Stratasys Prodigy Plus User Manual
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Stratasys Prodigy Plus User Manual

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Summary of Contents for Stratasys Prodigy Plus

  • Page 1 User Guide...
  • Page 2 Changes or modifications to the Prodigy Plus system not expressly approved by Stratasys, the party responsible for compliance, could void the user’s authority for use.

  • Page 3: Introduction

    Introduction Prodigy Plus is designed with ultimate simplicity in mind. Prodigy Plus enables you to build parts quickly, even if you’ve never used a modeler before. Its display panel prompts you to press a few keys to get you modeling quickly.
  • Page 4 Prodigy Plus User Guide...

  • Page 5: Table Of Contents

    Table of Contents Introduction................3 Installation Checklist..............9 Overview................... 11 Finding More Information ............13 Setting up Prodigy Plus ..............13 Using Prodigy Plus ............... 13 Consumables ................. 14 Setup..................15 Workspace ................15 Unpacking ................16 Power Connections ..............17 Powering On Prodigy Plus ............
  • Page 6 Tip Cleaning Assembly ..............46 As Needed Maintenance ............47 Chamber Lamp ................47 Tip Shroud..................48 Troubleshooting...............53 Troubleshooting Checklist ............53 Fault Determination Codes.............54 Loss of Extrusion..............55 Diagnosing Loss of Extrusion............55 Recovering From Loss of Extrusion ..........56 Prodigy Plus User Guide...
  • Page 7 To unload material cartridges: ........... 31 To verify tip depth: ..............32 To build a test part: ..............33 To send a “job” to Prodigy Plus: ..........33 To build a part:................35 To read the display panel while building:........35 To continue operation from Standby mode:.......
  • Page 8 To replace the chamber lamp: ...........47 To diagnose loss of extrusion: ...........55 To recover from loss of extrusion:..........57 Clearing drive block obstructions: ..........60 Clearing the support liquefier inlet tube:.........61 Clearing the model liquefier inlet tube: ........62 Prodigy Plus User Guide...

  • Page 9: Installation Checklist

    Installation Checklist This guide is designed to help you set up and configure your new Prodigy Plus modeling system. The following steps include easy- to-follow instructions. Step 1 Workspace Step 2 Unpacking Step 3 Power Connections Step 4 Powering On Prodigy Plus...
  • Page 10 Prodigy Plus User Guide...

  • Page 11: Overview

    Overview Prodigy Plus builds models, including internal features, directly from CAD .stl files. The system builds three-dimensional parts by extruding a bead of ABS plastic through a computer-controlled extrusion head, producing high quality parts that are ready to use immediately after completion. With three layer resolution settings, you can choose to build a part quickly for design verification, or you can choose a finer setting for higher quality surface detail.
  • Page 12 Insight, the preprocessing software that runs on a Windows NT, Windows 2000, or Windows XP platform. Prodigy Plus’s build envelope measures 203 x 203 x 305 mm (8 x 8 x 12 in). Each material cartridge contains 922 cc (56.3 cu. in.) of usable material —...

  • Page 13: Finding More Information

    Overview 13 Finding More Information Several references are available for use with Prodigy Plus. Setting up Prodigy Plus Prodigy Plus User Guide Step-by-step instructions for installing, setting up and operating the Prodigy Plus system. Using Prodigy Plus Insight Online Users Guide Simple operating instructions for Insight are online.

  • Page 14: Consumables

    Tip Cleaning Kit (1 brush, 5 flickers) 540-10000 Tip Shroud 300-01100 ABS Glue (case of 12) 340-02000 24 V 20 W Halogen Bulb (qty. 4) To order consumables for your Prodigy Plus system, contact: North America: Stratasys, Inc. Consumable Orders +1.800.937.3010 (US toll-free) +1.952.906.2727 (fax) consumables@stratasys.com...

  • Page 15: Setup

    Setup Workspace Observe the following when placing Prodigy Plus in its operating location: • Prodigy Plus has an approximate weight of 128 kg (282 lbs.) and requires a table capable of safely supporting 300 lbs. • System Dimensions: 864 x 686 x 1041 mm (34 x 27 x 41 in) Four-inch minimum space behind unit for air circulation •...

  • Page 16: Unpacking

    16 Setup Unpacking This section describes the recommended procedures for unpacking and preparing Prodigy Plus for its first use. To unpack the machine: 1. Before unpacking machine, use a forklift to move it near its intended location. 2. Remove the plastic banding from around the cardboard, and slide the cardboard up and off the pallet.

  • Page 17: Power Connections

    (down) position. Prodigy Plus is provided with two power cords: one for 110 V and one for 220 V. To prepare all power connections: 1.

  • Page 18: Powering On Prodigy Plus

    (536° F) respectively. Use the leather safety gloves provided in the Startup Kit when working inside the machine. To power on Prodigy Plus, simply flip the large red power switch on the lower right side of the machine (see Figure 4).

  • Page 19: Powering Off Prodigy Plus

    You should complete the current build and unload the material before a planned power-off. If you wish to power-off Prodigy Plus, simply flip the large red power switch on the lower right side of the cabinet (see Figure 4 page 18).

  • Page 20: Cycling Power

    Setting Network Addresses You will need to set up your network addresses before sending files from the workstation to Prodigy Plus. If this has not been done already follow the steps below. Ask your IT department for your network addresses before beginning this process.
  • Page 21 Idle or starts warming up. 8. If you have not done so already, plug in the network patch cable from your network to the rear of Prodigy Plus. 9. From any workstation on your network, open a DOS window and type: “ping...”...

  • Page 22: Installing Software

    22 Setup Installing Software Insight is the preprocessing software that controls Prodigy Plus. If you have not already done so, you will need to install the Insight software and optional utilities on your workstation. You will find the Insight disk in your Startup Kit.

  • Page 23: Workstation Requirements

    2 button or 3 button Web Browser Internet Explorer 5.5 or later for online help Note: Changes to supported platforms, operating systems and graphics cards are periodically updated. Visit the customer login section at www.stratasys.com for the latest supported versions. Prodigy Plus User Guide...

  • Page 24: To Install Insight

    7. Compare the version number to the controller software CD provided in the Startup Kit. 8. If the version on the controller software CD is newer than the system version, follow the controller software upgrade process instructions provided in the Startup Kit. Prodigy Plus User Guide...

  • Page 25: Operation

    Operation Display Panel and Keypad The main interface to Prodigy Plus is the Display Panel and Keypad (see Figure Display Panel Context-sensitive displays Keypad buttons Figure 5: Prodigy Plus display panel and keypad The display panel and keypad is very easy to use. It consists of a larger multiple-line LCD display on top, and four single-line context- sensitive displays, each with one button (or key).

  • Page 26: Inserting A Plastic Modeling Base

    Building on a used modeling area may cause a part to curl or break loose from the modeling base. Before inserting a used modeling base into the machine, make sure that all material above the previous part’s first layer is removed from the base. Prodigy Plus User Guide...

  • Page 27: Loading Material

    Plug must be removed before cartridge can be installed. a. Turn the plug a quarter turn counter clockwise. b. Lift up the plug to remove it from the cartridge - discard (or recycle) the plug. Figure 7: Remove red plug before loading Prodigy Plus User Guide...
  • Page 28 If this occurs, there is no way to retrieve the filament without opening the cartridge and exposing the material to humidity, which reduces shelf life to a few days. Prodigy Plus User Guide...
  • Page 29 6. Press the Material Load button, which will be blinking. The panel first displays Unloading and then it instructs you to insert the cartridges with the prompt Replace Both Cartridges. 7. Insert each cartridge. The panel displays Ready to Load. Prodigy Plus User Guide...
  • Page 30 Pressing Yes returns the machine to the Ready to Build state. Note If the display shows Load Failed, press Retry. If load fails again, remove the cartridges, snip the material at an angle (see Figure 10 page 29), and reinsert the cartridge. Prodigy Plus User Guide...

  • Page 31: Unloading Material

    The system’s tip depth has been set at the factory and normally does not need adjustment. During shipment, however, tip depth may be altered. Customers that self-install need to verify the tip depth setting prior to building. Building with the wrong tip depth can Prodigy Plus User Guide...

  • Page 32: To Verify Tip Depth

    The etched set must meet the following criteria to pass: • -5 must be visible in at least one set of numbers. • +10 must not be visible in any set of numbers. Prodigy Plus User Guide...

  • Page 33: Building A Test Part

    Stratasys Customer Support for more information on adjusting tip depth. Building a Test Part Stratasys has factory-preloaded test parts into Prodigy Plus. It is recommended that you build a test part as your first build to familiarize yourself with the system.
  • Page 34 Completes all processing to create a .cmb file for Prodigy Plus 7. Click on the Status icon on the desktop of your workstation to send your file to Prodigy Plus. For more information on Status, refer to the Insight help files. Prodigy Plus User Guide...

  • Page 35: Building A Part From Your Cmb File

    To turn the lights on continuously until the power is cycled, you must be in the Idle or Ready to Build mode. Press Maintenance and then press Next until Setup Maintenance is displayed. Press Lights Always. Prodigy Plus User Guide...

  • Page 36: Pausing Build

    Resume. Prodigy Plus resumes modeling. Resuming Operations from Standby Mode After several minutes of inactivity, Prodigy Plus enters Standby mode. During Standby, the head and build envelope temperatures lower to save energy. To continue operation from Standby mode: 1.

  • Page 37: Canceling A Job

    Operation 37 2. Press Start Model to start modeling. Prodigy Plus may require a few minutes to warm up to build temperatures. You can view the temperature values rising in the display. Canceling a Job You can cancel a job at any time while the part is being built.

  • Page 38: Waterworks

    For information on reusing a plastic modeling base, see page WaterWorks Prodigy Plus uses WaterWorks, a water-based solution designed to simply wash away the support material. Your part is left smooth and clean with the fine details intact. The soluble support material...
  • Page 39 Dissolving supports is affected by four parameters: • Chemistry: Stratasys produces soluble concentrate in packages of 12 bottles. Each bottle of soluble concentrate is designed to produce the optimal concentration when mixed with 40 liters (approx. 11 US gallons) of water. More or less concentrate can be used at once, however, always maintain the correct ratio of concentrate to water.

  • Page 40: To Check The Part And Water Level

    If you build parts using the Sparse build style, allow them to fully drain, since the solution gets trapped inside the part. Allow parts to dry thoroughly. Then quickly rinse parts under hot water to keep the water out. If water gets inside, repeat this step. Prodigy Plus User Guide...

  • Page 41: To Dry Parts

    Household cleaners 9-12 Dishwasher detergent 10-11 Check your local, state, and/or international regulatory statutes for what pH level is acceptable for disposal. Stratasys recommends that disposal procedures be verified by the proper authorities in your region. Prodigy Plus User Guide...

  • Page 42: Soluble Solution Drain Effluent

    42 Operation Stratasys cannot anticipate local, state, or international regulatory statutes. Stratasys cannot be held liable if the solution is not disposed of properly. You may need to document how you dispose of the concentrate. Soluble Solution Drain Effluent You can dilute the solution with water using the appropriate ratio to meet your acceptable pH level.

  • Page 43: Maintenance

    Prodigy Plus. Startup Kit Tools Provided in your Prodigy Plus Startup Kit is a set of tools used to help you maintain the system, as well as replacement parts. The following list is of the tools contained in the Startup Kit that are used in Maintenance and Troubleshooting procedures.

  • Page 44: Daily Maintenance

    Z- stage to jam at its upper limit. Weekly Maintenance Vacuum Build Chamber Vacuum the build chamber to remove all foreign particles and purged material. Prodigy Plus User Guide...

  • Page 45: Quarterly Maintenance

    Lubricate the following items using the Krytox grease provided in the Startup Kit. Use the grease sparingly. See Figure 15 locations. • Z-axis lead screw • Both Z-axis guide rods • All X and Y-axis guide rods Prodigy Plus User Guide...

  • Page 46: Clean Fan Filter

    Clean fan filter To clean the fan filter: 1. Locate the lower fan on the rear panel of Prodigy Plus and snap off the plastic frame that secures the fan filter. 2. Clean the filter with soap and water, and blot it dry.

  • Page 47: As Needed Maintenance

    2. Locate the lamp socket plug about 3 inches beneath the lamp socket. Unplug lamp socket from wire harness. 3. Lightly pull the socket wires away from the socket while pulling lamp straight out of the socket. Prodigy Plus User Guide...

  • Page 48: Tip Shroud

    CAUTION Head area is very hot! Use gloves when installing a new shroud! 1. Enter Maintenance and access the Table Maintenance function. The head temperature decreases. Prodigy Plus User Guide...
  • Page 49 Figure 18. There is a small notch on the bottom of the plate for this purpose. Mounting Screw in Retaining Notch Figure 18: Head plate in shroud replacement position Prodigy Plus User Guide...
  • Page 50 11. Slide the metal shield back over the shroud. 12. Check that both the shroud and shield are positioned correctly. IMPORTANT Apply a thin coat of anti-seize compound to the threads of the shroud mounting screws. Prodigy Plus User Guide...
  • Page 51 14. Lower the head cover into position, and tighten both head cover screws. 15. Exit the Table Maintenance function. 16. Build a test part to verify system is operating correctly. See Building a Test Part page Prodigy Plus User Guide...
  • Page 52 52 Maintenance Prodigy Plus User Guide...

  • Page 53: Troubleshooting

    20). Panel Cannot communicate with system Incorrect IP address – check that the IP through network addresses within the Prodigy Plus system and Insight are the same values (see Setting Network Addresses page 20). Make sure IP address is static on your network (contact your IT department).

  • Page 54: Fault Determination Codes

    55). Fault Determination Codes If a fault occurs, which would prevent Prodigy Plus from executing an operator request, the system begins shutting down and cooling. The panel then displays one or two error codes. An error-code list (with the filename “error.txt”) can be found on the CD-ROM for the controller software.

  • Page 55: Loss Of Extrusion

    If material steadily flowed from both tips, the head is not experiencing loss of extrusion. Push Done to return the machine to an idle state. If material did not extrude from both tips follow the procedure in the following section, Recovering From Loss of Extrusion. Prodigy Plus User Guide...

  • Page 56: Recovering From Loss Of Extrusion

    6. Inspect the drive block funnels for obstructions. 7. Inspect the liquefier inlets for material buildup. 8. Clean the inside of the liquefier inlets. 9. Replace both drive-block assemblies. 10. Clean the drive wheels. 11. Check for extrusion. Prodigy Plus User Guide...

  • Page 57: To Recover From Loss Of Extrusion

    If not, continue with step 3. a. Run both filament motors forward while gently pushing the filament that stopped extruding into the filament guide rollers. Do so for about three seconds. Prodigy Plus User Guide...
  • Page 58 If material did not purge, continue with the following steps. 3. Snip both filaments approximately 1 inch from the fixed part of the head (see Figure 21). Figure 21: Materials coming out of feed tubes Prodigy Plus User Guide...
  • Page 59 5. Remove both drive block assemblies from the swivel part of the head. a. Set a material cartridge on top of the tray to support the removed drive block assemblies. Prodigy Plus User Guide...

  • Page 60: Clearing Drive Block Obstructions

    Use the 7/64” Allen wrench provided in the Startup Kit by removing the filament-guide mounting screw as shown in Figure b. Remove any excess material; use the needle-nose pliers if necessary. c. Replace the filament guide. Prodigy Plus User Guide...

  • Page 61: Clearing The Support Liquefier Inlet Tube

    If this doesn’t work, remove the liquefier inlet funnel using a 1/4” nut driver (see Figure 23). Dissolve support material from the funnel with the Waterworks solution. Prodigy Plus User Guide...

  • Page 62: Clearing The Model Liquefier Inlet Tube

    Press Select Drive repeatedly until the display shows Both Drive Motors. b. Press Reverse. c. With the glue brush provided in the Startup Kit, clear any material buildup from each drive by brushing its serrated drive wheel. Prodigy Plus User Guide...
  • Page 63 30 seconds, and then press Stop to halt extrusion. iii. Push Done. The panel displays Is material loaded? iv. Press Yes. The panel displays Exiting maintenance and you can resume normal operation. Prodigy Plus User Guide...
  • Page 64 64 Troubleshooting Prodigy Plus User Guide...
  • Page 68 14950 Martin Drive Eden Prairie, MN 55344 USA Telephone: (952) 937-3000 Fax: (952) 937-0070 E-mail: support@stratasys.com Web Site: www.stratasys.com Stratasys Document # 105833-0007...

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