X motor belt around the X motor pulley. 5.
  • Page 408 Figure 326: Belt tension gauge zero block Old dial indicator New dial indicator 9. Zero the dial indicators by adjusting the dial indicator up or down until the gauge reads: a. The old dial indicator will be at zero when the large hand is on 0 and the small hand is on 2.7, when at zero use a ⁄...
  • Page 409 Figure 327: Setting the dial indicator Set screw New dial indicator Old dial indicator 10. Remove the zero block from the belt tension gauge. 11. Move the head to the far right side of the printer. 12. Place the belt tension gauge on the center of the X drive belt. See Figure 328.
  • Page 410 13. Using a ⁄ ” nut driver or box wrench, tighten the X drive belt by turning the X drive belt tensioning nut clockwise until: a. The old dial indicators large hand is between 20 and 25 mils and the small hand is nearly on 1.6.

  • Page 411: Drive Belt (Belt Drive)

    X Drive Belt (Belt Drive) Required Tools • ⁄ ” allen wrench • ⁄ ” allen wrench • Small standard screwdriver • Belt tensioning tool • Belt tension gauge • Dial Indicator Removing the X Drive Belt: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position.
  • Page 412 7. Loosen, but do not remove the 4 right side X drive belt clamp screws using a ⁄ ” allen wrench. See Figure 331. Figure 331: Right side X drive belt clamp screw locations 4 clamp screws 8. Remove the X drive belt from the right side belt clamp. 9.

  • Page 413: Installing The X Drive Belt

    10. Loosen, but do not remove the 4 left side X drive belt clamp screws using a ⁄ ” allen wrench. See Figure 333. Figure 333: Left side X drive belt clamp screw locations 4 clamp screws 11. From the left side of the printer, pull the X drive belt through the X drive and discard. Installing the X Drive Belt: 1.
  • Page 414 2. Using a ⁄ ” allen wrench, tighten the 4 left side belt clamp screws. 3. Route the X drive belt up though the left indexer. See Figure 335. 4. Wrap the belt around the X drive pulley. See Figure 335. 5.

  • Page 415: Y Bot (Home) Sensor (Belt Drive)

    Y BOT (Home) Sensor (Belt Drive) Required Tools • ⁄ ” allen wrench • Cutters Removing the Y BOT (Home) Sensor: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position. 2.
  • Page 416 Figure 338: Y BOT sensor connector location Wire tie 8. Using a ⁄ ” allen wrench, remove the 2 Y BOT sensor mounting screws. See Figure 339. Figure 339: Y BOT sensor mounting screw locations 2 mounting screws 9. Remove the Y BOT sensor and discard. 5-279...

  • Page 417: Installing The Y Bot (Home) Sensor

    Installing the Y BOT (Home) Sensor: 1. Align the Y BOT sensor with the mounting holes and use a ⁄ ” allen wrench to reinstall the 2 mounting screws. 2. Route the Y BOT sensor wire through the hole in the frame and reconnect by pushing the connectors together.

  • Page 418: Y Eot (End Of Travel) Sensor (Belt Drive)

    Y EOT (End of Travel) Sensor (Belt Drive) Required Tools • Small phillips screwdriver • Cutters Removing the Y EOT Sensor: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position. 2.
  • Page 419 Figure 341: Y EOT sensor connector location Y EOT sensor Wire tie Y EOT sensor connector 8. Using a small phillips screwdriver, remove the Y EOT sensor mounting screw. See Figure 342. Figure 342: Y EOT sensor mounting screw location Mounting screw 9.

  • Page 420: Installing The Y Eot Sensor

    Installing the Y EOT Sensor: 1. Align the Y EOT sensor with the mounting holes and use a small phillips screwdriver to reinstall the mounting screw. Be sure to use the brass mounting screw to avoid interference with the magnetic sensor. 2.

  • Page 421: Y Motor (Belt Drive)

    Y Motor (Belt Drive) Required Tools • ⁄ ” allen wrench • XY motor belt tension tool Removing the Y Motor: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position. 2.
  • Page 422 Figure 344: Y motor cable location Y motor connector Wire clip 8. Using a ⁄ ” allen wrench, remove the 3 Y motor mounting screws. See Figure 345. Figure 345: Y motor mounting screw locations 3 mounting screws 9. Remove the Y motor and discard. 5-285...

  • Page 423: Installing The Y Motor

    Installing the Y Motor: 1. Align the Y motor with the mounting holes. Align the Y motor so the cable is at the top of the motor. 2. Using a ⁄ ” allen wrench, loosely reinstall the 3 mounting screws. 3.

  • Page 424: Y Motor Belt (Belt Drive)

    Y Motor Belt (Belt Drive) Required Tools • ⁄ ” allen wrench • XY motor belt tension tool Removing the Y Motor Belt: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position. 2.

  • Page 425: Installing The Y Motor Belt

    Figure 348: Y motor mounting screw locations 3 mounting screws 7. Raise the Y motor and remove the Y motor belt from the Y motor pulley and the Y drive pulley. Installing the Y Motor Belt: 1. Place the Y motor belt around the Y motor pulley and the Y drive pulley. 2.
  • Page 426 Figure 349: XY belt tension tool location Y drive pulley Y motor pulley 4. Using a ⁄ ” allen wrench, completely tighten the 3 mounting screws. 5. Remove the XY motor belt tension tool. 6. Reconnect the Y motor cable by pushing the connectors together. 7.

  • Page 427: Y Drive Belt (Belt Drive)

    Y Drive Belt (Belt Drive) Required Tools • ⁄ ” nut driver or box wrench • ⁄ ” nut driver or standard screwdriver • ⁄ ” allen wrench • Needle nose pliers • XY motor belt tension tool • Belt tension gauge •...
  • Page 428 Figure 351: Shaft retaining ring location Shaft retaining ring 8. Using a ⁄ ” nut driver or box wrench, remove the right side Y belt tension nut and washer. Figure 352. Figure 352: Right side Y drive belt tension nut location Right side Y drive belt tension nut 5-291...
  • Page 429 9. Pull the clevis from the XY table and push the pulley shaft out of the front right Y pulley. Figure 353. Figure 353: Pulley shaft removal 10. Remove the Y drive belt from the Y pulley. 11. Locate the Y motor. See Figure 354.
  • Page 430 Figure 355: Y motor mounting screw locations 3 mounting screws 13. Raise the Y motor and remove the Y motor belt from the Y motor pulley and the Y drive pulley. 14. Using a ⁄ ” allen wrench, remove the 4 right side Y belt clamp mounting screws and remove the belt clamp.
  • Page 431 15. Using a ⁄ ” nut driver or standard screwdriver, remove the 4 rear frame bracket mounting screws. See Figure 357. Figure 357: Rear frame bracket mounting screw locations 4 mounting screws 16. Using a ⁄ ” allen wrench, remove the 2 right side Y drive rod assembly mounting screws. Figure 358.
  • Page 432 Figure 359: Left side Y drive rod assembly mounting screw locations 18. Lift the Y drive assembly upwards and remove the right side Y drive belt by looping over the large Y rear drive pulley. See Figure 360. Figure 360: Removing the right side Y drive belt 19.

  • Page 433: Installing The Right Side Y Drive Belt

    Installing the Right Side Y Drive Belt: 1. Loop the replacement Y drive belt over the large right side Y drive rod pulley. 2. Align the Y drive rod assembly with the mounting holes and use a ⁄ ” allen wrench to rein- stall the 4 mounting screws.
  • Page 434 11. Using a ⁄ ” allen wrench, completely tighten the 3 mounting screws. 12. Remove the XY motor belt tension tool. 13. Insert the belt tension gauge zero block into the belt tension gauge. See Figure 362. 14. Zero the dial indicators by adjusting the dial indicator up or down until the gauge reads: a.
  • Page 435 15. Remove the zero block from the belt tension gauge. 16. Move the head to the rear of the printer. 17. Place the belt tension gauge on the center of the right side Y drive belt. See Figure 363. Figure 363: Belt tension gauge location Front View Right View 18.
  • Page 436 Figure 364: Dial indicator readings Old dial indicator New dial indicator 19. Remove the tension gauge and move the head from front to back several times. 20. Reattach the tension gauge to the right side Y drive belt and measure belt tension. If tension is out of specification, repeat steps until the belt tension is within specification.

  • Page 437: Removing The Left Side Y Drive Belt

    Removing the Left Side Y Drive Belt: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position. 2. Unplug the AC power cord, RJ-45 network cable and UPS cable (if used) from the rear of the printer.
  • Page 438 Figure 366: Shaft retaining ring location Shaft retaining ring 8. Using a ⁄ ” nut driver or box wrench, remove the left side Y belt tension nut and washer. Figure 367. Figure 367: Left side Y drive belt tension nut location Left side Y drive belt tension nut 9.
  • Page 439 Figure 368: Pulley shaft removal 10. Using a ⁄ ” allen wrench, remove the 4 left side Y belt clamp mounting screws and remove the belt clamp. See Figure 369. Figure 369: Left side Y belt clamp mounting screw locations Right side Y belt clamp 11.
  • Page 440 Figure 370: Rear frame bracket mounting screw locations 4 mounting screws 12. Using a ⁄ ” allen wrench, remove the 2 right side Y drive rod assembly mounting screws. Figure 371. Figure 371: Right side Y drive rod assembly mounting screw locations 13.
  • Page 441 Figure 372: Left side Y drive rod assembly mounting screw locations 14. Lift the Y drive assembly upwards and remove the left side Y drive belt by looping over the rear drive pulley. See Figure 373. Figure 373: Removing the left side Y drive belt 15.

  • Page 442: Installing The Left Side Y Drive Belt

    Installing the Left Side Y Drive Belt: 1. Loop the replacement Y drive belt over the large right side Y drive rod pulley. 2. Align the Y drive rod assembly with the mounting holes and use a ⁄ ” allen wrench to rein- stall the 4 mounting screws.
  • Page 443 Figure 374: Belt tension gauge zero block Set screw Set screw Old dial indicator New dial indicator 11. Remove the zero block from the belt tension gauge. 12. Move the head to the rear of the printer. 13. Place the belt tension gauge on the center of the left side Y drive belt. See Figure 375.
  • Page 444 Figure 375: Belt tension gauge location Front View Left View 14. Using a ⁄ ” nut driver or box wrench, tighten the left side Y drive belt by turning the drive belt tensioning nut clockwise until: a. The old dial indicators large hand is between 90 and 20 mils and the small hand is nearly on 1.6.
  • Page 445 15. Remove the tension gauge and move the head from front to back several times. 16. Reattach the tension gauge to the right side Y drive belt and measure belt tension. If tension is out of specification, repeat steps until the belt tension is within specification. 17.

  • Page 446: Y Pulley (Belt Drive)

    Y Pulley (Belt Drive) Required Tools • ⁄ ” allen wrench • ⁄ ” nut driver or box wrench • Needle nose pliers or standard screwdriver • Belt tension gauge • Dial Indicator Removing the Right Side Y Pulley: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position.
  • Page 447 Figure 378: Shaft retaining ring location Shaft retaining ring 8. Using a ⁄ ” allen wrench, remove the 4 right side Y belt clamp mounting screws and remove the belt clamp. See Figure 379. Figure 379: Right side Y belt clamp mounting screw locations Right side Y belt clamp 9.
  • Page 448 Figure 380: Right side Y drive belt tension nut location Right side Y drive belt tension nut 10. Pull the clevis from the XY table and push the pulley shaft out of the front right Y pulley. Figure 381. Figure 381: Pulley shaft removal 11.

  • Page 449: Installing The Right Side Y Pulley

    Installing the Right Side Y Pulley: 1. Loop the right side Y drive belt around the front right pulley. 2. Align the front right pulley with the clevis. 3. Push the pulley shaft through the clevis and pulley. 4. Using a needle nose pliers or standard screwdriver, reinstall the shaft retaining ring to the pulley shaft.
  • Page 450 Figure 382: Belt tension gauge zero block Set screw Set screw Old dial indicator New dial indicator 8. Remove the zero block from the belt tension gauge. 9. Move the head to the rear of the printer. 10. Place the belt tension gauge on the center of the right side Y drive belt. See Figure 383.
  • Page 451 Figure 383: Belt tension gauge location Front View Right View 11. Using a ⁄ ” nut driver or box wrench, tighten the right side Y drive belt by turning the drive belt tensioning nut clockwise until: a. The old dial indicators large hand is between 90 and 20 mils and the small hand is nearly on 1.6.

  • Page 452: Removing The Left Side Y Pulley

    12. Remove the tension gauge and move the head from front to back several times. 13. Reattach the tension gauge to the right side Y drive belt and measure belt tension. If tension is out of specification, repeat steps until the belt tension is within specification. 14.
  • Page 453 Figure 386: Shaft retaining ring location Shaft retaining ring 8. Using a ⁄ ” allen wrench, remove the 4 left side Y belt clamp mounting screws and remove the belt clamp. See Figure 387. Figure 387: Left side Y belt clamp mounting screw locations Right side Y belt clamp 9.
  • Page 454 Figure 388: Left side Y drive belt tension nut location Left side Y drive belt tension nut 10. Pull the clevis from the XY table and push the pulley shaft out of the front left Y pulley. See Figure 389. Figure 389: Pulley shaft removal 11.

  • Page 455: Installing The Left Side Y Pulley

    Installing the Left Side Y Pulley: 1. Loop the left side Y drive belt around the front left pulley. 2. Align the front left pulley with the clevis. 3. Push the pulley shaft through the clevis and pulley. 4. Using a needle nose pliers or standard screwdriver, reinstall the shaft retaining ring to the pulley shaft.
  • Page 456 Figure 390: Belt tension gauge zero block Set screw Set screw Old dial indicator New dial indicator 8. Remove the zero block from the belt tension gauge. 9. Move the head to the rear of the printer. 10. Place the belt tension gauge on the center of the left side Y drive belt. See Figure 391.
  • Page 457 Figure 391: Belt tension gauge location Front View Left View 11. Using a ⁄ ” nut driver or box wrench, tighten the left side Y drive belt by turning the drive belt tensioning nut clockwise until: a. The old dial indicators large hand is between 90 and 20 mils and the small hand is nearly on 1.6.
  • Page 458 12. Remove the tension gauge and move the head from front to back several times. 13. Reattach the tension gauge to the right side Y drive belt and measure belt tension. If tension is out of specification, repeat steps until the belt tension is within specification. 14.

  • Page 459: Y Drive Assembly (Belt Drive)

    Y Drive Assembly (Belt Drive) Required Tools • ⁄ ” allen wrench • ⁄ ” allen wrench • ⁄ ” nut driver or box wrench • ⁄ ” nut driver or standard screwdriver • XY motor belt tension tool • Belt tension gauge •...
  • Page 460 7. Using a ⁄ ” nut driver or box wrench, remove the left side Y belt tension nut and washer. Figure 394. Figure 394: Left side Y drive belt tension nut location Left side Y drive belt tension nut 8. Locate the Y motor. See Figure 395.
  • Page 461 9. Loosen, but do not remove the 3 Y motor mounting screws using a ⁄ ” allen wrench. See Figure 396. Figure 396: Y motor mounting screw locations 3 mounting screws 10. Raise the Y motor and remove the Y motor belt from the Y motor pulley and the Y drive pulley.
  • Page 462 12. Using a ⁄ ” allen wrench, remove the 4 left side Y belt clamp mounting screws and remove the belt clamp. See Figure 398. Figure 398: Left side Y belt clamp mounting screw locations Right side Y belt clamp 13.
  • Page 463 14. Using a ⁄ ” allen wrench, remove the 2 right side Y drive rod assembly mounting screws. Figure 400. Figure 400: Right side Y drive rod assembly mounting screw locations 15. Using a ⁄ ” allen wrench, remove the 2 left side Y drive rod assembly mounting screws. Figure 401.
  • Page 464 Figure 402: Removing the right side Y drive belt 17. Lift the Y drive assembly upwards and remove the left side Y drive belt by looping over the rear drive pulley. See Figure 403. Figure 403: Removing the left side Y drive belt 18.

  • Page 465: Installing The Y Drive Assembly

    Installing the Y Drive Assembly: 1. Loop the Y drive belt over the large right side Y drive pulley. 2. Loop the Y drive belt over the left side Y drive pulley. 3. Align the Y drive assembly with the mounting holes and use a ⁄...
  • Page 466 Figure 405: Belt tension gauge zero block Set screw Set screw New dial indicator Old dial indicator 11. Remove the zero block from the belt tension gauge. 12. Move the head to the rear of the printer. 13. Place the belt tension gauge on the center of the right side Y drive belt. See Figure 406.
  • Page 467 Figure 406: Belt tension gauge location Front View Right View 14. Using a ⁄ ” nut driver or box wrench, tighten the right side Y drive belt by turning the drive belt tensioning nut clockwise until: a. The old dial indicators large hand is between 90 and 20 mils and the small hand is nearly on 1.6.
  • Page 468 15. Remove the tension gauge and move the head from front to back several times. 16. Reattach the tension gauge to the right side Y drive belt and measure belt tension. If tension is out of specification, repeat steps until the belt tension is within specification. 17.
  • Page 469 19. Remove the zero block from the belt tension gauge. 20. Move the head to the rear of the printer. 21. Place the belt tension gauge on the center of the left side Y drive belt. See Figure 409. Figure 409: Belt tension gauge location Front View Left View 22.
  • Page 470 Figure 410: Dial indicator readings Old dial indicator New dial indicator 23. Remove the tension gauge and move the head from front to back several times. 24. Reattach the tension gauge to the right side Y drive belt and measure belt tension. If tension is out of specification, repeat steps until the belt tension is within specification.

  • Page 471: Xy Table Assembly (Belt Drive)

    XY Table Assembly (Belt Drive) Required Tools • ⁄ ” allen wrench • ⁄ ” allen wrench • ⁄ ” allen wrench • ⁄ ” nut driver or standard screwdriver • ⁄ ” nut driver • Cam wrench or large crescent wrench •...
  • Page 472 7. Disconnect the Y EOT sensor by pressing the tab in and pulling outwards. See Figure 412. Figure 412: Y EOT sensor location Y EOT connector 8. Using a cutters, cut the wire tie from the Y BOT sensor cable and Y BOT sensor connector. Figure 413.
  • Page 473 10. Disconnect the Y motor cable by pressing the tab in and pulling outwards. See Figure 414. 11. Un-clip the Y motor cable wire tie and remove the Y motor cable. See Figure 414. Figure 414: Y motor connector location Y motor connector Wire clip...
  • Page 474 Figure 416: X motor connector location X motor connector and wire tie 16. Disconnect the X EOT sensor by pressing the tab in and pulling outwards. See Figure 417. Figure 417: X EOT connector location X EOT connector 17. Locate the head ground wire and use a ⁄...
  • Page 475 Figure 418: Head ground wire location Front head ground wire mounting screw 18. At the TC Amp board, disconnect the model (upper) and support (lower) thermocouples by pulling outwards. See Figure 419. Note the location of the model and support thermocouples for reinstallation 19.
  • Page 476 21. Using a ⁄ ” nut driver or standard screwdriver, remove the 4 mounting screws. See Figure 420. Note the location of the ground wire. Figure 420: Mounting screw locations Ground wire 4 mounting screws 22. Using a phillips screwdriver, loosen the 2 self retaining screws from the left side of the head and open the head by pulling outward.
  • Page 477 23. Disconnect the model motor connector by pressing the tab in and pulling outwards. See Figure 422. 24. Disconnect the support motor connector by pressing the tab in and pulling outwards. See Figure 422. 25. Pull the support motor wire clip from the translator. See Figure 422.
  • Page 478 Figure 423: Translator access slot location Pull model and support thermocouples through slot 29. Remove the model and support liquefier and motor connectors from the translator by pressing the tabs in and pushing outwards. See Figure 424. Figure 424: Umbilical connector detail Support liquefier Model liquefier connector...
  • Page 479 Figure 425: Head hinge pin set screw location Hinge pin set screw 31. Remove the head hinge pin by lifting upwards. See Figure 426. Figure 426: Removing the head hinge pin 32. Remove the head from the printer. 33. Using a ⁄...
  • Page 480 Figure 427: Umbilical hose mounting screw locations Mounting screw on opposite side of 3 mounting screws umbilical hose 34. Pull the umbilical hose away from the translator. 35. Disconnect the material tubes by pushing the lock ring in and pulling the tubes outwards. Figure 428.
  • Page 481 Figure 429: Left side XY table mounting screw locations 37. Using a ⁄ ” allen wrench, remove the 2 left side XY Table cams. See Figure 430. Figure 430: Left side XY table mounting screw locations 38. Using a ⁄ ”...
  • Page 482 Figure 431: Right side XY table mounting screw locations 39. Using a ⁄ ” allen wrench, remove the right side XY Table cam. See Figure 432. Figure 432: Right side XY table cam screw location 40. Using a ⁄ ” allen wrench, remove the right side XY Table fixed mounting screw. See Figure 433.
  • Page 483 Figure 433: Right side XY table fixed screw location 41. Lift the XY table out of the printer. It will be easier to remove the XY table from the printer with 2 people. 5-346...

  • Page 484: Installing The Xy Table Assembly

    Installing the XY Table Assembly: 1. Lift the XY table and position in the printer. 2. Level the XY table with the frame of the printer by eye. 3. Using a ⁄ ” allen wrench, reinstall the right side XY table fixed screw. 4.
  • Page 485 23. Using a ⁄ ” nut driver or standard screwdriver, reinstall the ground wire to the front right side of the head. 24. Reconnect the J301, J303, model thermocouple and support thermocouple wires at the TC Amp board by pushing into place. The model thermocouple will be connected to the upper connector and the support thermocouple will be connected to the lower connector.
  • Page 486 Figure 435: Head bracket mounting screws Dial indicator mounting screw 39. Align the dial indicator with the head bracket and use a ⁄ ” allen wrench to install the mounting screw. See Figure 436. Figure 436: Dial indicator installation 40. Using a marker, mark the Z platen in the rear left corner, rear right corner, front left corner and front right corner.
  • Page 487 Figure 437: Z platen marking locations Rear left (RL) Rear right (RR) Front right (FR) Front left (FL) 41. Manually raise the Z stage, by turning the lead screw with a gloved hand, until the Z platen contacts the dial indicator and moves the gauge approximately 2 full rotations. 42.
  • Page 488 43. Move the dial indicator to the mark on the front right corner of the Z platen and record the value. 44. Move the dial indicator to the mark on the front left corner of the Z platen and record the value.
  • Page 489 72. Perform tip offset calibrations. See “Tip Offset Calibration” on page 6-8. 73. Perform part based calibrations. See “Part Based Calibration” on page 6-12. 74. Build a test part to verify proper operation of the printer. 75. Return the bad XY Table to Stratasys, Inc. 5-352...

  • Page 490: Z Stage Components

    Z Stage Components Thermostat Snap Switch Required Tools • ⁄ ” nut driver or standard screwdriver • ⁄ ” allen wrench Removing the Thermostat Snap Switch: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position.
  • Page 491 6. Using a ⁄ ” nut driver or standard screwdriver, remove the 4 right side chamber heater cover mounting screws. See Figure 442. Figure 442: Right side heater cover mounting screw locations 4 right side chamber fan cover mounting screws 7.
  • Page 492 Figure 443: Thermostat snap switch detail Wire clip mounting screw 9. Using a ⁄ ” allen wrench, remove the 2 mounting screws. See Figure 444. Figure 444: Thermostat snap switch mounting screw locations 2 Mounting screws 10. Discard the thermostat snap switch. 5-355...

  • Page 493: Installing The Thermostat Snap Switch

    Installing the Thermostat Snap Switch: 1. Align the thermostat snap switch with the mounting holes and use a ⁄ ” allen wrench to reinstall the 2 mounting screws. 2. Reconnect TH1 and TH2 by pushing onto the spade connectors. 3. Place wires in wire clip and use a ⁄...

  • Page 494: Tip Wipe Assembly

    Tip Wipe Assembly Required Tools • ⁄ ” allen wrench • Gloves Replacing the Flicker Blade: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position. 2. Unplug the AC power cord, RJ-45 network cable and UPS cable (if used) from the rear of the printer.

  • Page 495: Replacing The Brush

    Replacing the Brush: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position. 2. Unplug the AC power cord, RJ-45 network cable and UPS cable (if used) from the rear of the printer.

  • Page 496: Z Stage Components - 3 Lead Screw

    Z Stage Components - 3 Lead Screw The following Z Stage components are for the three LS (lead screw) system. Chamber Thermocouple (3 Lead Screw) Required Tools • ⁄ ” nut driver or standard screwdriver Removing the Chamber Thermocouple: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position.
  • Page 497 6. Locate the chamber thermocouple. See Figure 448. 7. Using a ⁄ ” nut driver or standard screwdriver, remove the 2 chamber thermocouple mounting screws. See Figure 448. Figure 448: Chamber thermocouple location 2 mounting screws 8. Working from the left side of the machine carefully pull the foam insulation slightly away from the back of the chamber thermocouple.

  • Page 498: Installing The Chamber Thermocouple

    9. Remove the chamber thermocouple by grasping the back of the thermocouple housing then pulling back and downward until free. 10. Feed the chamber thermocouple wire out the cutout on the back of the electronics bay. 11. Discard the chamber thermocouple. Installing the Chamber Thermocouple: 1.

  • Page 499: Chamber Heaters (3 Lead Screw)

    Chamber Heaters (3 Lead Screw) Required Tools • ⁄ ” nut driver or standard screwdriver • ⁄ ” box wrench Removing the left side Chamber Heaters: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position.
  • Page 500 6. Disconnect the 2 left side chamber fans by pressing the tab in and pulling apart. See Figure 451. Figure 451: Left side chamber fan connector locations Chamber fan connectors 7. Using a ⁄ ” nut driver or standard screwdriver, remove the 8 chamber heater cover mounting screws.
  • Page 501 8. Open the chamber heater cover away from the front of the printer. See Figure 453. Do not stress the heater wires running into the housing. Figure 453: Opening the chamber heater cover 9. Using a ⁄ ” box wrench, remove the chamber heater wire nuts and washers from both left side chamber heaters.

  • Page 502: Installing The Left Side Chamber Heaters

    10. Using a ⁄ ” nut driver or standard screwdriver, remove the 2 heater mounting screws from both left side chamber heaters. See Figure 455. Figure 455: Left side chamber heater mounting screw locations Chamber heater mounting screws 11. Remove the chamber heaters and discard. Installing the left side Chamber Heaters: 1.

  • Page 503: Removing The Right Side Chamber Heaters

    Removing the right side Chamber Heaters: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position. 2. Unplug the AC power cord, RJ-45 network cable and UPS cable (if used) from the rear of the printer.
  • Page 504 Figure 457: Right side chamber fan connector locations Chamber fan connectors 7. Using a ⁄ ” nut driver or standard screwdriver, remove the 8 chamber heater cover mounting screws. See Figure 458. Figure 458: Chamber heater cover mounting screw locations 8.
  • Page 505 Figure 459: Opening the chamber heater cover 9. Using a ⁄ ” box wrench, remove the chamber heater wire nuts and washers from both right side chamber heaters. See Figure 454. Note the orientation of the heater wires. Black on the left post and white on the right post.

  • Page 506: Installing The Right Side Chamber Heaters

    Figure 461: Right side chamber heater mounting screw locations Chamber heater mounting screws 11. Remove the chamber heaters and discard. Installing the right side Chamber Heaters: 1. Align the right side chamber heaters with the mounting holes and use a ⁄...

  • Page 507: Z Switches (3 Lead Screw)

    Z Switches (3 Lead Screw) Required Tools • ⁄ ” allen wrench • ⁄ ” nut driver or standard screwdriver • Marker Removing the Z BOT (Home) Switch: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position.
  • Page 508 6. Disconnect the 2 right side chamber fans by pressing the tab in and pulling apart. See Fig- ure 463. Figure 463: Right side chamber fan connector locations Chamber fan connectors 7. Using a ⁄ ” nut driver or standard screwdriver, remove the 8 chamber heater cover mounting screws.
  • Page 509 8. Open the chamber heater cover away from the front of the printer. See Figure 459. Do not stress the heater wires running into the housing. Figure 465: Opening the chamber heater cover 9. Locate the Z BOT switch at the upper left corner. See Figure 466.
  • Page 510 10. Mark the location of the Z BOT switch mounting bracket for easy reinstallation. See Figure 467. 11. Using a ⁄ ” nut driver or standard screwdriver, remove the 2 Z BOT switch mounting bracket mounting screws. See Figure 467. Figure 467: Marking the Z BOT switch 2 mounting screws Mark mounting...

  • Page 511: Installing The Z Bot (Home) Switch

    15. Using a ⁄ ” allen wrench, remove the 2 Z BOT switch mounting screws from the Z BOT mounting bracket. See Figure 469. Note the orientation of the Z BOT switch on the mounting bracket. Figure 469: Z BOT mounting screw locations 2 mounting screws 16.
  • Page 512 4. Insert the Z BOT switch into the chamber by tilting and pushing inwards. 5. Align the Z BOT switch mounting bracket with the mark from step 10 on page 373 6. Using a ⁄ ” nut driver or standard screwdriver, reinstall the 2 mounting screws. 7.

  • Page 513: Removing The Z Eot Switch

    Removing the Z EOT Switch: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position. 2. Unplug the AC power cord, RJ-45 network cable and UPS cable (if used) from the rear of the printer.
  • Page 514 Figure 472: Right side chamber fan connector locations Chamber fan connectors 7. Using a ⁄ ” nut driver or standard screwdriver, remove the 8 chamber heater cover mounting screws. See Figure 473. Figure 473: Chamber heater cover mounting screw locations 8.
  • Page 515 Figure 474: Opening the chamber heater cover 9. Locate the Z EOT switch at the lower left corner. See Figure 475. Figure 475: Z BOT location 10. Mark the location of the Z EOT switch mounting bracket for easy reinstallation. See Figure 476.
  • Page 516 11. Using a ⁄ ” nut driver or standard screwdriver, remove the 2 Z BOT switch mounting bracket mounting screws. See Figure 476. Figure 476: Marking the Z EOT switch 2 mounting screws Mark mounting bracket location 12. Remove the Z EOT switch from the chamber by tilting and pulling outwards. 13.

  • Page 517: Installing The Z Eot Switch

    15. Using a ⁄ ” allen wrench, remove the 2 Z BOT switch mounting screws from the Z BOT mounting bracket. See Figure 478. Note the orientation of the Z BOT switch on the mounting bracket. Figure 478: Z BOT mounting screw locations 2 mounting screws 16.
  • Page 518 4. Insert the Z EOT switch into the chamber by tilting and pushing inwards. 5. Align the Z EOT switch mounting bracket with the mark from step 10 on page 378 6. Using a ⁄ ” nut driver or standard screwdriver, reinstall the 2 mounting screws. 7.

  • Page 519: Z Jam Sensor (3 Lead Screw)

    Z Jam Sensor (3 Lead Screw) Required Tools • ⁄ ” allen wrench • ⁄ ” nut driver or standard screwdriver • Marker Removing the Z Jam Sensor: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position.
  • Page 520 8. Using a ⁄ ” nut driver or standard screwdriver, remove the 6 Z stage base plate mounting screws. See Figure 481. Figure 481: Z stage base plate mounting screw locations 9. Lower the Z stage base plate and remove the Z jam sensor cable and Z motor cable through the slots.
  • Page 521 11. Using a ⁄ ” allen wrench, remove the 2 Z jam sensor L bracket mounting screws. See Fig- ure 483. Figure 483: Z jam sensor L bracket mounting screw locations 2 mounting screws 12. Using a ⁄ ” allen wrench, remove the Z jam sensor mounting screw from the L bracket. Figure 484.

  • Page 522: Installing The Z Jam Sensor

    Installing the Z Jam Sensor: 1. Align the Z jam sensor with the L bracket and use a 2. Align the Z jam sensor L bracket with the mounting holes and use a . Be sure the Z jamming flag is in the center of the sensor. See Figure 485.

  • Page 523: Z Motor Belt (3 Ls)

    Z Motor Belt (3 LS) Required Tools • ⁄ ” allen wrench • ⁄ ” allen wrench • ⁄ ” nut driver or standard screwdriver • Dial indicator • Head bracket • Marker Removing the Z Motor Belt: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position.
  • Page 524 8. Using a ⁄ ” nut driver or standard screwdriver, remove the 6 Z stage base plate mounting screws. See Figure 487. Figure 487: Z stage base plate mounting screw locations 9. Lower the Z stage base plate and remove the Z jam sensor cable and Z motor cable through the slots.
  • Page 525 11. Locate the Z motor belt tension idler pulley. See Figure 489. Figure 489: Z motor belt tension idler pulley location Z idler pulley 12. Using a ⁄ ” nut driver or standard screwdriver, loosen, but do not remove, the 2 Z idler pulley screws.

  • Page 526: Installing The Z Motor Belt

    Installing the Z Motor Belt: 1. Place the belt around the Z pulleys. See Figure 491. Figure 491: Z motor belt installation 2. Using a standard screwdriver, push back on the idler pulley to tension the Z motor belt. 3. With the Z motor belt tight, use a ⁄...
  • Page 527 c. Using a ⁄ ” allen wrench, remove the dial indicator mounting screw from the head bracket. See Figure 493. Figure 493: Head bracket mounting screws Dial indicator mounting screw d. Align the dial indicator with the head bracket and use a ⁄...
  • Page 528 e. Using a light colored marker, mark the Z platen in the rear center and left and right front corners. See Figure 495. Figure 495: Z platen mark locations Align the head bracket and dial indicator with the head fan mounting holes and use a ⁄...
  • Page 529 g. Raise the Z stage until it is 2 inches from the upper limit by turning the lead screws. h. Move the dial indicator to the rear center mark and zero the dial indicator by loosening the set screw and turning the dial until the long hand is at 0. Once the dial indicator is at zero, tighten the set screw.
  • Page 530 o. Move the dial indicator to the front right corner and verify the reading is still at 0. If not repeat steps until the reading is 0. p. Move the dial indicator to the front left corner and read the dial indicator. If the reading is less than .003”...

  • Page 531: Z Stage Motor (3 Lead Screw)

    Z Stage Motor (3 Lead Screw) Required Tools • ⁄ ” allen wrench • ⁄ ” allen wrench • ⁄ ” allen wrench • ⁄ ” nut driver or standard screwdriver • Dial indicator • Head bracket • Marker Removing the Z Motor: 1.
  • Page 532 Figure 498: Z jam sensor connector location Z motor connector Z jam sensor connector 8. Using a ⁄ ” nut driver or standard screwdriver, remove the 6 Z stage base plate mounting screws. See Figure 499. Figure 499: Z stage base plate mounting screw locations 9.
  • Page 533 10. Slide the Z stage base plate out of the printer. See Figure 500. Figure 500: Z stage base plate removal Guide cables out of Z base plate through slots 11. Locate the Z motor belt tension idler pulley. See Figure 501.
  • Page 534 Figure 502: Z motor belt tension idler pulley screw locations Z Idler screws 13. Slide the Z motor belt tension idler pulley until there is no tension on the Z motor belt. 14. Using a ⁄ ” allen wrench, remove the 4 Z motor mounting screws. See Figure 503.

  • Page 535: Installing The Z Motor

    Installing the Z Motor: 1. Align the Z motor with the mounting holes and use a ⁄ ” allen wrench to reinstall the 4 mounting screws. Make sure the Z motor cable is to the right when aligning the Z motor with the mounts.
  • Page 536 Figure 505: Head fan mounting screw locations 2 mounting screws c. Using a ⁄ ” allen wrench, remove the dial indicator mounting screw from the head bracket. See Figure 506. Figure 506: Head bracket mounting screws Dial indicator mounting screw d.
  • Page 537 Figure 507: Dial indicator installation e. Using a light colored marker, mark the Z platen in the rear center and left and right front corners. See Figure 508. Figure 508: Z platen mark locations 5-400...
  • Page 538 Align the head bracket and dial indicator with the head fan mounting holes and use a ⁄ ” allen wrench to install the 2 mounting screws. Position the head fan behind the head bracket. See Figure 509. Figure 509: Head bracket and dial indicator installation g.
  • Page 539 Figure 510: Zero the dial indicator Set screw Move the dial indicator to the front right corner and read the dial indicator. If the reading is less than .003” proceed to step . If the reading is greater than .003” loosen the Z motor belt tension idler pulley mounting screws using a ⁄...
  • Page 540 belt tension idler pulley mounting screws using a ⁄ ” nut driver or standard screwdriver. q. Hold the Z motor belt tightly against the front right and rear center pulleys not allowing the belt to move from the pulley. It may be easier to accomplish holding the Z belt in place with another person.

  • Page 541: Z Stage Bearings (3 Lead Screw)

    Z Stage Bearings (3 Lead Screw) Required Tools • ⁄ ” allen wrench • ⁄ ” nut driver • ⁄ ” nut driver • Bearing replacement kit: • Snap ring tool • Hinged collars (4) • Z casting leveling blocks •...
  • Page 542 9. Manually move the Z stage down until it rests on the leveling blocks by turning the lead screw. 10. Remove the front bezel. See “Removing the Front Bezel:” on page 5-13. 11. Remove the receiver assembly. See “Removing the Galvanized Receiver Assembly:” on page 5-470.
  • Page 543 Figure 513: Z stage base plate mounting screw locations 15. Lower the Z stage base plate and remove the Z jam sensor cable and Z motor cable through the slots. See Figure 514. 16. Slide the Z stage base plate out of the printer. See Figure 514.
  • Page 544 Figure 515: Z motor belt tension idler pulley location Z idler pulley 18. Using a ⁄ ” nut driver or standard screwdriver, loosen, but do not remove, the 2 Z idler pulley screws. See Figure 516. Figure 516: Z motor belt tension idler pulley screw locations Z Idler screws 19.
  • Page 545 22. Using a ⁄ ” allen wrench, loosen the 2 set screws from each lead screw pulley (6 total). See Figure 517. Figure 517: Lead screw pulley set screw locations 2 set screws 23. Remove the pulleys, spacers and Z jamming flag (front right lead screw only) by pulling down.
  • Page 546 24. Using a ⁄ ” nut driver or standard screwdriver, remove the 2 mounting screws from the 3 lead screw bearing caps (6 mounting screws total). See Figure 519. Figure 519: Lead screw bearing cap locations 25. Remove the bearing caps and springs from the 3 lead screws by lifting upwards. See Figure 520.
  • Page 547 26. Remove the lead screws from the printer by turning counter clockwise. See Figure 521. Figure 521: Removing the lead screws Lead screws 27. Using a ⁄ ” nut driver or standard screwdriver, remove the 3 guide rod mounting screws from the bottom of the printer.
  • Page 548 Figure 523: Removing the guide rods Slide guide rod upwards Do NOT loosen these screws 29. Remove the Z stage casting from the machine. Place the Z stage casting face down with the lead nuts facing up. See Figure 524. 30.
  • Page 549 Figure 525: Bearing retaining clip 32. Using a ⁄ ” nut driver or standard screwdriver, remove the 2 lower bearing mounting screws from the 3 lower bearings and lift upwards to remove. See Figure 526. Figure 526: Lower lead screw bearing location 2 mounting screws 33.

  • Page 550: Installing The Z Stage Bearings

    Installing the Z Stage Bearings: 1. Align the lead nuts and bearing with the Z stage casting and use a ⁄ ” allen wrench to reinstall the mounting screws. 2. Reinstall the lower bearings. Do not tighten screws. 3. Place the Z casting on the leveling blocks inside machine. 4.
  • Page 551 Figure 529: Top bearing Mounting screws Top of lead screw 9. Use a ⁄ ” nut driver or standard screwdriver to tighten the lower bearing while pushing the bearing assembly out towards the exterior wall. See Figure 530. Figure 530: Bottom bearings 10.
  • Page 552 Figure 531: Left and rear pulleys Left side pulley Rear pulley 11. Reinstall the right pulley with the Z jamming flag and spacer, applying two drops of Loctite between the pulley and the flag. See Figure 532. Figure 532: Third pulley and flag sensor Z jamming flag Apply 2 small drops Pulley...
  • Page 553 Figure 533: Z motor belt installation 14. Using a standard screwdriver, push back on the idler pulley to tension the Z motor belt. 15. With the Z motor belt tight, use a ⁄ ” nut driver or standard screwdriver to tighten the 2 idler pulley screws.
  • Page 554 Figure 535: Head bracket mounting screws Dial indicator mounting screw d. Align the dial indicator with the head bracket and use a ⁄ ” allen wrench to install the mounting screw. See Figure 536. Figure 536: Dial indicator installation e. Using a light colored marker, mark the Z platen in the rear center and left and right front corners.
  • Page 555 Figure 537: Z platen mark locations Align the head bracket and dial indicator with the head fan mounting holes and use a ⁄ ” allen wrench to install the 2 mounting screws. Position the head fan behind the head bracket. See Figure 538.
  • Page 556 17. Attach the 2 hinged collars to the rear lead screw. Press the collars firmly toward the platen while tightening the set-screws. See Figure 539. Figure 539: Upper and lower hinged collar locations Upper Collar Lower Collar h. Move the dial indicator to the rear center mark and zero the dial indicator by loosening the set screw and turning the dial until the long hand is at 0.
  • Page 557 Move the dial indicator to the front right corner and read the dial indicator. If the reading is less than .003” proceed to step . If the reading is greater than .003” loosen the Z motor belt tension idler pulley mounting screws using a ⁄...

  • Page 558: Z Foam Retainers

    Z Foam Retainers Required Tools • ⁄ ” allen wrench Removing the Z Foam Retainers: 1. Remove the foam substrate. 2. Using a ⁄ ” allen wrench, remove the 4 foam retainer mounting screws from the left side retainer. See Figure 541.
  • Page 559 Foam retainer Figure 542: Foam Retainer 5-422...

  • Page 560: Z Stage Components (1 Lead Screw)

    Z Stage Components (1 Lead Screw) Chamber Thermocouple (1 Lead Screw) Required Tools • Standard screwdriver • Needle nose pliers Removing the Chamber Thermocouple: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position. 2.
  • Page 561 6. Using a standard screwdriver or needle nose pliers, pull the chamber thermocouple retainer out from the chamber. See Figure 544. Figure 544: Removing the chamber thermocouple 7. Disconnect the chamber thermocouple by pulling outwards. a. For Gen 2 and Gen 3 electronics, disconnect the chamber thermocouple from the power distribution board.

  • Page 562: Installing The Chamber Thermocouple

    b. For Gen 1 electronics, disconnect the chamber thermocouple from the 186 processor board. See Figure 546. Figure 546: Gen 1 chamber thermocouple connector location Gen 1 chamber thermocouple connection 8. Discard the chamber thermocouple. Installing the Chamber Thermocouple: 1. Reconnect the chamber thermocouple by pushing into the connector. Be sure the + terminal of the chamber thermocouple is at the top when reconnecting.

  • Page 563: Chamber Fans (1 Lead Screw)

    Chamber Fans (1 Lead Screw) There are 4 chamber fans in the heater area, 2 on each side. In most cases all 4 chamber fans will be replaced at the same time. Required Tools • ⁄ ” nut driver or standard screwdriver •...
  • Page 564 6. Disconnect the 2 left side fan cables by pressing the tab in and pulling outwards. See Figure 548. 7. Using a ⁄ ” nut driver or standard screwdriver, remove the 4 left side chamber heater cover mounting screws. See Figure 548.

  • Page 565: Installing The Left Side Chamber Fans

    Figure 549: Left side chamber fan mounting screw locations 2 chamber fan 2 chamber fan mounting screws mounting screws 9. Remove the 2 left side chamber fans from the envelope and discard. Installing the Left Side Chamber Fans: 1. Align the chamber fans with the mounting holes and use a ⁄...

  • Page 566: Removing The Right Side Chamber Fans

    Removing the Right Side Chamber Fans: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position. 2. Unplug the AC power cord, RJ-45 network cable and UPS cable (if used) from the rear of the printer.
  • Page 567 Figure 551: Right side chamber fan connector and mounting screw locations 4 right side chamber fan cover mounting screws 2 right side chamber fan connectors 8. Using a ⁄ ” nut driver or standard screwdriver, remove the 2 chamber fan mounts for both right side fans.

  • Page 568: Installing The Right Side Chamber Fans

    Figure 552: Right side chamber fan mounting screw locations 2 chamber fan 2 chamber fan mounting screws mounting screws 9. Remove the 2 right side chamber fans from the envelope and discard. Installing the Right Side Chamber Fans: 1. Align the chamber fans with the mounting holes and use a ⁄...

  • Page 569: Chamber Heaters (1 Lead Screw)

    Chamber Heaters (1 Lead Screw) Required Tools • ⁄ ” nut driver or standard screwdriver • ⁄ ” nut driver or box wrench Removing the Left Side Chamber Heater: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position.
  • Page 570 6. Using a ⁄ ” nut driver or standard screwdriver, remove the 4 left side chamber heater cover mounting screws. See Figure 554. Figure 554: Left side chamber heater cover mounting screw locations 4 left side chamber heater cover mounting screws 7.

  • Page 571: Installing The Left Side Chamber Heater

    8. Remove the outter washers, black and white heater wires and the inner washers from the left side chamber heater. 9. Using a ⁄ ” nut driver or standard screwdriver, remove the 2 left side chamber heater mounting screws. See Figure 556.

  • Page 572: Removing The Right Side Chamber Heater

    Removing the Right Side Chamber Heater: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position. 2. Unplug the AC power cord, RJ-45 network cable and UPS cable (if used) from the rear of the printer.
  • Page 573 Figure 558: Right side chamber heater cover mounting screw locations 4 right side chamber heater cover mounting screws 7. Using a ⁄ ” nut driver or box wrench, remove the right side chamber heater wire nuts. See Figure 559. Figure 559: Right side chamber heater wire nut locations Right side chamber heater wire nuts 5-436...

  • Page 574: Installing The Right Side Chamber Heater

    8. Remove the outter washers, black and white heater wires and the inner washers from the right side chamber heater. 9. Using a ⁄ ” nut driver or standard screwdriver, remove the 2 right side chamber heater mounting screws. See Figure 560.

  • Page 575: Z Jam Sensor (1 Lead Screw)

    Z Jam Sensor (1 Lead Screw) The Z Jam Sensor is installed on printers with serial numbers less than P4000 Required Tools • ⁄ ” nut driver or standard screwdriver • ⁄ ” allen wrench Removing the Z Jam Sensor: 1.
  • Page 576 7. Using a ⁄ ” nut driver or standard screwdriver, remove the 2 Z jam sensor mounting bracket screws. See Figure 562. Figure 562: Z jam sensor mounting screw locations (looking up) 2 mounting screws 8. Follow the Z jam sensor cable to the next wire clip. Un-clip the wire clip and remove the Z jam sensor cable.
  • Page 577 9. Follow the Z jam sensor cable to the next wire clip. Un-clip the wire clip and remove the Z jam sensor cable. See Figure 564. Figure 564: Z jam sensor wire clip location Wire clip 10. Disconnect the Z jam sensor cable J57/J155 by pressing the tab in and pulling outwards. Figure 565.

  • Page 578: Installing The Z Jam Sensor

    11. Using a ⁄ ” allen wrench, remove the 2 Z jam sensor mounting screws from the mounting bracket. See Figure 566. Figure 566: Z jam sensor mounting screw locations 2 mounting screws 12. Discard the Z jam sensor. Installing the Z Jam Sensor: 1.

  • Page 579: Z Sensors (1 Lead Screw)

    Z Sensors (1 Lead Screw) Required Tools • Phillips screwdriver Removing the Z BOT (Home) Sensor: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position. 2. Unplug the AC power cord, RJ-45 network cable and UPS cable (if used) from the rear of the printer.
  • Page 580 7. On the left side of the printer, locate and disconnect the Z BOT sensor wire by pressing the tab in and pulling outwards. See Figure 568. Figure 568: Z BOT sensor connector location Z BOT connector 8. Using a phillips screwdriver, remove the Z BOT sensor mounting screw. See Figure 569.

  • Page 581: Installing The Z Bot (Home) Sensor

    Installing the Z BOT (Home) Sensor: 1. Align the Z BOT sensor with the mounting hole and use a phillips screwdriver to reinstall the mounting screw. 2. Run the Z BOT sensor wire through the frame and reconnect by pushing the connectors together.
  • Page 582 7. On the left side of the printer, locate and disconnect the Z EOT sensor wire by pressing the tab in and pulling outwards. See Figure 571. Figure 571: Z EOT sensor connector location Z EOT connector 8. Using a phillips screwdriver, remove the Z EOT sensor mounting screw. See Figure 572.

  • Page 583: Installing The Z Eot Sensor

    Installing the Z EOT Sensor: 1. Align the Z EOT sensor with the mounting hole and use a phillips screwdriver to reinstall the mounting screw. 2. Run the Z EOT sensor wire through the frame and reconnect by pushing the connectors together.

  • Page 584: Z Motor Belt (1 Lead Screw)

    Z Motor Belt (1 Lead Screw) Required Tools • ⁄ ” nut driver or standard screwdriver Removing the Z Motor Belt: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position. 2.
  • Page 585 Figure 574: Z jam sensor location Z Motor Z Jam Sensor 7. Using a ⁄ ” nut driver or standard screwdriver, remove the front Z jam sensor mounting bracket screw, and loosen the rear mounting bracket screw. Swing the Z jam sensor away from the mounting bracket.
  • Page 586 8. Using a ⁄ ” nut driver or standard screwdriver, remove the 4 Z motor mounting bracket screws. See Figure 576. Figure 576: Z motor mounting bracket screw locations Z disc Z motor mounting Z motor bracket screws mounting bracket screws 9.

  • Page 587: Installing The Z Motor Belt

    Installing the Z Motor Belt: 1. Slide the Z motor belt around the lead screw pulley. 2. Lift the Z motor pulley up through the Z motor belt. 3. Align the Z motor bracket with the mounting holes and use a ⁄...

  • Page 588: Z Motor (1 Lead Screw)

    Z Motor (1 Lead Screw) Required Tools • ⁄ ” allen wrench • ⁄ ” nut driver or standard screwdriver Removing the Z Motor: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position. 2.
  • Page 589 Figure 579: Z motor cable location Z motor cable connector Wire clip 7. Using a ⁄ ” nut driver or standard screwdriver, remove the 4 Z motor mounting bracket screws. See Figure 580. Figure 580: Z motor mounting bracket screw locations Z disc Z motor mounting...

  • Page 590: Installing The Z Motor

    8. Using a ⁄ ” allen wrench, remove the 4 mounting screws from the Z motor mounting bracket. See Figure 581. Note the alignment of the Z motor with the Z motor mounting bracket. Figure 581: Z motor bracket mounting screw locations 4 mounting screws 9.

  • Page 591: Z Stage Assembly - 1 Ls

    Z Stage Assembly - 1 LS • Printers with a serial number less than P4000 will have a Z jam sensor assembly. See Fig- ure 583. • Printers with a serial number greater than P2985 will have a Z disc located below the Z jam flag.
  • Page 592 Figure 582: Z motor location 7. If printer serial number is less than P4000, locate the Z jam sensor. See Figure 583. If serial number is greater than P4000 continue to step 5-455...
  • Page 593 Figure 583: Z jam sensor location Z Motor Z Jam Sensor 8. Using a ⁄ ” nut driver or standard screwdriver, remove the front Z jam sensor mounting bracket screw, and loosen the rear mounting bracket screw. Swing the Z jam sensor away from the mounting bracket.
  • Page 594 9. Using a ⁄ ” nut driver or standard screwdriver, loosen, but do not remove the 4 Z motor mounting bracket screws. See Figure 585. Figure 585: Z motor mounting bracket screw locations Z disc Z motor mounting Z motor bracket screws mounting bracket screws...
  • Page 595 11. Slide the pulley off the lead screw shaft and out of the Z drive belt. 12. Using a ⁄ ” nut driver or standard screwdriver, remove the 2 lower guide rod mounting screws. See Figure 587. Figure 587: Lower guide rod mounting screw locations Lower guide rod screws 13.
  • Page 596 14. Using a ⁄ ” allen wrench, remove the tip wipe assembly mounting screws. Remove the tip wipe assembly by lifting up and set aside. See Figure 589. Figure 589: Brush/flicker mounting screw locations Brush/flicker mounting screws 15. Using a ⁄...
  • Page 597 Figure 590: Steel plate mounting screw locations 3 front screws 2 left side screws 2 right side screws 16. Move the head towards the front of system and to the left side in order to lift up the stain- less steel plate. 17.
  • Page 598 Figure 591: Propping the steel plate Use an object that will allow 4-5 inches clearance 18. Using a ⁄ ” ratchet driver, remove the lead screw retaining nuts. See Figure 592. 19. Using a ⁄ ” ratchet driver, remove the upper guide rod screws. See Figure 592.
  • Page 599 21. Remove the Z stage: a. Grasp both guide rods, lift up and tilt the bottom outwards. See Figure 593. b. Angle the top of the Z stage out of the chamber door. See Figure 593. Figure 593: Removing the Z stage 22.

  • Page 600: Installing The Z Stage Assembly

    Figure 594: Z stage platen mounting screw locations Z platen Z stage platen mounting screws Installing the Z Stage Assembly: 1. Carefully remove the new Z Stage assembly from the shipping package. Caution: Do not remove cardboard inserts from housing until guide rods are inserted.
  • Page 601 4. Carefully slide the guide rods through the translator, pushing the cardboard inserts out. Figure 596. Figure 596: Removing the cardboard inserts 5. With the pin facing the top of the Z stage, install the lead screw into the translator until it is centered.
  • Page 602 17. Using a ⁄ ” nut driver or standard screwdriver, loosely reinstall the upper and lower guide rod retainer screws. Do not tighten at this time. 18. Tighten only the left upper and left lower guide screws. The right guide rod mounting holes are slotted to allow the guide rod to self-align.
  • Page 603 Figure 597: Head fan mounting screw locations 2 mounting screws 34. Using a ⁄ ” allen wrench, remove the dial indicator mounting screw from the head bracket. Figure 598. Figure 598: Head bracket mounting screws Dial indicator mounting screw 35. Align the dial indicator with the head bracket and use a ⁄...
  • Page 604 Figure 599: Dial indicator installation 36. Using a marker, mark the Z platen in the rear left corner, rear right corner, front left corner and front right corner. See Figure 600. Figure 600: Z platen marking locations Rear left (RL) Rear right (RR) Front right (FR) Front left (FL)
  • Page 605 37. Manually raise the Z stage, by turning the lead screw with a gloved hand, until the Z platen contacts the dial indicator and moves the gauge approximately 2 full rotations. 38. Move the dial indicator to the mark on the right rear corner and zero the dial indicator by loosening the set screw and turning the ring until the the dial is on the 0.
  • Page 606 51. Power on the system. The system should reach Idle with no displayed errors. 52. Perform tip depth calibrations. See “Tip Depth Calibration” on page 6-2. 53. Run a small test part and monitor system operation during build. 54. Send the bad Z stage back to Stratasys, Inc. 5-469...

  • Page 607: Receiver Components

    Receiver Components Galvanized Receiver Assembly The galvanized receiver assembly will only be used on Gen 1 electronics. Required Tools • ⁄ ” nut driver or standard screwdriver Removing the Galvanized Receiver Assembly: 1. Unload material. 2. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position.
  • Page 608 Figure 602: J7 cable location J7 on power distribution board J18 on 186 processor board 9. Locate the upper wire clip near the Z jam flag and un-clip. Pull the receiver cable through the electronics bay towards the receiver. See Figure 603.
  • Page 609 Figure 603: Wire clip location Wire clip 10. Disconnect the model and support material tubes from the receiver by pushing the black lock ring in and pulling the tubes outwards. See Figure 604. Mark the material tubes with a marker or a piece of tape for correct reinstallation.
  • Page 610 Figure 604: Material tube locations Pull tube outwards Push lock ring in Pull tube outwards Push lock ring in 11. Using a ⁄ ” nut driver or standard screwdriver, remove the 2 galvanized receiver mount- ing screws. See 5-473...
  • Page 611 Figure 605: Galvanized receiver mounting screw locations 2 mounting screws 12. Pull the galvanized receiver assembly out from the front of the printer and discard. 5-474...

  • Page 612: Installing The Galvanized Receiver Assembly

    Installing the Galvanized Receiver Assembly: 1. Align the galvanized receiver assembly with the mounting holes on the frame. 2. Using a ⁄ ” nut driver or standard screwdriver, reinstall the 2 mounting screws. 3. Reconnect the model and support material tubes by pushing into the lock rings. 4.

  • Page 613: Galvanized Receiver Plate

    Galvanized Receiver Plate The galvanized receiver plate will be used on Gen 2 and Gen 3 electronics. Required Tools • ⁄ ” allen wrench Removing the Galvanized Receiver Plate: 1. Unload material. 2. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position.
  • Page 614 9. Using a ⁄ ” allen wrench, remove the 3 galvanized receiver plate mounting screws. See Figure 607. Figure 607: Galvanized receiver plate mounting screw locations 3 mounting screws 10. Pull the galvanized receiver out of the printer and discard. 5-477...

  • Page 615: Installing The Galvanized Receiver Plate

    Installing the Galvanized Receiver Plate: 1. Slide the galvanized receiver plate into the printer and align with the receiver frame. 2. Using a ⁄ ” allen wrench, reinstall the 3 mounting screws. 3. Run the receiver cable up to the power distribution board, inserting into wire clips and closing wire clips along the way.

  • Page 616: Calibrations & Adjustments

    Calibrations & Adjustments This chapter guides you through various calibration and adjustment procedures. For Maraca instructions, see “Maraca Help” on page 3-7. The contents and page numbers of this chapter are as follows: Tip Depth Calibration ........................6-2 Leveling the Liquefier ........................6-4 Tip Offset Calibration ........................

  • Page 617: Tip Depth Calibration

    Tip Depth Calibration Adjusting Tip Depth (Foam) Build And Inspect the Tip Depth Calibration Model: 1. Use the control panel to build the "test_tipdepth.cmb" model. 2. After the part is completed, remove the modeling foam and inspect the raster patterns of each two raster set.
  • Page 618 Adjusting Tip Depth on Plastic Substrate Build And Inspect the Tip Depth Calibration Model: 1. Use the control panel to build the test_tipdep_plstc.cmb model. The model will create six pairs of numbers at different Z heights as shown in Fig. 2. Each pair will have a set of numbers on the left and right.

  • Page 619: Leveling The Liquefier

    Leveling the Liquefier The two main signs that the liquefier is un-leveled are: • A ridge along the front face of a part (support tip too low). • Support is knocked over by the model tip (support tip too high). Top exposed layer looks rough.
  • Page 620 8. Starting at the squared corner (lower left), use your fingernail to carefully lift and remove the top layer from the part on the left (support material). See Figure 4. 9. Using a micrometer or digital caliper, measure the thickness of the support layer (top layer that was removed in step ).
  • Page 621 Figure 5: Liquefier Swivel Plate Screw Location Liquefier swivel plate screw Liquefier swivel plate Liquefier Liquefier leveling screw Liquefier leveling screw Liquefier swivel plate screws 17. For the following step refer to the figures derived from step . Assume, as an example, the support thickness was 0.008"...
  • Page 622 26. Using a ⁄ ” allen wrench, turn the screw on the right counterclockwise ( ⁄ turn for BST, ⁄ turn for SST). Next turn the left side leveling screw clockwise by the same amount. 27. Tighten the TOP CENTER liquefier swivel plate screw first. Then tighten the left and right swivel plate screws.

  • Page 623: Tip Offset Calibration

    Tip Offset Calibration Adjusting Z Clearance (SST Only): The Z Clearance parameter adjusts the Z table height at which support roads are built relative to model roads. A Z Clearance value of +0.0002 means that the Z table moves down 0.0002" when extruding support material.
  • Page 624 3. Inspect the nested squares and visually identify the one in which the inner square is best centered within the outer squares in the X direction (left to right). Repeat for the Y direc- tion. Note that the square with the best X centering will not necessarily have the best Y cen- tering.
  • Page 625 Figure 7: Example XY Tip Offset Part. This example requires an adjustment of X = + 2 mils, Y = - 4 mils 8. Once the values have been determined, open the Maraca software from a workstation or laptop connected to the printer. 9.

  • Page 626: Y Lash

    Y Lash Mechanical lash is the tendency of the gantry to remain stationary after a change in direction until the mechanical slop in the system is taken up by the move. Build And Inspect the Hysteresis Calibration Model: 1. Use the control panel to build the “test_lash” model. 2.

  • Page 627: Part Based Calibration

    Part Based Calibration Required Tools • Set of basic service tools • 6” digital calipers • Maraca CD Part based calibration consists of building a part and then taking six measurements - front, right, left, rear, left rear and left front. Figure 5. These measurements are then entered using Maraca. When to Perform Part Based Calibration Cable drive XY table.
  • Page 628 Figure 9: Locating the filled circle (B) 9. Using a digital caliper, measure and record the diameter of circle B along the center line between A and C. See Figure 10. Reference letters are not actually “printed” on the part. Figure 10: Measuring diameter of B 10.
  • Page 629 Figure 11: Measuring distance from outside edges of B & A 11. Next measure and record the distance from the outside edges of circle B and C. See Figure Ensure that the caliper is not seated on the small bump of circle C. Figure 12: Measuring distance from outside edges of B &...
  • Page 630 Figure 13: Measuring all circles 14. Next measure the width of the center circle. Take the measurement at the same diagonal as the center line measurement to be taken (e.g. left rear). See Figure 14. Figure 14: Measuring width of center circle (E) 15.
  • Page 631 16. Next measure and record the distance from the outside edges of circle E and G. Ensure that the caliper is seated on the small bump of circle G. See Figure 13. 17. Add the lengths derived from steps (C-E and E-G) and then subtract the width of circle E (from step ).

  • Page 632: Tensioning The Xy Cable Table

    Tensioning the XY Cable Table XY cable tension is critical in the proper and accurate operation of the machine. Cable tension should be checked as part of routine field maintenance. Parts and Tools Required • ⁄ ” allen wrench • ⁄...
  • Page 633 Figure 16: Zeroing the Gauge Gauge set to “0” Bezel Calibration bar 3. Remove the calibration bar from the gauge. 4. Slide the two “spacers” onto the tension gauge posts and tighten set screws. See Figure 17. Figure 17: Spacer alignment Spacer Notch 5.
  • Page 634 Figure 18: Y cable clamp Y cable clamp Clamp set screw Clamp mounting screw 7. The Y cable clamp must be loosened to properly adjust the Y cable tension. 8. Remove the cable clamp set screw using a ⁄ ” allen wrench. 9.
  • Page 635 12. Gauge should read between 0.090 to 0.100 (counter clockwise) deflection when indicator is zeroed using the zero gauge, see Figure 20. When reading the gauge, ensure the indicator is behind the zero point. Always double check to ensure the reading is more negative than positive.
  • Page 636 18. Again check Y cable tension. Repeat steps through until correct tension is achieved. Remove gauge. 19. Secure the Y cable clamp by tightening the two mounting screws and replacing and tight- ening the set screw. X Cable Adjustment: 1. Rezero the tension gauge. 2.
  • Page 637 12. Using a ⁄ ” allen wrench, turn the screw clockwise to tighten and counter clockwise to loosen. When tightening the X cable, one turn of the tensioning screw increases cable ten- sion by about 4.5 kg (0.045”). 13. Continue to turn the screw until desired value is reached. 14.

  • Page 638: Leveling The Xy Table (Cable Drive)

    Leveling the XY Table (Cable Drive) Required Tools • ⁄ ” allen wrench • ⁄ ” allen wrench • ⁄ ” nut driver or standard screwdriver • Head bracket • Dial indicator Leveling Procedure: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position.
  • Page 639 Figure 24: Head bracket mounting screws Dial indicator mounting screw 7. Align the dial indicator with the head bracket and use a ⁄ ” allen wrench to install the mounting screw. See Figure 25. Figure 25: Dial indicator installation 8. Using a light colored marker, mark the Z platen in the rear left, rear right, front left and front right corners.
  • Page 640 Figure 26: Z platen mark locations 9. Align the head bracket and dial indicator with the head fan mounting holes and use a ⁄ ” allen wrench to install the 2 mounting screws. Position the head fan behind the head bracket.
  • Page 641 11. Raise the Z stage until it is 2 inches from the upper limit by turning the lead screws. 12. Carefully move head to each of the 4 corners of the platen to determine the HIGHEST cor- ner of the XY (LOWEST indicator reading). 13.
  • Page 642 16. Calculate the number of shims needed at each of the three corners. See Figure 29. Figure 29: Shim calculation One shim: Indicator reads +0.006 One shim: Indicator reads +0.004 Three shims: Highest corner: 0 Indicator reads +0.012 17. Once the number of shims has been determined, loosen all four of the XY table mounting screws using a ⁄...
  • Page 643 29. Reconnect the AC power cord, RJ-45 network cable and UPS cable (if used). 30. Power on the system. The system should reach with no displayed errors. Idle 31. Open Maraca from a lap top or workstation PC. 32. Connect to the printer. 33.

  • Page 644: Leveling The Xy Table (Belt Drive For 3 Ls)

    Leveling the XY Table (Belt Drive for 3 LS) This process is only needed when installing a XY table (belt drive) into a three lead-screw system. Required Tools • Shims (0.010 thick) • Dial indicator • Head bracket • Standard service tools •...
  • Page 645 11. Each 0.010 shim will cause the head to raise approximately 0.004” at the corner of the 8 inch build envelope. 12. As an example: If a corner of the XY is low 0.012 (indicator reads +0.012) it will take three shims to raise it to the correct height.

  • Page 646: Tensioning The X & Y Motor Belts (Belt Table)

    Tensioning the X & Y Motor Belts (Belt Table) X Motor Belt Required Tools • ⁄ ” allen wrench • Belt tension tool 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position. 2.
  • Page 647 Figure 34: X motor mounting screw locations 3 mounting screws 7. Insert the XY motor belt tension tool between the X motor pulley and the X drive pulley by squeezing the tension tool and releasing pressure when in place. See Figure 35.
  • Page 648 9. Remove the belt tension tool. 10. Reinstall the side panels. See “Side Panels” on page 5-11. 11. Reinstall the rear door. See “Installing the Rear Door:” on page 5-10. 12. Reconnect the AC power cord, RJ-45 network cable and UPS cable (if used). 13.
  • Page 649 Figure 37: Y motor mounting screw locations 3 mounting screws 7. Insert the XY belt tension tool between the Y motor pulley and the Y drive pulley by squeezing the handles together. When in place, release the handles to obtain tension. See Figure 38.

  • Page 650: Tensioning The X & Y Drive Belts (Belt Table)

    Tensioning the X & Y Drive Belts (Belt Table) X Drive Belt Required Tools • ⁄ ” allen wrench • ⁄ ” allen wrench • ⁄ ” nut driver or box wrench • Small standard screwdriver • XY motor belt tensioning tool •...
  • Page 651 Figure 39: Belt tension gauge zero block Old dial indicator New dial indicator 7. Zero the dial indicators by adjusting the dial indicator up or down until the gauge reads: a. The old dial indicator will be at zero when the large hand is on 0 and the small hand is on 2.7, when at zero use a ⁄...
  • Page 652 Figure 40: Setting the dial indicator Set screw New dial indicator Old dial indicator 8. Remove the zero block from the belt tension gauge. 9. Move the head to the far right side of the printer. 10. Place the belt tension gauge on the center of the X drive belt. See Figure 41.
  • Page 653 11. Using a ⁄ ” nut driver or box wrench, tighten the X drive belt by turning the X drive belt tensioning nut clockwise until: a. The old dial indicators large hand is between 20 and 25 mils and the small hand is nearly on 1.6.
  • Page 654 Y Drive Belt Required Tools • ⁄ ” nut driver or box wrench • ⁄ ” nut driver or standard screwdriver • ⁄ ” allen wrench • Belt tension gauge • Dial Indicator Tension the Right Side Y Drive Belt: 1.
  • Page 655 Figure 44: Right side Y belt clamp mounting screw locations Right side Y belt clamp 9. Insert the belt tension gauge zero block into the belt tension gauge. See Figure 45. 10. Zero the dial indicators by adjusting the dial indicator up or down until the gauge reads: a.
  • Page 656 Figure 45: Belt tension gauge zero block Set screw Set screw Old dial indicator New dial indicator 11. Remove the zero block from the belt tension gauge. 12. Move the head to the rear of the printer. 13. Place the belt tension gauge on the center of the right side Y drive belt. See Figure 46.
  • Page 657 Figure 46: Belt tension gauge location Front View Right View 14. Using a ⁄ ” nut driver or box wrench, tighten the right side Y drive belt by turning the drive belt tensioning nut clockwise until: a. The old dial indicators large hand is between 90 and 20 mils and the small hand is nearly on 1.6.
  • Page 658 15. Remove the tension gauge and move the head from front to back several times. 16. Reattach the tension gauge to the right side Y drive belt and measure belt tension. If tension is out of specification, repeat steps until the belt tension is within specification. 17.
  • Page 659 8. Using a ⁄ ” allen wrench, remove the 4 left side Y belt clamp mounting screws and remove the belt clamp. See Figure 49. Figure 49: Left side Y belt clamp mounting screw locations Right side Y belt clamp 9.
  • Page 660 Figure 50: Belt tension gauge zero block Set screw Set screw Old dial indicator New dial indicator 11. Remove the zero block from the belt tension gauge. 12. Move the head to the rear of the printer. 13. Place the belt tension gauge on the center of the left side Y drive belt. See Figure 51.
  • Page 661 Figure 51: Belt tension gauge location Front View Left View 14. Using a ⁄ ” nut driver or box wrench, tighten the left side Y drive belt by turning the drive belt tensioning nut clockwise until: a. The old dial indicators large hand is between 90 and 20 mils and the small hand is nearly on 1.6.
  • Page 662 15. Remove the tension gauge and move the head from front to back several times. 16. Reattach the tension gauge to the right side Y drive belt and measure belt tension. If tension is out of specification, repeat steps until the belt tension is within specification. 17.

  • Page 663: Leveling The Xy Table (Belt Drive)

    Leveling the XY Table (Belt Drive) Required Tools • ⁄ ” allen wrench • Cam wrench or large crescent wrench • Head bracket • Dial indicator Removing the XY Table Assembly: 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position.
  • Page 664 Figure 54: Head bracket mounting screws Dial indicator mounting screw 7. Align the dial indicator with the head bracket and use a ⁄ ” allen wrench to install the mounting screw. See Figure 55. Figure 55: Dial indicator installation 8. Using a marker, mark the Z platen in the rear left corner, rear right corner, front left corner and front right corner.
  • Page 665 Figure 56: Z platen marking locations Rear left (RL) Rear right (RR) Front right (FR) Front left (FL) 9. Manually raise the Z stage, by turning the lead screw with a gloved hand, until it is about 2 inches from the upper limit. 10.
  • Page 666 11. Move the dial indicator to the mark on the front right corner of the Z platen and record the value. 12. Move the dial indicator to the mark on the front left corner of the Z platen and record the value.
  • Page 667 22. Zero the dial indicator by loosening the set screw and turning the dial until the indicator is at 0. 23. Using a ⁄ ” allen wrench, loosen the front left XY table mounting screw and cam screw. 24. Using the cam wrench or large crescent wrench, adjust the front right cam until the dial indicator reads the value given by the XY Table level calculator.

  • Page 668: Adjusting Z Bot (Home) Switch

    Adjusting Z BOT (Home) Switch Required Tools • ⁄ ” allen wrench • ⁄ ” nut driver or standard screwdriver • Marker 1. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position. 2.
  • Page 669 6. Disconnect the 2 right side chamber fans by pressing the tab in and pulling apart. See Fig- ure 61. Figure 61: Right side chamber fan connector locations Chamber fan connectors 7. Using a ⁄ ” nut driver or standard screwdriver, remove the 8 chamber heater cover mounting screws.
  • Page 670 8. Open the chamber heater cover away from the front of the printer. See Figure 63. Do not stress the heater wires running into the housing. Figure 63: Opening the chamber heater cover 9. Locate the Z BOT switch at the upper left corner. See Figure 64.
  • Page 671 10. Using a ⁄ ” nut driver or standard screwdriver, loosen the 2 mounting screws. 11. Adjust the Z BOT switch: a. Locate the Z drive belt. The belt is located beneath the Z stage assembly. b. Reach under the Z stage and pull on the Z motor belt to raise the Z stage until the Z BOT switch engages and makes a click sound.

  • Page 672: Get/Send Calibration Files

    Get/Send Calibration Files The “Get” button copies the .cal file from the system hard drive to the system calibration floppy. The “Send” copies the .cal file from the system calibration floppy (located in the electronics bay of the system) to the system hard drive. Important •...
  • Page 673 “Get” .cal file – from the system hard drive to the calibration floppy: This would typically be used after changing calibration values or if the .cal file has not been stored on the floppy. 1. Remove the system calibration floppy from the electronics bay and insert it into the workstation floppy drive.

  • Page 674: Z Tray Leveling (Cantilever Z Stage, Foam)

    Z Tray Leveling (Cantilever Z Stage, Foam) This procedure should only be used for single lead screw Z stages with foam substrates. The Z stage is initially squared at the factory using a fixture. The XY table is then installed and leveled to the Z stage.
  • Page 675 Checking Spacing Using the Spacer Part: 1. Build the spacer part. Two sides of the part are used to check the tray spacing. The 768/ Elite side of the part is 0.150” thick. The 1200es side of the part is 0.210” thick. The side with the lip is used for adjusting the tray level, and is 0.180”...

  • Page 676: Leveling The Z Platen

    Leveling the Z platen: 1. Using a ⁄ ” allen wrench, remove the 2 head cooling fan mounting screws. Set the fan off to the side. See Figure 68. Figure 68: Head fan mounting screw locations 2 mounting screws 2. Using a ⁄...
  • Page 677 Figure 70: Dial indicator installation 4. Using a marker, mark the Z platen in the rear left corner, rear right corner, front left corner and front right corner. See Figure 71. Figure 71: Z platen marking locations Rear left (RL) Rear right (RR) Front right (FR) Front left (FL)
  • Page 678 5. Manually raise the Z stage, by turning the lead screw with a gloved hand, until it is about 2 inches from the upper limit. 6. Move the dial indicator to the mark on the right rear corner and zero the dial indicator by loosening the set screw and turning the ring until the the dial is on the 0.

  • Page 679: Aligning Single Lead Screw Z Stage

    Aligning Single Lead Screw Z Stage: 1. Using the keypad, go to Table Maintenance and move the Z stage to the middle. 2. Power down the system using the power-down switch. Once the system is powered down, switch the circuit breaker to the off position. 3.

  • Page 680: Preventive Maintenance

    Preventive Maintenance In this chapter you will learn preventive maintenance procedures. Follow the simple procedures to ensure continued proper operation of the system. The contents and page numbers of this chapter are as follows: Startup Kit ........................... 7-2 Daily Maintenance......................7-2 Weekly Maintenance ......................

  • Page 681: Startup Kit

    Startup Kit Provided with the system is a Startup Kit that includes a set of tools used to help you maintain the system, as well as replacement parts. The following lists the tools contained in the Startup Kit that are used in Maintenance and Troubleshooting procedures.

  • Page 682: Weekly Maintenance

    Weekly Maintenance Vacuum Build Chamber Vacuum the build chamber to remove all foreign particles and purged material. Quarterly Maintenance Fan Filter Cleaning the fan filter: 1. Locate the lower fan on the rear panel of the system and snap off the plastic frame that secures the fan filter.

  • Page 683: As Needed Maintenance

    Figure 1: Replacing the tip wipe assembly As Needed Maintenance The following maintenance items have no routine schedule but should be tended to as needed. Chamber Lamp Replacing the chamber lamp: 1. Power down the system. 2. Locate the lamp socket plug about three inches beneath the lamp socket. Unplug lamp socket from wire harness.

  • Page 684: Index

    Index Numerics 120/240 VAC Jumper Configuration ....................Appendix-15 186 Processor Board Functionality ..........................2-6 Layout ............................2-9 Replacing ..........................5-128 Safety Devices ....................... 2-8, 2-20, 2-32 48VDC Power Supply (Dual) ....................5-156 5VDC Piggyback Supply ......................5-136 Adjusting Upper Z Limit Switch ......................6-53 As Needed Maintenance .......................
  • Page 685 1 Lead Screw .........................5-423 Errors Overview ...........................2-5 Fan Filter ............................7-3 Foam Retainer ..........................5-421 Galvanized Receiver Assembly ..........................5-470 Get/Send Calibration Files ......................6-57 Hazard Classifications ........................1-1 Head Components ........................5-184 Head Cooling Fan ........................5-184 Head Temp Snap Switch ......................5-188 Heater ............................5-362 Hot Surface Sign ..........................1-1 Layer Resolution ..........................2-3 LED’s ...........................2-10, 2-23,...
  • Page 686 Powering Up ............................2-4 Product Safety Symbols .........................1-1 Purge Container ..........................7-2 Quarterly Maintenance ........................7-3 Receiver Assembly Galvanized ..........................5-470 Receiver Components ........................5-470 Regulatory Compliance .........................2-3 Removing Debris Buildup ......................7-2 Reset Button ........................2-9, 2-21, 2-33 Safety ..............................1-1 Safety Devices ..........................1-1 Single Board Computer ........................2-11 Software Architecture ........................3-2 Special Facility Requirements .......................2-3 Specifications ...........................2-3...
  • Page 687 XY Table Cable Components ....................5-231 Y Drive Assembly ........................5-322 Y Drive Belt ..........................5-290 Y EOT Limit Switch ........................5-236 Y EOT Sensor ..........................5-281 Y Home Sensor ..........................5-278 Y Homing Sensor ........................5-239 Y Lash .............................6-11 Y Motor ............................5-284 Y Motor Belt ..........................5-287 Y Pulley ............................5-309 Z EOT Limit Switch ........................5-370 Z Jam Sensor...
  • Page 688 Appendix The appendix contains the following types of documents: • Illustrated parts breakdown • Reference Diagrams • Miscellaneous procedures • Checklists Illustrated Parts Breakdown ....................Appendix-2 Cable Drive XY Table Components ................Appendix-2 Belt Drive XY Table Components................Appendix-3 Head Area Components ...................Appendix-4 Chamber Heater Area Components (3 Lead Screw Z Stage) ......Appendix-5 Z Stage Area Components (3 Lead Screw Z Stage) ..........Appendix-6 Chamber Heater Area Components (1 Lead Screw Z Stage) ......Appendix-7...
  • Page 689 Illustrated Parts Breakdown Cable Drive XY Table Components Reference # Part Number Description 201301-0001 Y EOT limit switch 201307-0011 X BOT (home) sensor 201307-0010 Y home sensor (optical) 201857-0002 Head umbilical cable (gen 1 electronics) 201627-0001 Umbilical hose 202409-0001 Chamber snap switch (90° C) 201473-0001 X EOT sensor (optical) 200100-CS01...
  • Page 690 Belt Drive XY Table Components Reference # Part Number Description 201920-0002 Y drive Belt 201921-0002 X motor 202176-0001 X EOT sensor (with bracket) 201924-0001 Y motor Belt 201921-0002 Y motor 202409-0001 Chamber snap switch (90° C) 201898-0003 Y drive assembly 201627-0001 Umbilical hose 102537-0003...
  • Page 691 Head Area Components Reference # Part Number Description 201307-0012 Z foam optical sensor (gen 1 electronics) 102531-0001 Z foam optical sensor (gen 2/3 electronics) 201633-0001 Z foam sensor assembly (short arm, cable XY table) 205156-0001 Z foam sensor assembly (long arm, belt XY table) 202229-CS01 Head, swivel (BST) 202230-CS01...
  • Page 692 Chamber Heater Area Components (3 Lead Screw Z Stage) Reference # Part Number Description 201301-0001 Z BOT limit switch (upper) 30000089 Chamber heater 202050-0001 Z EOT limit switch (lower) Not Shown 201402-0001 Chamber fan Figure 4: Chamber Heater (3 Lead Screw) Reference Numbers Appendix-5...
  • Page 693 Z Stage Area Components (3 Lead Screw Z Stage) Reference # Part Number Description 200788-0001 Z jam flag 201307-0010 Z jam sensor 201302-0001 Z drive belt 205098-0002 Z axis stepper motor 200790-0002 Foam retainer 201308-0001 Thermocouple, chamber Figure 5: 3 lead Z stage area reference numbers Appendix-6...
  • Page 694 Chamber Heater Area Components (1 Lead Screw Z Stage) Reference # Part Number Description 202152-0001 Chamber heater, 400 watt 202114-0001 Chamber thermostat main Figure 6: Chamber heater reference numbers Appendix-7...
  • Page 695 Z Stage Area Components (1 Lead Screw Z Stage) Reference # Part Number Description 202150-0002 Thermocouple, chamber 201307-0010 Z jam sensor (serial numbers <P4000) 201924-0001 Z drive belt 202147-0002 Z jam flag (serial numbers <P4000) 202179-0001 Z axis stepper motor 202149-0001 Sensor, Z EOT, Z BOT (home) 206322-CS01...
  • Page 696 Head Cooling Fan Components Reference # Part Number Description 201400-0001 Head cooling fan Figure 8: Head cooling fan reference numbers Appendix-9...
  • Page 697 Gen 1 Electronics Bay Area Components Reference # Part Number Description 201403-0001 Upper electronics bay cooling fan 201976-0001 Dual 48 VDC power supplies (behind upper electronics bay cooling fan) 201872-CS05 Power distribution board 201403-0001 Lower electronics bay cooling fan 202003-0001 5/12 VDC power supply 201891-0002 24 VDC power supply...
  • Page 698 Gen 2 Electronics Bay Area Components Reference # Part Number Description 202143-CS05 Power distribution board 202325-0001 +24 VDC power supply 201403-0001 Electronics bay cooling fan 205503-CS01 +120 VDC aux. power supply 202326-0001 +5/12 VDC power supply 201525-0002 Circuit breaker 201598-0001 AC input 205509-0002 15 A Line filter board (behind input panel)
  • Page 699 Gen 3 Electronics Bay Area Components Reference # Part Number Description 202569-CS01 Power distribution board (PDB) 205659-0001 24 VDC power supply 201403-0001 Electronics bay cooling fan 205503-0005 120 VDC aux. power supply 202326-0001 5/12 VDC power supply 205510-0002 Circuit breaker 202182-0001 AC input 205509-0002...
  • Page 700 Galvanized Receiver Area Components Reference # Part Number Description 202119-0001 Receiver assembly (Gen 1 electronics) 206333-0001 Receiver assembly (Gen 2 electronics) 206400-0001 Receiver assembly (Gen 3 electronics) 202038-0002 Receiver cable single motor (Gen 1 electronics) 102539-0002 Receiver cable single motor (Gen 1 electronics) 202581-0001 Receiver cable single motor (Gen 1 electronics) 204427-0001...
  • Page 701 Printer Front (Misc. Components) Reference # Part Number Description Not shown 201780-0001 Door switch Not shown 201786-0002 Door solenoid Not shown 201901-0001 Door assembly Not shown 201635-0002 LCD display 206334-0001 Bezel assembly BST (white with old foam serial numbers <P1586) 206337-0001 Bezel assembly BST (white with new foam serial numbers P1586-P4000) 206335-0001...

  • Page 702: 120/240 Vac Jumper Configuration

    120/240 VAC Jumper Configuration Jumpers are located towards the bottom of the Power Distribution Board. Figure 14: 120/240VAC Jumper Configuration Jumper 120VAC Configuration 240VAC Configuration Appendix-15...

  • Page 703: Fuse Specifications

    Fuse Specifications Fuses are located on the Power Distribution Board. Fuses must be replaced with the same type and rating as listed below. Head Thermal Cutout Fuse (Snap): Temperature cutout at 150° C (300° F) Chamber Thermal Cutout Fuse (Snap): Temperature cutout at 83° C (180° F) Table 1: F1 24VDC Fused Voltage...

  • Page 704: Device Voltages

    Device Voltages Device Voltage Cartridge drive motor 12 VDC Cartridge solenoids 24 VDC Chamber heaters 120 VAC (parallel) 240 VAC (series) Chamber heater fans 24 VDC Chamber lights 24 VDC Chamber fans 24 VDC Door solenoid 12 VDC Head drive motors 12 VDC Home and EOT sensors 5 VDC...

  • Page 705: Hard Drive Installation Checklist

    If unable to save to floppy disc or CD, save to workstation. Discuss any of the customer’s questions or issues with them. Pack the old hard drive into the shipping box along with the RMA documentation and shipping back to Stratasys. Appendix-18...

  • Page 706: Xy Table Installation Checklist

    If unable to save to floppy disc or CD, save to workstation. Discuss with the customer any questions or issues they may have. Pack the old XY table into the shipping box along with the RMA documentation and ship back to Stratasys. Appendix-19...

  • Page 707: Head Installation Checklist

    Head Installation Checklist If you have any questions before or during installation, contact Stratasys technical support. Replace the head. Verify that all cables are connected correctly. Clean and lube the system. See “Preventive Maintenance” on page 7-1. Power system up and verify that head reaches temperature and the system homes correctly.

  • Page 708: Pre-Installation Checklist

    Ensure that no extension cords or power strips will be connected to the system. Verify minimum workstation requirements. Network address should be determined. Static IP addresses only. Stratasys does not provide the network cable. Key contacts should be available for system training during install. System Information...

  • Page 709: System Installation Checklist

    Check that system completes XY home and goes to Idle. Once up to temperature use the keypad to enter the IP address. Plug system into the customer’s network. Note: Stratasys does not provide the network cable. Install workstation software. Verify workstation is communicating with the system.

  • Page 710: Training Checklist

    Training Checklist Workspace System weights 282 lbs. (128 Kg) 110-120 VAC or 220-240 VAC dedicated outlet Ethernet 10/100 base T network. Static IP address only. Optional UPS for brown out conditions. Unpacking Remove wire ties securing the head. Table needs to support 300 lbs. Install fork lift covers once systems is placed at intended location.
  • Page 711 Material Demonstrate the correct way to load and unload material. Have customer load and unload material. Discuss effect of wet material on part quality. Demonstrate how to install modeling base. Explain the effects of building on “used” modeling base. Instruct customer on how to remove a part. FDM process Explain the process of Fused Deposition Modeling.

  • Page 712: Required Tool List

    Nut driver set Digital caliper Serial data cable (for issuing HyperTerminal commands). USB/Serial cable adapter. Supplied by Stratasys Cable/belt tension gauge (for adjusting XY table drive belts and cables) Motor belt tensioning tool (for adjusting belt XY table motor belts) Dial indicator...
  • Page 713 Appendix-26...

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