Stratasys FORTUS 360mc Service Manual
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Stratasys FORTUS 360mc Service Manual

3d production system
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FORTUS 360mc/400mc™
3D Production System
Service Manual
Part No. 109156-0003, Rev. A

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Summary of Contents for Stratasys FORTUS 360mc

  • Page 1 | c-support@stratasys.com FORTUS 360mc/400mc™ 3D Production System Service Manual Part No. 109156-0003, Rev. A...
  • Page 2 Trademark Acknowledgments Stratasys, Insight, FORTUS, and FDM are registered trademarks of Stratasys Inc. FORTUS 360mc/400mc is a trademark of Stratasys Inc. in the United States and other countries. Windows NT, Windows 2000, and Windows XP are registered trademarks of Microsoft Corporation.

  • Page 3: Table Of Contents

    Table of Contents Safety ____________________________________________________________ 1-1 Safety ________________________________________________________________ 1-2 Safe Environment _________________________________________________ 1-2 Safe Human Interface _____________________________________________ 1-2 Hazard Classifications _____________________________________________ 1-3 Potential Safety Hazard Areas______________________________________ 1-4 Guard Door Interlocks _____________________________________________ 1-4 General Safety Practices __________________________________________ 1-4 Removing Electrical Power ____________________________________________ 1-5 System Overview__________________________________________________ 2-1 Specifications ________________________________________________________ 2-2 System Specifications______________________________________________ 2-2...
  • Page 4 Tip Sensor ____________________________________________________ 2-54 Linear Compensation _________________________________________ 2-56 Setup and Installation _____________________________________________ 3-1 General Information __________________________________________________ 3-2 Installation Checklist _______________________________________________ 3-2 Installation ________________________________________________________ 3-2 Un-Crate the System ___________________________________________ 3-2 Stabilize System________________________________________________ 3-2 Pre-Power Up Checks __________________________________________ 3-3 AC Power Verification ________________________________________ 3-12 Initial Power Up, Network Configuration and System Activation__ 3-14 Upgrade Controller Software __________________________________ 3-20 System Verification and Calibration____________________________ 3-21...
  • Page 5 Procedures ___________________________________________________ 4-24 Service Procedures________________________________________________ 5-1 General ______________________________________________________________ 5-5 Panels ____________________________________________________________ 5-5 Panel Removal ________________________________________________ 5-6 Panel Installation ______________________________________________ 5-7 System Power Down/Power Up_____________________________________ 5-8 System Power Down ___________________________________________ 5-8 System Power Up ______________________________________________ 5-9 Operator Power Down/Power Up _________________________________ 5-10 Operator Power Down ________________________________________ 5-10 Operator Power Up ___________________________________________ 5-10 Oven Door Window ______________________________________________ 5-11...
  • Page 6 X and Y Bellow Installation_____________________________________ 5-35 Y Bridge _________________________________________________________ 5-36 Y Bridge Removal_____________________________________________ 5-36 Y Bridge Installation ___________________________________________ 5-40 X-Axis Guide Rod/Pillow Block _____________________________________ 5-44 X-Axis Guide Rod/Pillow Block Bearing Removal ________________ 5-44 X-Axis Guide Rod/Pillow Block Bearing Installation ______________ 5-48 Z Stage ______________________________________________________________ 5-53 Z Drive Motor_____________________________________________________ 5-53 Z Drive Motor Removal ________________________________________ 5-53...
  • Page 7 Computer _______________________________________________________ 5-85 Computer Removal___________________________________________ 5-85 Computer Installation _________________________________________ 5-86 Oven Components___________________________________________________ 5-87 Upper Waste Chute Funnel Kapton Barrier _________________________ 5-87 Upper Waste Chute Funnel Kapton Barrier Replacement________ 5-87 Oven Blower _____________________________________________________ 5-88 Oven Blower Removal ________________________________________ 5-88 Oven Blower Installation_______________________________________ 5-91 Oven Thermocouple _____________________________________________ 5-93 Oven Thermocouple Removal_________________________________ 5-93 Oven Thermocouple Installation _______________________________ 5-94...
  • Page 8 Manual Z Zero Calibration ______________________________________ 6-3 Auto Z Zero Calibration ________________________________________ 6-4 Tip Offset Calibrations _____________________________________________ 6-5 AutoCal Tips___________________________________________________ 6-5 XYZ Tip Offset __________________________________________________ 6-6 PPU/Scaling Calibration __________________________________________ 6-10 Adjustment __________________________________________________________ 6-12 Platen Level Adjustment __________________________________________ 6-12 Upper Z Stage Hard Stop Adjustment ______________________________ 6-16 Head Filament Alignment_________________________________________ 6-19 Head Filament Presence Detect Switch Adjustment ________________ 6-21 Belt Tension Gauge Setup ________________________________________ 6-23...
  • Page 9 Part build won’t start __________________________________________ 7-12 Part build stopped ___________________________________________ 7-15 Part quality ___________________________________________________ 7-17 Operation: Failure ________________________________________________ 7-22 Part download failed _________________________________________ 7-22 Material load failed ___________________________________________ 7-23 Loss of extrusion (LOE)_________________________________________ 7-26 Operation: Condition_____________________________________________ 7-29 Odor/Burning_________________________________________________ 7-29 Error Messages ______________________________________________________ 7-30 UI Messages _____________________________________________________ 7-30 UI HELP Messages ________________________________________________ 7-31 CFG File ERROR Messages ________________________________________ 7-32...
  • Page 10 Z Motor Cable 102351_________________________________________ 9-19 Head Umbilical Cable 102628 _________________________________ 9-20 Signal Motor Driver Board Cable 102630 _______________________ 9-21 Power Motor Drive Board Cable 102631 ________________________ 9-22 Filament Sensor Cable 102997 _________________________________ 9-23 MIO AC Board Interface Cable 103027 ________________________ 9-24 Top Hood Switch Solenoid Cable 103029 _______________________ 9-25 Thermal Fuse Cable 103031 ___________________________________ 9-26 Twin Tower Tip Wipe Comp Cable 103033 ______________________ 9-27...
  • Page 11 Display Panel ___________________________________________________ 10-27 Display Panel Removal_______________________________________ 10-27 Display Panel Installation _____________________________________ 10-29 Computer ______________________________________________________ 10-30 Computer Removal__________________________________________ 10-30 Computer Installation ________________________________________ 10-31 Calibration and Adjustment ________________________________________ 10-33 Linear Compensation ___________________________________________ 10-33 X and Y Belt Tension Settings _____________________________________ 10-36 Component Adjustment _________________________________________ 10-37 Tip Wipe Height Adjustment __________________________________ 10-37 Tip Clean Position / Purge Location ___________________________ 10-41...
  • Page 12 Revision Log FORTUS 360mc/400mc Service ManualfA Date Description of Changes December 2012 New release of this manual. April 2014 Added Nylon 12 material information throughout. Incorporated Head Filament Presence Detect Switch Adjustment procedure instructions. Added 3mm belt upgrade information to Chapter 6.

  • Page 13: Safety

    Safety The following basic safety tips are given to ensure safe installation, operation, and maintenance of Stratasys equipment and are not to be considered as comprehensive on matters of safety. The Fortus 360mc/ 400mc system is designed to be safe and reliable rapid prototyping system.

  • Page 14: Potential Safety Hazard Areas

    High Voltage Sign. The high voltage sign indicates the presence of high voltages. Always stay away from any exposed electrical circuitry. It is recommended that all jewelry be removed. Hot Surface Sign. The hot surface sign indicates the presence of devices with high temperatures.

  • Page 15: Guard Door Interlocks

    Guard Door Interlocks Interlock switches are used to communicate the status of the oven door and the top covers to the system. For safety reasons, the oven door and top covers must be closed before the X, Y, and Z motors will operate. General Safety Practices Use the following safety practices when working with this system.
  • Page 16 Chapter 1: Safety This chapter describes the Stratasys Fortus 360mc/400mc system and its safety information. Safety _______________________________________________________________ 1-2 Safe Environment__________________________________________________ 1-2 Safe Human Interface _____________________________________________ 1-2 Hazard Classifications______________________________________________ 1-3 Potential Safety Hazard Areas ______________________________________ 1-4 Guard Door Interlocks _____________________________________________ 1-4...

  • Page 17: Safety

    The following basic safety tips are given to ensure safe installation, operation, and maintenance of Stratasys equipment and are not to be considered as comprehensive on matters of safety. The Fortus360mc/400mc system is designed to be safe and reliable rapid prototyping system.

  • Page 18: Hazard Classifications

    Do not touch sharp objects as they may cause a loss of body parts. Crushed–Hand Sign. The crushed hand sign indicates that a crushing hazard exists between two objects. Use standard electrostatic discharge (ESD) precautions when working on or near electrical circuits. FORTUS 360mc/400mc Service Manual...

  • Page 19: General Safety Practices

    Warning: High voltage is present in the system when powered off and unplugged due to the UPS (Uninterruptible Power Supply). Warning: Only use an OSHA or CE approved step stool when accessing the gantry area under the top covers (located at the top of the system). FORTUS 360mc/400mc Service Manual...

  • Page 20: Removing Electrical Power

    UPS when servicing the system. Warning: Make sure the UPS is manually turned off and not powering components in the system. Procedure • Power down the system and turn Off the power. (See “System Power Down” on page 5- FORTUS 360mc/400mc Service Manual...
  • Page 21 Chapter 2: System Overview This chapter provides system specifications and a theory of operation for the Fortus 360mc/400mc systems. Specifications________________________________________________________ 2-2 System Specifications ______________________________________________ 2-2 Liquefier Tip Specifications _________________________________________ 2-4 Theory of Operation _________________________________________________ 2-12 General__________________________________________________________ 2-12 FDM Technology ______________________________________________ 2-12...

  • Page 22: Specifications

    50.25 inches (1277 mm) wide x 35.25 inches (896 mm) deep x 77.25 inches (2197 mm) high Weight 1600 pounds (726 kg) shipping weight Environmental Maximum Environmental Temperature: 85°F (29°C) Requirements Maximum Dew Point: 78°F (25°C) FORTUS 360mc/400mc Service Manual...
  • Page 23 DIN ISO 8573-1 Quality Class 5 or better is recommended to improve onboard filter life. Air Source The air source connector must meet dimensional standard (A-A-59439) for Connection the quick disconnect female ¼-inch coupler. The system is equipped with a standard ¼-inch quick disconnect male plug (A-A-59439). FORTUS 360mc/400mc Service Manual...

  • Page 24: Liquefier Tip Specifications

    T20 model which uses T16 support. For Fortus 360mc systems - Table 2-1 shows the available material and tips. Table 2-2 shows the tip life. Table 2-1: Fortus 360mc Available Tips Model Material Model Tip Support Material Support Tip ABS-M30 T10, T12,T16, T20 SR20...
  • Page 25 Table 2-2: Fortus 360mc Tip Life Model Tip Life Support Tip Life Model Model Material cm. Canisters Support Tip Canisters ABS-M30 10160 T12SR20 4420 T12SR30 ABS-M30 12620 T12SR20 9010 T12SR30 ABS-M30 15080 10.0 T12SR20 10550 T12SR30 ABS-M30 15080 10.0 T12SR20...
  • Page 26 Tip Life is directly related to the amount of material that passes through the tip. The amounts listed above are approximates of how much material will pass through a tip before the tip will need to be replaced. Because other factors can affect tip life, the material amounts are only approximates. FORTUS 360mc/400mc Service Manual...
  • Page 27 Material Canisters Support Tip Canisters ABSi 620 10160 T12SR20 4420 ABSi 770 12620 T12SR20 9010 ABSi 920 15080 10.0 T12SR20 640 10550 ABSi 920 15080 10.0 T12SR20 640 10550 ABS-M30 620 10160 T12SR20 4420 ABS-M30i T12SR30 FORTUS 360mc/400mc Service Manual...
  • Page 28 T12SR100 4420 12060 6030 T12SR100 9010 13570 7540 T12SR100 10553 13570 7540 PC-ABS 4420 T12SR20 4420 PC-ABS 9010 T12SR20 9010 PC-ABS 828 13570 T12SR20 640 10550 PC-ABS 828 13570 T12SR20 640 10550 PC-ISO 740 12060 6030 FORTUS 360mc/400mc Service Manual...
  • Page 29 Tip Life is directly related to the amount of material that passes through the tip. The amounts listed above are approximates of how much material will pass through a tip before the tip will need to be replaced. Because other factors can affect tip life, the material amounts are only approximates. FORTUS 360mc/400mc Service Manual...
  • Page 30 The T12SR20 tip or T12SR30 is clearly marked on the top side of the plate. When using SR-110 Soluble Support material, you must use a T12SR100 support tip for all model tips. Figure 2-1: Fortus 360mc/400mc Tip Identification The T12SR20 tip is shorter than the T12SR30 tip and...
  • Page 31 330° C (626° F) 110° C (230° F) PC/PC-ISO 365° C (689° F) 145° C (293° F) Ultem* 9085 400° C (752° F) 190° C (374° F) PPSF 415° C (779° F) 225° C (437° F) FORTUS 360mc/400mc Service Manual 2-11...

  • Page 32: Theory Of Operation

    • Tip Life - normal operation will result in side wall deposits within the tip. Over time, the tip will not extrude material correctly, and will need to be replaced. Each material type has a different tip life associated with it. FORTUS 360mc/400mc Service Manual 2-12...
  • Page 33 • If extrusion is too slow, material can burn and crystallize. If extrusion is too fast, material will not have enough time to liquefy for proper extrusion. FORTUS 360mc/400mc Service Manual 2-13...

  • Page 34: First Layer Adhesion

    It is also important that the build sheet be heated to the correct build temperature to improve adhesion of the first layer. Z Zero position is another critical factor. Thermal expansion or contraction that occurs after the last Z Zero calibration affects first layer extrusion results. (See “Thermal Expansion” on FORTUS 360mc/400mc Service Manual 2-14...
  • Page 35 First Layer - Over extrusion insures consistent adhesion despite varying gap. Model Tip Build Sheet Top View of First Layer Layer is thinner when there is more gap. Layer is thicker when there is less gap. FORTUS 360mc/400mc Service Manual 2-15...

  • Page 36: Thermal Expansion

    This results in a significant impact on the accuracy of the Z Zero position. (See “Auto Z Zero” on page 2-53.) • Gantry belt tensions will change due to different expansion rates of the frame, pulleys, axle bolts, and belts. FORTUS 360mc/400mc Service Manual 2-16...

  • Page 37: Systems

    The AC board then rectifies the 120 volts AC to 120 volts DC. This is then distributed to the head through the MIO board. Power goes to the transformer and returns on connection JP4. Power goes to the head on connection JP23. FORTUS 360mc/400mc Service Manual 2-17...
  • Page 38 • D28 – Tip N/A • D29 – UPS • D30 – Head Blower • D31 – Light • D32 – Sys • D33 – Cooling Fan for Air Compressor • D34 – RX • D35 – TX FORTUS 360mc/400mc Service Manual 2-18...

  • Page 39: Computer

    The computer PMD board distributes motor speed and direction through the MIO Board. The motor encoder provides position information feedback to the computer through the MIO board. Motor rotational motion is translated to the platen linear motion through the motor drive pulleys and drive belt. FORTUS 360mc/400mc Service Manual 2-19...

  • Page 40: Mio Board

    Head filament drive motor servo amplifiers • Part of the MIO board circuitry - P1 (Model), P2 (Support). • The motion control board(s) sends signals to each amplifier. • The amplifier applies power to the motor. FORTUS 360mc/400mc Service Manual 2-20...
  • Page 41 MIO fuses: • 48V DC • 24V DC LEDs • D4 24V DC • D3 48V DC • D13 Oven heater signal • D6 PIC • D8 CPLD • D9 Door locked • D11 Hood locked FORTUS 360mc/400mc Service Manual 2-21...

  • Page 42: Head

    • The heaters are electrically connected to the head board. • Heat control is provided through a thermocouple installed in the back half of each heater block and electrically connected to the head board. FORTUS 360mc/400mc Service Manual 2-22...
  • Page 43 A purge of the tip and a tip wipe is performed. The head is moved to the build area and modeling begins. As the active tip nears completion of its layering cycle, a preheat command is sent to the inactive tip (“look ahead”). FORTUS 360mc/400mc Service Manual 2-23...
  • Page 44 This process is repeated as long as there is support structure to build. At the end of build, the head will move to the park position and the tip temperatures will be lowered to Idle. FORTUS 360mc/400mc Service Manual 2-24...

  • Page 45: Head Cooling Fan

    If the filament softens too early, filament mis-feed will occur. • The Head Cooling Fan directs cooling air to the drive wheel and tip flange area. This allows the tip to reach extruding temperature while filament entering flange remains solid. FORTUS 360mc/400mc Service Manual 2-25...
  • Page 46 Material within the flange must be softened for extrusion. If the fan is running, the time necessary to heat the filament within the flange is excessive. The cooling fan is turned on again after the extrusion begins. FORTUS 360mc/400mc Service Manual 2-26...

  • Page 47: Gantry (Xy Table)

    • The Y-axis belt is the bottom belt and is 144.5 inches (3670.3 mm) in length (367 mm). • Correct belt tension is critical to proper system operation. (See “XY Gantry Belt Tension” on page 6-24.) FORTUS 360mc/400mc Service Manual 2-27...
  • Page 48 • Deflects heated airflow around the tips during the extrusion process. • Attached to the Y-Axis heat shield. Axis Motors: • There is a separate servomotor for each axis. • Motors are equipped with optical encoders. FORTUS 360mc/400mc Service Manual 2-28...
  • Page 49 The ability of the servomotors to operate simultaneously and in conjunction with the infinite positions available to the head. The movement must be within the limits of axis travel and account for the application of extruded material at the exact location and time required. FORTUS 360mc/400mc Service Manual 2-29...

  • Page 50: Canister

    Components Figure 2-4: Canister Assembly Table 2-8: Key to Figure 2-4 Item Nomenclature Item Nomenclature Canister Base Filament Spool Canister Cover Desiccant Bags (Drying Agent) Snout Bobber Canister EEPROM Filament Filament Spool Assembly Anti-Rotation Plug FORTUS 360mc/400mc Service Manual 2-30...
  • Page 51 The cassette board reads stored information and updates the remaining quantity of the canister as filament is used by the system. Material use is calculated by monitoring the head motor encoders. FORTUS 360mc/400mc Service Manual 2-31...

  • Page 52: Canister Drive Block

    • Detects presence of filament in drive block. • Normally Open (NO) - switch closes when filament is loaded in drive block. Pogo Pins: • Provide electrical contact for canister EEPROM between canister drive and system. FORTUS 360mc/400mc Service Manual 2-32...
  • Page 53 Model Bay 1 No Jumper Model Bay 2 Pin 1 to Pin 12 Support Bay 1 Pin 2 to Pin 13 Support Bay 2 Pin 1 to Pin 12 and Pin 2 to Pin 13 FORTUS 360mc/400mc Service Manual 2-33...
  • Page 54 Moisture contamination and cross-winding of the filament within the canister will likely cause the canister to be unusable. Install brake in filament feed door and then close the door to make sure material does not feed back into the canister. FORTUS 360mc/400mc Service Manual 2-34...
  • Page 55 The filament present switch opens when filament no longer contacts the switch arm. The cassette board detects the open filament switch, stops the drive motor, turns off the status LED, and sends a ‘No Filament’ command to the MIO board. FORTUS 360mc/400mc Service Manual 2-35...

  • Page 56: Loading/Unloading Filament To The Head

    On a four-bay system the status of the second bay of the same material type (model or support) is checked. • If the status is ‘Ready’ or ‘Empty’, the Y-block is assumed to be free of material and the load process continues. FORTUS 360mc/400mc Service Manual 2-36...
  • Page 57 The cooling fan cycles ON and a series of tip purges and tip wipes are performed. The head is moved to its parked position and the tip temperature is reduced to Standby. The canister drive is turned OFF and the canister status LED displays steady green. FORTUS 360mc/400mc Service Manual 2-37...
  • Page 58 When the unload process stops, approximately 9 feet (2700 mm) of material remains within the filament tube system. This material will be unloaded from the system when the canister is removed. (See “Removing a canister:” on page 2-34.) FORTUS 360mc/400mc Service Manual 2-38...
  • Page 59 The system performs the load process for the other readied canister bay. (See “Load filament to head:” on page 2-36.) When material load is complete, the system exits ‘pause’ and the build will continue from the point at which it was paused. FORTUS 360mc/400mc Service Manual 2-39...

  • Page 60: Door Interlock

    The system sends an ‘Enable Lock’ command to the MIO board. If a Move command is initiated, the MIO board applies voltage to the interlock solenoids - locking the doors. • The MIO also enables the three servomotors amplifiers. FORTUS 360mc/400mc Service Manual 2-40...

  • Page 61: Air Dryer System

    Air Dryer Assembly Air Compressor Pressure Adjustment Filter Components There are two air systems available: Internal and External Internal: • 230V air compressor, diaphragm pump. • The pump runs constantly when the system is powered-on. FORTUS 360mc/400mc Service Manual 2-41...

  • Page 62: Operation

    • The system switches the active and inactive elements with each other using an air valve in timed cycles of 30 seconds. The fine mesh filter of the element traps moisture. 95% of the dryer air is supplied to the filament tube system at the Y-block. FORTUS 360mc/400mc Service Manual 2-42...

  • Page 63: Vacuum System

    • A gasket along the edge of the platen allows the build sheet to seal against the surface. Vacuum filter: • Traps debris that may enter the vacuum system from the oven. • Located in-line and ahead of the intake for the vacuum system. FORTUS 360mc/400mc Service Manual 2-43...
  • Page 64 Figure 2-6: External Vacuum System Block Diagram Y Block Air Flow Y Block Vacuum Sensor Air Dryer Pressure Looped Tube to Gauge Vacuum Reduce Heat Vacuum Gauge Solenoid Air In Vacuum Muffler Generator Air Regulator and Filter FORTUS 360mc/400mc Service Manual 2-44...
  • Page 65 It is recommend to build only if the vacuum is -15 Hg or greater (more negative). Figure 2-7: Internal Vacuum System Block Diagram Y Block Air Flow Y Block Vacuum Sensor Pressure Air Dryer Looped Tube to Gauge Reduce Heat Vacuum Vacuum Vacuum Gauge Compressor Air Regulator Generator FORTUS 360mc/400mc Service Manual 2-45...

  • Page 66: Oven Temperature Control

    • A series of three ducts used to channel and circulate heated air. • Ducts intersect at bottom corners of oven. Oven heater fans: • Two 230V AC, high temperature fans circulate air through oven. • Located at bottom right side of plenum. FORTUS 360mc/400mc Service Manual 2-46...
  • Page 67 - sending the heat on or heat off signal to the computer. The computer then sends the duty cycle to the AC PIC, which commands the three solid state relays to power the heater elements. FORTUS 360mc/400mc Service Manual 2-47...

  • Page 68: Thermal Safety Circuit

    • Thermally activated breaker mounted on the outside of the oven. (The probe is mounted inside the heater compartment above the heaters.) AC board: • Monitors state of thermal safety circuit. MIO Board: • Interfaces with thermal safety devices and AC board. FORTUS 360mc/400mc Service Manual 2-48...
  • Page 69 Figure 2-9: Thermal Safety Circuit Upper Gantry Thermal Fuse Oven Thermal Breaker Coil of Main Contactor J30-2 J30-1 J24-1 J24-2 JP2-1 JP2-2 J25-2 JP18-10 AC Board JP18-20 J25-9 Fuse FORTUS 360mc/400mc Service Manual 2-49...

  • Page 70: Calibration And Sensors

    At completion of the homing process, the Homing flag is set to “HOMED”. Z stage is always “Homed” first. Components Motion Control Board (PMDs - Installed in the computer). Servo amplifiers (Installed on the MIO board). Servomotors. XY Gantry. Z stage. Z stage homing switch. FORTUS 360mc/400mc Service Manual 2-50...

  • Page 71: Z Stage Homing

    Z stage movement is stopped when the homing switch opens. This position is saved in Memory as the Z home position. Z home values are normally set between 16.2 (41.148 cm) to 16.5 inches (41.91 cm). FORTUS 360mc/400mc Service Manual 2-51...

  • Page 72: Gantry Homing

    Both the X and Y-axis are moved in a positive distance of 0.5 inches (12.7mm). This position becomes the Global Zero position of the axis. The homing process is completed by moving the head to the park position. FORTUS 360mc/400mc Service Manual 2-52...

  • Page 73: Auto Z Zero

    When contact of the tip to the build sheet is determined due to an increase in following error, the Z stage position is recorded as Z Zero. The Z stage is lowered, full torque is applied to the X and Y motors, and the head is returned to its parked position. FORTUS 360mc/400mc Service Manual 2-53...

  • Page 74: Measure Flatness

    Two electrical leads (one white, one black) complete the electrical circuit to the MIO board (J9). • The polarity of the circuit must be observed - black lead to contact screw and pin 1; white lead to contact plate and pin 2. FORTUS 360mc/400mc Service Manual 2-54...
  • Page 75 • For Z calibration, the process is done 3 times and an average taken for better accuracy. Toggles support tip, runs across tip wipes, moves to support tip to plunger center. Finds Z position for support using the same method as model. FORTUS 360mc/400mc Service Manual 2-55...

  • Page 76: Linear Compensation

    X and Y axis. These measurements are entered in the system to compensate for any dimensional accuracy errors. The actual values are entered into the system and the system calculates the new PPU values. FORTUS 360mc/400mc Service Manual 2-56...
  • Page 77 Stabilize System ________________________________________________ 3-2 Pre-Power Up Checks __________________________________________ 3-3 AC Power Verification_________________________________________ 3-12 Initial Power Up, Network Configuration and System Activation __ 3-14 Upgrade Controller Software __________________________________ 3-20 System Verification and Calibration ____________________________ 3-21 Final Test _____________________________________________________ 3-22 FORTUS 360mc/400mc Service Manual...

  • Page 78: General Information

    General Information Installation Checklist Complete and return the Installation Checklist (107168-XXXX) for Fortus 360mc/400mc systems when the Setup and Installation is accomplished. Installation Un-Crate the System Refer to the Site Preparation Guide for detailed information on site requirements and uncrating.

  • Page 79: Pre-Power Up Checks

    Verify that the top panel, top door, and oven door interlock flags appear to be centrally aligned to the sensor vanes on the system. Figure 3-2: Interlock Flags Interlock Flag Sensor Vanes Interlock Flag (3X) FORTUS 360mc/400mc Service Manual...
  • Page 80 Remove the upper and lower side panels from both sides of the system.(See “Panel Removal” on page 5-6.) Remove the safety cover from the AC board using a 5/32-inch hex key. Figure 3-4: Safety Cover Safety Cover Safety Cover Screws FORTUS 360mc/400mc Service Manual...
  • Page 81 Normal position Remove the box containing the head from the oven and set aside. Cut and remove the cable ties securing the UPS cover and air fitting in the oven. FORTUS 360mc/400mc Service Manual...
  • Page 82 Figure 3-6: Internal Shipping Restraints Cut Cable Ties UPS Cover Transit Tape Air Fitting (under foam) Cut and remove the cable ties securing the waste chute funnel. Figure 3-7: Waste Chute Funnel Cut Cable Ties Waste Chute Funnel FORTUS 360mc/400mc Service Manual...
  • Page 83 Manually move the gantry (Y bridge) to verify full and free travel in the X and Y direction. Cut and remove the cable ties securing the Z stage end plates. Figure 3-9: Z Stage End Plates Cut Cable Ties FORTUS 360mc/400mc Service Manual...
  • Page 84 Connections must be secure and fully inserted into the fittings. Make sure all internal wiring connectors are fully seated. Remove the screws securing the UPS/PS tray and slide the tray out. Figure 3-12: UPS/PS Tray UPS Spacer Bracket FORTUS 360mc/400mc Service Manual...
  • Page 85 Slide the UPS/PS tray back into the system unit it contacts the UPS spacer bracket. Tighten the UPS spacer bracket screws. Inspect the back of computer making sure all connections are secure. Install the two flicker/brush assemblies from the Startup Kit. Figure 3-15: Flicker/Brush Assemblies Flicker/Brush Assemblies FORTUS 360mc/400mc Service Manual...
  • Page 86 Purge Ledge Check the flicker/brush height and adjust if necessary. (See “Tip Wipe Height Adjustment” on page 6-30.) Figure 3-17: Flicker/Brush Height Flicker/Brush Assembles If a large oven option was purchased, install the filament drive kit. FORTUS 360mc/400mc Service Manual 3-10...
  • Page 87 External Air Hose Connect the system to the RJ45 connection on the lower left back of the system. (See Figure 3-18.) Check XY gantry belt tensions at room temperature. (See “XY Gantry Belt Tension” on page 6-24.) FORTUS 360mc/400mc Service Manual 3-11...

  • Page 88: Ac Power Verification

    Open the high-voltage AC access door and make sure the incoming AC and ground lines are secure. Figure 3-19: System AC Power Connections Ground Close and secure the high-voltage AC access door and connect AC power to the system. FORTUS 360mc/400mc Service Manual 3-12...
  • Page 89 • C to GND:100 to 160 VAC Turn OFF the main circuit breaker and re-install the AC board safety cover. Warning: Verify that AC voltage is not present at the AC board before re-installing the safety cover. FORTUS 360mc/400mc Service Manual 3-13...

  • Page 90: Initial Power Up, Network Configuration And System Activation

    • The operator panel will display the following message when the computer boot up is complete: FDM 360mc or 400mc *Download a Setup Code to Proceed* >Network Configuration Obtain the setup code from the customer or from Stratasys. FORTUS 360mc/400mc Service Manual 3-14...
  • Page 91 IP address. > IP: [172.14.16.70] 195.165.30.15 Press Enter. Move the cursor down to “MASK:”. Enter the mask value and then press Enter. Move the cursor down to “GW:”. Enter the GW value and then press Enter. FORTUS 360mc/400mc Service Manual 3-15...
  • Page 92 Insight. Both Insight and Control Center software will be installed during this process. On the workstation, open the Control Center software (Start > Programs > Stratasys > Insight X.X > Control Center). Setup machine in “Manage FDM System”. Select Manage FDM System.
  • Page 93 Select a Network FDM System and then click Add System. If the UPnP is OFF, click Add Manually. Fill in the appropriate information for the system being connected to and click, Add System. Close the FDM System menu. FORTUS 360mc/400mc Service Manual 3-17...
  • Page 94 Send the Setup Code to the system. Select the Services Tab. Select the machine from the drop-down list. Select Setup Code. FORTUS 360mc/400mc Service Manual 3-18...
  • Page 95 Unlock Door Press Enter on the operator panel to perform the Autohome XYZ calibration. In the Control Center Services Tab, select System Time and update the system time to the current time in your zone. FORTUS 360mc/400mc Service Manual 3-19...

  • Page 96: Upgrade Controller Software

    360-400mc.upg • If downloaded from the Internet, the upgrade files are located in the ‘Stratasys’ folder on the workstation. Select the Upgrade file (.UPG file) from the dialog box and then press Enter. From the modeler, select Reboot and Install Software Upgrade <E> and then press Enter.

  • Page 97: System Verification And Calibration

    Load model and support material to the head. Perform an Auto Tip-to-Tip Calibration (Operator Control > Calibrate > AutoCal Tips). (See “Z Zero Calibrations” on page 6-3.) Perform the XYZ tip offset calibration. (See “XYZ Tip Offset” on page 6-6.) FORTUS 360mc/400mc Service Manual 3-21...

  • Page 98: Final Test

    • Support material around the perimeter edge should be smooth. • For BASS material, layer on underside of model should peel off easily. For PPSF, this check must be made before the model has cooled. FORTUS 360mc/400mc Service Manual 3-22...
  • Page 99 AREA C - Check quality of fill A (spokes) around holes. Complete all the fields in the System Installation Report Card. The Report Card should be submitted electronically and can be found on the Stratasys website. FORTUS 360mc/400mc Service Manual 3-23...

  • Page 100: Software

    Chapter 4: Software This chapter provides information on using Insight Software for the Fortus 360mc/400mc systems. Insight _______________________________________________________________ 4-2 Building a Part _____________________________________________________ 4-2 Start Insight ____________________________________________________ 4-2 Open an STL File _______________________________________________ 4-2 Modeler Set-Up ________________________________________________ 4-3 Prepare the Part _______________________________________________ 4-6...

  • Page 101: Insight

    Insight Building a Part Start Insight Select Start > Programs > Stratasys > InsightVxx > Insight. As an option, double-click the Insight desktop shortcut (if installed). Open an STL File Click File > Open. Select the directory that contains the file you wish to access. (See Figure 4-1.)

  • Page 102: Modeler Set-Up

    • Select the modeler from the Modeler Field. • Select a modeling material - the Support Material field will be automatically populated. • Select a model tip size - the Support Tip field and Slice Height field will be automatically populated. FORTUS 360mc/400mc Service Manual...
  • Page 103 Part Interior style - sets the interior of the part. • Solid - normal will be stronger. • Sparse - will build faster and use less material. • Sparse-double dense -fill increased density of internal sparse. Visible surface style • Normal enhanced FORTUS 360mc/400mc Service Manual...
  • Page 104 Support style - type of supports • SMART • Sparse • Basic • Surround • Breakaway Figure 4-4: Build Parameters Window STL Rotate Window FORTUS 360mc/400mc Service Manual...

  • Page 105: Prepare The Part

    Orient the Part • The Orient STL menu appears. • Click Rotate. • Select the rotation parameters in the STL Rotate Operation window (Figure 4-5). Figure 4-5: STL Rotate Window FORTUS 360mc/400mc Service Manual...
  • Page 106 Slice the Part The part must be sliced into layers that the system will extrude to construct the part. Click the Slice button. Red slice curves are displayed in the graphics window. Figure 4-6: Red Slice Curves Slice FORTUS 360mc/400mc Service Manual...
  • Page 107 Most parts require supports and a base to increase part stability while building. This also optimizes the surface finish of a part. Click the Support button. Gray slice curves are displayed in the graphics window. Figure 4-7: Gray Support Curves Support FORTUS 360mc/400mc Service Manual...
  • Page 108 The Flag button is a shortcut used to automate part preparation procedures. It will perform any of the following steps: • Slice the Part • Build Supports and a Base for the Part • Save the Job File • Create Toolpaths • Save the Toolpath (.CMB file) FORTUS 360mc/400mc Service Manual...
  • Page 109 • Click the Schedule Job button to add the job to the jobs schedule. Option Two: Select Jobs > Schedule Job... from the Menu Bar. • Use the Schedule Job window to add the job to the jobs schedule. FORTUS 360mc/400mc Service Manual 4-10...

  • Page 110: User Interface (Ui) Menu Structure

    15:12 3-Show Sample Job Queue >1) “Name of Sample Job” <E> 5:23 2) “Name of Sample Job” <E> 121:45 hr 3) “Name of Sample Job” <E> 15:12 4) “Name of Sample Job” <E> 121:45 hr FORTUS 360mc/400mc Service Manual 4-11...

  • Page 111: Load/Unload Material

    M1L:PPSF 92.0 in3 (Ready) >M2L:PC 91.6 in3 <E> (Loaded) S1L:PC_S 92.3 in3 (Ready) S2L:PPSF_S 41.4 in3 (Ready) 4-Material Status M: PC 92.3 in3(Ready) ** M: PC 67.1 in3(Loaded) S: PC_S 92.3 in3(Loaded) S: PC_S in3(Empty)1 FORTUS 360mc/400mc Service Manual 4-12...
  • Page 112 <E> 182.7 () Select Calibration Part Position.. Unlock Door <E> 5-Reset Tip Odometers (if user placement off) Reset Model in3 <E> 633.5 () Reset Supp. in3 <E> 182.7 () >Load and Calibrate.. Unlock Door <E> FORTUS 360mc/400mc Service Manual 4-13...

  • Page 113: Modeler Status

    3-Calibrate >Set Z Stage Zero.. | Calibration Job <E> AutoCal Tips <E> Tip Offset Value.. AutoHome XYZ <E> 4-Set Z Stage Zero >Manual Z Zero <E> Modify Current Z Zero.. Auto Z Zero Calibrate <E> FORTUS 360mc/400mc Service Manual 4-14...
  • Page 114 145° C <E> Cool Down Oven to: 85° C <E> >Auto Cool Oven: <E> 3-Move Head/Stage Move Head to Service Location <E> Move Head to Center-Front Location<E> Move Z Stage to Bottom <E> >Move Relative.. FORTUS 360mc/400mc Service Manual 4-15...

  • Page 115: Temperatures

    3-Material Status ** M: 56.4 in3 (Loaded) in3 (None) ** S: PC_S 21.4 in3 (Loaded) in3 (None) 3-Tip Status Material Amount *Model tip 0.0 in3 *Support tip : 0.0 in3 *Tips: Model <T16> Support <T16>.. FORTUS 360mc/400mc Service Manual 4-16...
  • Page 116 Filament at Model Head: -NOT Sensed- Filament at Support Head: -NOT Sensed- Tip Sensor: -ON- Vacuum Switch: -Vacuum or No Vacuum Model Fil: MotorOff:RevFilament EE Model Fil: MotorOff:RevNoFilament Supp Fil: MotorOff:RevFilament EE Supp Fil: MotorOff:RevFilament EE FORTUS 360mc/400mc Service Manual 4-17...
  • Page 117 Networking =YES Hostname = “400mc (SN)” PEERDNS = NO GATEWAY “xx.xx.xxx.1” PEERDNS = NO PEERDNS = NO PEERDNS = NO 4-UPS Status Status=(x) IPV=XXX.XX IPFV=XXX OPV=XXX.XX OPL=XXX.XX OPFreq=XX.XX BattV=XX.XX UPSTemp=XX.X Update=XX.XX CPUSPALETemp=N/A Ident=Invensys Powerware 5 FORTUS 360mc/400mc Service Manual 4-18...

  • Page 118: Maintenance

    Dynamic IP: NO <E> UpnP: ON <E> Configure Static Network Address 5-Configure Static Network Address (Dynamic IP=NO) >IP 172.16.70.10] MASK [255.255.0.0] [172.16.100.1] 4-Receive Software Upgrade or Code >Waiting for Software Upgrade or Code Press <MENU> key to Cancel FORTUS 360mc/400mc Service Manual 4-19...
  • Page 119 Enter Measured Distance: 00.000 PPU values current: 9021.0 new: 0.0 7-Move Relative Set Distance= 1.000 in <E> *Move Head: +X<6> -X<4> +Y<2> -Y<8> *Move Z Stage: +Z<9> -Z<3> *Current: X: 12.831 Y: 6.014 Z: 16.775 FORTUS 360mc/400mc Service Manual 4-20...
  • Page 120 Mod 280°C / 300°C Sup 300°C / 300°C 6-Set Purge Loc Go To Purge Loc <E> X: 18.990 Y: 6.079 Unlock Hood/Door <E> Set Distance= 0.100 in <E> Set Purge Loc: <E> X: 18.000 Y: 7.500 FORTUS 360mc/400mc Service Manual 4-21...
  • Page 121 Toggle Support Tip: <E> -Supp Tip UP- Toggle Hood/Door Solenoid -Lock Re- Test Bay Light.. 7-Filament Motor Bay-1 Fil Stopped Select Canister Number 0-3 Press <del> to Stop, <.> to Start Press <up/down> to Set Direction FORTUS 360mc/400mc Service Manual 4-22...
  • Page 122 Go to Purge LOC <E> xxx.xxx.xxx.xxx Go to Park Location <E> 6-EEPROM Deep Read Read Cassette EEPROM.. 7-Read Cassette Model 1 0.0 of 0.0 Model 2 ABS-M30 xxxxxxxxxxxxxxxxx 56.0 Supp 3 0.0 of 0.0 Supp 4 SR30 xxxxxxxxxxxxxxxxx 72.8.0 FORTUS 360mc/400mc Service Manual 4-23...

  • Page 123: Procedures

    4-Change Head *M ABS-M30 [L | L ] SR20 S Unload Model and Support Unlock Door <E> >Turn Off Head Power 4-Menu After Head Power Is Turned Off *OK to Install New Head Reboot System <E> FORTUS 360mc/400mc Service Manual 4-24...

  • Page 124: Service Procedures

    Chapter 5: Service Procedures This chapter describes the process of removing and replacing components and service assemblies for the Fortus 360mc/400mc systems. General _____________________________________________________________ 5-5 Panels ____________________________________________________________ 5-5 Panel Removal ________________________________________________ 5-6 Panel Installation_______________________________________________ 5-7 System Power Down/Power Up _____________________________________ 5-8...
  • Page 125 Platen ___________________________________________________________ 5-72 Platen Removal ______________________________________________ 5-72 Platen Installation _____________________________________________ 5-73 Electronic Components ______________________________________________ 5-74 Display Panel ____________________________________________________ 5-74 Display Panel Removal________________________________________ 5-74 Display Panel Installation ______________________________________ 5-75 AC Board ________________________________________________________ 5-75 AC Board Removal ___________________________________________ 5-75 FORTUS 360mc/400mc Service Manual...
  • Page 126 Tip Sensor/Cable Installation__________________________________ 5-110 Filament Path ______________________________________________________ 5-112 Filament Drive___________________________________________________ 5-112 Filament Drive Removal ______________________________________ 5-112 Filament Drive Installation ____________________________________ 5-114 Y Block _________________________________________________________ 5-116 Y Block Removal_____________________________________________ 5-116 Y Bock Installation ___________________________________________ 5-117 Internal Air Components ___________________________________________ 5-118 FORTUS 360mc/400mc Service Manual...
  • Page 127 Internal Vacuum Pump __________________________________________ 5-118 Internal Vacuum Pump Removal _____________________________ 5-118 Internal Vacuum Pump Installation____________________________ 5-119 Internal Air Compressor __________________________________________ 5-120 Internal Air Compressor Removal _____________________________ 5-120 Internal Air Compressor Installation ___________________________ 5-121 FORTUS 360mc/400mc Service Manual...

  • Page 128: General

    Top Center Panel Top Left Panel Upper Left Side Panel Top Right Panel Upper Right Side Panel Removal Not Needed Lower Left Side Panel Lower Right Middle Back Panel Torx Screw Lower Back Panel Side Panel Locations FORTUS 360mc/400mc Service Manual...

  • Page 129: Panel Removal

    After the top center panel has been removed the retaining screws can be removed from the remaining top panels so they can be removed from the system. FORTUS 360mc/400mc Service Manual...

  • Page 130: Panel Installation

    • Position the top center panel on the system. Make sure the sensor flag is aligned with the gap in the cover sensor and then install and tighten the screws. FORTUS 360mc/400mc Service Manual...

  • Page 131: System Power Down/Power Up

    Keep the button pressed until the fans turn off (the UPS will stop ‘beeping’) in approximately 4 to 5 seconds. Figure 5-2: UPS 5125 Power Switch Access (Lower Back Panel) Circuit Breaker UPS On Main Power UPS Off Breaker FORTUS 360mc/400mc Service Manual...

  • Page 132: System Power Up

    (upper button on right side of UPS panel). The UPS will power up by itself. For 5115 UPS systems - Press the power On button (green button) on the system front panel. The system will power up in approximately 5 minutes or less. FORTUS 360mc/400mc Service Manual...

  • Page 133: Operator Power Down/Power Up

    System Power Down procedure, use the System Power Up procedure. Procedure Press the Power On button (green button) on system front panel. The system will power up in approximately 5 minutes or less. FORTUS 360mc/400mc Service Manual 5-10...

  • Page 134: Oven Door Window

    5-8.) Carefully remove the eight outer window retaining screws (1/8-inch hex key) while supporting the window. Carefully remove the window panel from the door. Figure 5-4: Fortus 360mc/400mc Oven Door Glass 8 Retaining Screws Door with Window Panel Removed FORTUS 360mc/400mc Service Manual...

  • Page 135: Oven Door Window Installation

    Use care not to get the inside surfaces dirty during assembly. Carefully place the window panel in the proper location on the door and hold in place. Carefully install and tighten the eight outer window retaining screws (1/8-inch hex key). FORTUS 360mc/400mc Service Manual 5-12...

  • Page 136: Head

    Loosen the two head retaining screws (9/64-inch hex key). (See Figure 5-5.) Lift the head and place it in the head maintenance bracket. Secure the head to head maintenance bracket by tightening the retaining screws. Figure 5-5: Head Attachment Head Retaining Screws FORTUS 360mc/400mc Service Manual 5-13...

  • Page 137: Place Head In The Operating Position

    Loosen the retaining screws that secure the head to the head maintenance bracket. Lift the head and place it in the Y carriage assembly. Tighten the two head retaining screws. Close the gantry door and cover. FORTUS 360mc/400mc Service Manual 5-14...

  • Page 138: Head Cable

    • Move the carriage to straighten the chain for easier access. Figure 5-6: Energy Chain Link Separation Disconnect the head cable from the MIO board. Cut and remove the cable ties used to secure the cable. Remove the cable from the system. FORTUS 360mc/400mc Service Manual 5-15...

  • Page 139: Head Cable Installation

    Tube Tubing Tube Connect the head cable to head and then tighten the connector screws. Connect the head cable to MIO board and then tighten the connector screws. Replace the cable ties removed during disassembly. FORTUS 360mc/400mc Service Manual 5-16...

  • Page 140: Liquefier Tip

    5-13.) Loosen, but do not remove, the liquefier heater block clamp screws. Figure 5-8: Heater Block and Tip Liquefier Heater Liquefier Heater lock Clamp Screws Block Clamp Screws Remove the tip from the liquefier. FORTUS 360mc/400mc Service Manual 5-17...

  • Page 141: Liquefier Tip Installation

    Figure 5-9: Liquefier Tip Pin Liquefier Tip Holding Pin Liquefier Tip Grove Tighten the liquefier heater block clamp screws. Snug the screws at first and then completely tighten the screws. FORTUS 360mc/400mc Service Manual 5-18...

  • Page 142: Head

    “Liquefier Tip Removal” on page 5-17) The tips do not need to be removed if the head is not being replaced. Remove the head assembly from the head maintenance bracket by loosening the two head retaining screws. FORTUS 360mc/400mc Service Manual 5-19...

  • Page 143: Head Installation

    Power up the system. (See “System Power Up” on page 5-9.) Load material. Run the AutoCal Tips calibration. (See “AutoCal Tips” on page 6-5.) Run the XYZ Tip Offset calibration. (See “XYZ Tip Offset” on page 6-6.) FORTUS 360mc/400mc Service Manual 5-20...

  • Page 144: Xy Gantry

    Disconnect the wiring harness from the fan to be removed. (See Figure 5-19 on page 5- 36.) Remove the four fan retaining screws (7/64-inch hex key) and washers and then remove the fan and guard. FORTUS 360mc/400mc Service Manual 5-21...

  • Page 145: Gantry Cooling Fans Installation

    Connect the fan wiring harness to the fan. Power up the system. (See “System Power Up” on page 5-9.) Make sure that left side fans are moving air into system and the right side fans are pushing air out of the system. FORTUS 360mc/400mc Service Manual 5-22...

  • Page 146: Y Carriage Kapton Barrier

    Using a pliers, peel the existing Kapton barrier from the heat shield in the Y carriage. Figure 5-11: Kapton Barrier Installation Kapton Barrier Installed Here Y Carriage Assembly With Head Removed Gently scrape the remaining adhesive material from the heat shield. Install a new Kapton barrier. FORTUS 360mc/400mc Service Manual 5-23...

  • Page 147: And Y Belt

    Remove both ends of each belt from the tensioners by removing two belt clamp screws (3/32-inch hex key). Figure 5-12: Belt Tension Clamp Belt Clamp Screws Tensioner Belt Remove the two belts from the system. FORTUS 360mc/400mc Service Manual 5-24...
  • Page 148 Figure 5-13: X and Y Belt/Pulley Diagram X-Axis Belt/Pulley/Diagram X Motor Pulley Right X-Axis Belt Tensioner Left X-Axis Belt Tensioner Y-Axis Belt/Pulley/Diagram Y Motor Pulley Back Y-Axis Belt Tensioner Front Y-Axis Belt Tensioner FORTUS 360mc/400mc Service Manual 5-25...

  • Page 149: And Y Belt Installation

    Make sure the locating rod on the XY gantry slides into bore of the tensioner. Thread the Y belt through the pulleys. (See (Figure 5-13 on page 5-25)) Attach the free end of the Y belt to a tensioner. Tighten the clamp bolts. FORTUS 360mc/400mc Service Manual 5-26...
  • Page 150 Allow the system to temperature stabilize. (See Table 2-7 on page 2-16.) Verify the belt tension is within specification according to the temperature chart. (See Table 6-2 on page 6-25.) Perform a PPU/Scaling Calibration. (See “PPU/Scaling Calibration” on page 6-10.) FORTUS 360mc/400mc Service Manual 5-27...

  • Page 151: And Y Pulley

    This will create enough slack in the built to allow pulleys to be removed. Loosen the axle bolt of the pulley to be replaced (1/8-inch hex key) and remove the pulley from the XY table. Remove the axle bolt from the pulley. FORTUS 360mc/400mc Service Manual 5-28...

  • Page 152: And Y Pulley Installation

    Repeat step 1. through step 4. for all replacement pulleys. Verify proper routing of the belts and reattach the removed belt tensioners to the mount blocks. (See “X and Y Belt Installation” on page 5-26.) FORTUS 360mc/400mc Service Manual 5-29...
  • Page 153 Verify the belt tension is within specification according to the temperature chart. (See “X & Y Belt Tension Settings 5mm belt with zinc colored spring installed in belt tension gauge” on page 6-25.) Perform a PPU/Scaling Calibration. (See “PPU/Scaling Calibration” on page 6-10.) FORTUS 360mc/400mc Service Manual 5-30...

  • Page 154: And Y Motor

    Cut and remove the cable ties that hold the motor cables to the system frame. Disconnect the motor power and the encoder harnesses from the MIO board. Remove the four motor mount screws (5/32-inch hex key). Remove the motor assembly from the system. FORTUS 360mc/400mc Service Manual 5-31...

  • Page 155: And Y Motor Installation

    “Panel Installation” on page 5-7.) Adjust belt tension for X and Y drive belts. (See “XY Gantry Belt Tension” on page 6-24.) Power up the system. (See “System Power Up” on page 5-9.) Load material. FORTUS 360mc/400mc Service Manual 5-32...
  • Page 156 Verify the belt tension is within specification according to the temperature chart. (See Table 6-2 on page 6-25.) Install back and side panels. (See “Panel Installation” on page 5-7.) Perform a PPU/Scaling Calibration. (See “PPU/Scaling Calibration” on page 6-10.) FORTUS 360mc/400mc Service Manual 5-33...

  • Page 157: And Y Bellows

    Placing the head in the head maintenance bracket may make it easier to access locknuts. (See “Head Maintenance Position” on page 5-13.) Remove the bellows assembly. Figure 5-18: Bellows Assemblies X Bellows Mounting Rail Y Bellows Mounting Rail FORTUS 360mc/400mc Service Manual 5-34...

  • Page 158: And Y Bellow Installation

    Place the head in the operating position if necessary. (See “Place Head in the Operating Position” on page 5-14.) Manually push the XY gantry through the full travel of the X and Y movement to check for binding. FORTUS 360mc/400mc Service Manual 5-35...

  • Page 159: Y Bridge

    Figure 5-19: Exhaust Fan Electrical Connector Loosen, but do not remove, the 3 screws using a 5/32-inch hex key that hold the left side fan bank to the system frame. Remove the left side gantry fan bank from the system. FORTUS 360mc/400mc Service Manual 5-36...
  • Page 160 Remove the 8 nuts (4 nuts on each side) that hold the X bellows to Y bridge using an 11/ 32-inch open end wrench. Remove energy chain from the Y carriage by removing 2 screws using a 3/16-inch hex key. Figure 5-20: Energy Chain/Y Carriage Y Carriage Screws (2X) FORTUS 360mc/400mc Service Manual 5-37...
  • Page 161 Remove the 8 shoulder screws (5/32-inch hex key) with spring washers that attach the Y bridge to the rear X-axis linear bearings. Figure 5-21: Y Bridge Screw Location Shoulder Screws with Spring Washers (8X) Screws (8X) Lift the Y bridge from the system. FORTUS 360mc/400mc Service Manual 5-38...
  • Page 162 Remove the Y bridge heat shield using a 5/32-inch hex key. The heat shield will be reused. Remove the Y carriage heat shield by using a 9/64-inch hex key. The heat shield will be reused. Remove the front and rear Y bridge pulley assemblies to be reused. FORTUS 360mc/400mc Service Manual 5-39...

  • Page 163: Y Bridge Installation

    (See Figure 5-23). Figure 5-23: Rear Shoulder Bolt Attach the Y-bridge to the front X-axis linear bearings with the 8 front Y-bridge mounting screws. Do not tighten the bolts at this time. FORTUS 360mc/400mc Service Manual 5-40...
  • Page 164 Attach the T-Class gantry Squaring Fixture on the XY plate by aligning the pins on the fixture with the holes in the XY plate and tightening the two fixture retaining screws. Figure 5-25: Squaring Fixture Installation Fixture Retaining Screws XY Plate Alignment Pins (2X) Tabs (2X) FORTUS 360mc/400mc Service Manual 5-41...
  • Page 165 Using two clamps, secure the Y bridge assembly to the squaring fixture Make sure the two clamps are securely holding the Y bridge fixture to the squaring fixture. Figure 5-27: Fixture Clamps Squaring Clamp Fixture Y Bridge FORTUS 360mc/400mc Service Manual 5-42...
  • Page 166 Install the left and right upper side panels. (See “Panel Installation” on page 5-7.) Run the XYZ Tip Offset Calibration. (See “XYZ Tip Offset” on page 6-6.) Run the PPU/Scaling Calibration. (See “PPU/Scaling Calibration” on page 6-10.) FORTUS 360mc/400mc Service Manual 5-43...

  • Page 167: X-Axis Guide Rod/Pillow Block

    Disconnect electrical connectors to left hand side exhaust fans by pulling on the connector. Figure 5-28: Exhaust Fan Electrical Connector Loosen, but do not remove, the 3 screws that hold the left side fan bank to the system frame using a 5/32-inch hex key. FORTUS 360mc/400mc Service Manual 5-44...
  • Page 168 Remove the 8 nuts (4 nuts on each side) that hold the X bellows to Y bridge using an 11/ 32-inch wrench. Remove energy chain from the Y carriage by removing 2 screws using a 9/64-inch hex key. Figure 5-29: Energy Chain/Y Carriage Y Carriage Screws (2X) FORTUS 360mc/400mc Service Manual 5-45...
  • Page 169 Remove the 8 shoulder screws with spring washers that attach the Y bridge to the rear X- axis linear bearings using a 5/32-inch hex key. Remove the Y bridge from the system. Figure 5-30: Y Bridge Screw Location Shoulder Screws with Spring Washers (8X) Screws (8X) FORTUS 360mc/400mc Service Manual 5-46...
  • Page 170 Figure 5-32: X-Axis Guide Rod Do Not Remove These Screws Screws (18X) X-Axis Guide Rod Newer systems have 4 screws (rather than 3) attaching the rail to the standoff. Remove the X-axis guide rod assemblies from the system. FORTUS 360mc/400mc Service Manual 5-47...

  • Page 171: X-Axis Guide Rod/Pillow Block Bearing Installation

    Place the X-axis guide rods in the system so the bearing grease ports face to the center of the system. Install the screws into the X rails. Snug up each screw and then back out ½ turn. FORTUS 360mc/400mc Service Manual 5-48...
  • Page 172 XY plate and tightening the two fixture retaining screws. (See Figure 5-25 on page 5-41.) Position the Y bridge so the tabs of the squaring fixture contact the Y rail. (See Figure 5-26 on page 5-42.) FORTUS 360mc/400mc Service Manual 5-49...
  • Page 173 Tighten the eight front Y bridge mounting screws using a 3/32-inch hex key. Remove the T-Class gantry Squaring Fixture from the system. Attach the X bellows to the Y bridge using an 11/32-inch open end wrench. Install the X-axis home hard stop using a 5/32-inch hex key. FORTUS 360mc/400mc Service Manual 5-50...
  • Page 174 Install the X and Y drive belts. (See “X and Y Belt Installation” on page 5-26.) Tension the XY gantry belts. (See “XY Gantry Belt Tension” on page 6-24.) Install the head maintenance bracket using a 5/32-inch hex key. FORTUS 360mc/400mc Service Manual 5-51...
  • Page 175 Install the left and right upper side panels. (See “Panel Installation” on page 5-7.) Run the XYZ Tip Offset Calibration. (See “XYZ Tip Offset” on page 6-6.) Run the PPU/Scaling Calibration. (See “PPU/Scaling Calibration” on page 6-10.) FORTUS 360mc/400mc Service Manual 5-52...

  • Page 176: Z Stage

    Z stage motor to the adjusting plate (5/32-inch hex key). (See Figure 5-36 on page 5-54.) Remove the motor assembly from the system. FORTUS 360mc/400mc Service Manual 5-53...
  • Page 177 Figure 5-36: Z Motor Wiring Orientation Back View of System Adjusting Plate Bottom View Z Motor Wiring Connections Z Motor Mounting Screw (4X) FORTUS 360mc/400mc Service Manual 5-54...

  • Page 178: Z Drive Motor Installation

    Perform the Platen Level Adjustment. (See “Platen Level Adjustment” on page 6-12.) If the platen level was adjusted, perform the Upper Z Stage Hard Stop Adjustment. (See “Upper Z Stage Hard Stop Adjustment” on page 6-16.) FORTUS 360mc/400mc Service Manual 5-55...

  • Page 179: Lead Screw Assembly

    Upper Bearing Housing Screws Upper Bearing Housing Thrust Bearing Shim Nilos-Ring Spring Flat Washer Lead Screw Nut Mount Teflon Pad Preload Collar Nut Flange Shoulder Screws Snap Ring Nilos-Ring Shim Thrust Bearing Trantorque Coupler Pulley FORTUS 360mc/400mc Service Manual 5-56...

  • Page 180: Z Lead Screw Removal

    Remove the two shoulder screws (5/32-inch hex key) holding the nut mount to the lead screw assembly and remove the nut mount from the lead screw assembly. Follow steps 6 through 12 to remove the second lead screw FORTUS 360mc/400mc Service Manual 5-57...

  • Page 181: Z Lead Screw Installation

    Adjust the ball plunger ½ turn out so the ball protrudes from the end plate. A ½ turn will cause the plunger to protrude 0.020-inch to 0.030-inch from the end plate. Figure 5-38: Ball Plunger Adjustment Side View Front View Flush Ball Plungers 0.020-inch to 0.030-inch FORTUS 360mc/400mc Service Manual 5-58...
  • Page 182 Install the nut mount onto the lead screw and fasten in place using the two shoulder screws. Using a snap ring pliers, install the snap ring in the groove on the lower end of the lead screw. The snap ring grove is at the end of the lead screw threads. FORTUS 360mc/400mc Service Manual 5-59...
  • Page 183 Install the lead screw in the system. Insert the upper end of the lead screw through the upper frame and lower the lead screw into place in the lower frame. Install a flat washer onto upper end of lead screw. FORTUS 360mc/400mc Service Manual 5-60...
  • Page 184 Install the upper bearing housing and fasten with 4 screws. Use an alternating pattern when tightening the screws to maintain even spring pressure on the bearing housing. Install the upper bearing dust cover. FORTUS 360mc/400mc Service Manual 5-61...
  • Page 185 Perform the Platen Level Adjustment. (See “Platen Level Adjustment” on page 6-12.) If the platen level was adjusted, perform the Upper Z Stage Hard Stops Adjustment. (See “Upper Z Stage Hard Stop Adjustment” on page 6-16.) FORTUS 360mc/400mc Service Manual 5-62...

  • Page 186: Z Guide Rod/Pillow Block

    Figure 5-43: Guide Rod Assembly Component Locations Rod End Support Guide Rod Grease Fittings (4X) Pillow Block Z Stage End Plate Rod End Support Rod End Support Mounting Screws (8X) Clamp Screws FORTUS 360mc/400mc Service Manual 5-63...

  • Page 187: Z Guide Rod/Pillow Block Removal

    Slide the guide rod and rod end supports away from the Z stage. Remove the rod end supports from the guide rod. Remove the grease Zerk from the old bearing assemblies to be used on the new bearings. FORTUS 360mc/400mc Service Manual 5-64...

  • Page 188: Z Guide Rod/Pillow Block Installation

    Install the rod end supports onto each end of the guide rod. Figure 5-44: Lower Z Stage Hardware Lead Screw All Grease Fittings Must Face Away from the Lead Screw Pillow Block Rod End Supports End Clamp Screws FORTUS 360mc/400mc Service Manual 5-65...
  • Page 189 “Platen Level Adjustment” on page 6-12.) If the platen level was adjusted, perform the Upper Z Stage Hard Stops Adjustment. (See “Upper Z Stage Hard Stop Adjustment” on page 6-16.) Reinstall side panels. (See “Panel Installation” on page 5-7.) FORTUS 360mc/400mc Service Manual 5-66...

  • Page 190: Z Stage Drive Belt

    Turn the belt tension adjusting screw to reduce belt tension (3/16-inch hex key). Reduce the tension until the belt can be removed. Remove the belt from the pulleys. Figure 5-46: Z Stage Belt Tension Adjustment Motor Mount Adjusting Plate Screws Locknut Tension Adjusting Screw FORTUS 360mc/400mc Service Manual 5-67...

  • Page 191: Z Stage Drive Belt Installation

    6-12.) If the platen level was adjusted, perform the Upper Z Stage Hard Stops Adjustment. (See “Upper Z Stage Hard Stop Adjustment” on page 6-16.) Reinstall the side panels. (See “Panel Installation” on page 5-7.) FORTUS 360mc/400mc Service Manual 5-68...

  • Page 192: Z Stage Idler Pulley

    Remove the Z stage drive belt. (See “Z Stage Drive Belt Removal” on page 5-67.) Loosen the axle bolt of the pulley to be replaced (1/8-inch hex key) and remove the pulley. Remove the axle bolt from the pulley. FORTUS 360mc/400mc Service Manual 5-69...

  • Page 193: Z Stage Idler Pulley Installation

    6-12.) If the platen level was adjusted, perform the Upper Z Stage Hard Stops Adjustment. (See “Upper Z Stage Hard Stop Adjustment” on page 6-16.) Reinstall the side panels. (See “Panel Installation” on page 5-7.) FORTUS 360mc/400mc Service Manual 5-70...

  • Page 194: Platen Vacuum Screen

    Place the retaining ring into the platen with the concave side up. Retaining Ring Screen Use a socket to push the retaining ring into the platen. Make sure the retaining ring is secure in the platen. FORTUS 360mc/400mc Service Manual 5-71...

  • Page 195: Platen

    Remove the vacuum table mount screws from the underside of the platen (1/8-inch hex key). The mount screws are part of a spring assembly. They are located at the front left, front right, and back center of the platen. Lift the platen out of the system. FORTUS 360mc/400mc Service Manual 5-72...

  • Page 196: Platen Installation

    “Vacuum Screen Installation” on page 5-71.) Perform the Platen Level Adjustment. (See “Platen Level Adjustment” on page 6-12.) Perform the Upper Z Stage Hard Stops Adjustment. (See “Upper Z Stage Hard Stop Adjustment” on page 6-16.) FORTUS 360mc/400mc Service Manual 5-73...

  • Page 197: Electronic Components

    Disconnect the display interface cable from the display assembly. Remove the four display mounting nuts from the back of the display assembly (11/32- inch open end wrench). Remove the display assembly. Figure 5-50: Display Panel Removal Display Mounting Nuts FORTUS 360mc/400mc Service Manual 5-74...

  • Page 198: Display Panel Installation

    If the system has been disconnected from its AC voltage source, the system frame will not be a proper ground. Attach the wrist strap to a known good ground such as a steel electrical conduit. FORTUS 360mc/400mc Service Manual 5-75...
  • Page 199 Caution: Do not remove the ESD wrist strap until the AC board is placed in a static protection bag. Carefully lift the AC board from the system. Place the AC board in a static protection bag. FORTUS 360mc/400mc Service Manual 5-76...

  • Page 200: Ac Board Installation

    Tighten the eleven mounting screws. Improper grounding of the AC board can cause intermittent machine operation problems. Intermittent problems may result if all eleven mounting screws are not installed and properly tightened. FORTUS 360mc/400mc Service Manual 5-77...

  • Page 201: Mio Board

    MIO board. Do not remove the ESD wrist strap until the MIO board is placed in a static protection bag. Carefully lift the MIO board from the system. Place the MIO board in a static protection bag. FORTUS 360mc/400mc Service Manual 5-78...

  • Page 202: Mio Board Installation

    Table 5-1: MIO Connectors Connector Description MIO Board Connector Head Cable AC Board Interface cable Cassette Interface cable Oven Thermal Fuse Oven Thermocouple Tip Sensor Amplifier Cone Sensor Switch Vacuum Switch Z Homing Switch Power Supply Cable FORTUS 360mc/400mc Service Manual 5-79...
  • Page 203 Y-Axis Motor Power Cable Install the cable ties removed during disassembly. Install the lower back panel. (See “Panel Installation” on page 5-7.) Power up the system to verify operation. (See “System Power Up” on page 5-9.) FORTUS 360mc/400mc Service Manual 5-80...

  • Page 204: 24/48 Volt Power Supply

    Label and remove all wiring connections from the 24/48 volt power supply. (See Figure 5-54 on page 5-83.) Remove four 24/48 volt power supply mounting screws (#2 Phillips screwdriver). Carefully lift the 24/48 volt power supply from the system. FORTUS 360mc/400mc Service Manual 5-81...

  • Page 205: 24/48 Volt Power Supply Installation

    Install the lower back panel. (See “Panel Installation” on page 5-7.) Power up the system to verify operation. (See “System Power Up” on page 5-9.) Figure 5-53: UPS and 24/48 Volt Power Supply Tray Tray FORTUS 360mc/400mc Service Manual 5-82...
  • Page 206 Green Black 24/48 Volt Power Supply 24/48 Volt Power Supply Mounting Screws - 2 at front, 2 at back of unit. UPS Mounting Screws - 2 at the left and2 at the right of unit. FORTUS 360mc/400mc Service Manual 5-83...

  • Page 207: Ups

    “Panel Installation” on page 5-7.) Power up the system to verify operation. (See “System Power Up” on page 5-9.) Power down the system to verify proper shut-down sequence. (See “System Power Down” on page 5-8.) FORTUS 360mc/400mc Service Manual 5-84...

  • Page 208: Computer

    Loosen, but do not remove, the four computer mounting screws (9/64-inch hex key). Remove the computer from the system by sliding the computer toward the back of the system and then carefully lift the computer out of the system. FORTUS 360mc/400mc Service Manual 5-85...

  • Page 209: Computer Installation

    Load the controller software. (See “Upgrade Controller Software” on page 3-20.) Install the side panels. (See “Panel Installation” on page 5-7.) Run the XYZ Tip Offset calibration to verify system operation. (See “XYZ Tip Offset” on page 6-6.) FORTUS 360mc/400mc Service Manual 5-86...

  • Page 210: Oven Components

    Remove the old Kapton barrier from the upper waste chute funnel. Install the new Kapton barrier onto the upper waste chute funnel. Figure 5-56: Kapton Barrier Installation Kapton Barrier Heat Shield Reinstall the upper waste chute funnel into the system. FORTUS 360mc/400mc Service Manual 5-87...

  • Page 211: Oven Blower

    “Panel Removal” on page 5-6.) Remove the lower and middle back covers. (See “Panel Removal” on page 5-6.) Remove two oven blanket nuts (7-16-inch open end wrench) and washers. Figure 5-57: Oven Blanket Oven Blanket Nuts and Washers FORTUS 360mc/400mc Service Manual 5-88...
  • Page 212 Mark and disconnect the blower wiring harness from the blowers. Remove the five oven blower motor assembly screws using a T-25 Torx wrench. Figure 5-58: Oven Blower Motor Assembly Oven Blower Assembly Oven Blower Motor Assembly Screws Bottom View FORTUS 360mc/400mc Service Manual 5-89...
  • Page 213 Blower Mount Gasket Mounting Screws (3X) Remove the six blower mounting screws (three for each blower) using a 1/4-inch nut driver. Separate the two blowers and two blower gaskets from the mounting plate. Discard the gaskets. FORTUS 360mc/400mc Service Manual 5-90...

  • Page 214: Oven Blower Installation

    Blower Mount Gasket Mounting Screws (3X) Install the gasket and blower/mount assembly into system. Install and tighten five mounting screws. Make sure the blower mount gasket is properly seated between the blower mount and oven. FORTUS 360mc/400mc Service Manual 5-91...
  • Page 215 Make sure that the oven blanket does not interfere with the blowers or the Z stage end plate. Power up the system. (See “System Power Up” on page 5-9.) Verify the oven blower operation. Install the panels. (See “Panel Installation” on page 5-7.) FORTUS 360mc/400mc Service Manual 5-92...

  • Page 216: Oven Thermocouple

    Remove the two thermocouple mounting screws (T-10 Torx wrench). Remove the thermocouple/thermocouple wiring from the system by pulling the wire and plug into the oven through the oven Z stage seals. Figure 5-62: Oven Thermocouple Oven Thermocouple (viewed from above) FORTUS 360mc/400mc Service Manual 5-93...

  • Page 217: Oven Thermocouple Installation

    Left Bellows Rail Secure the thermocouple to the bracket beneath the X-axis bellows with two mounting screws. • Before tightening, route the wiring below the bracket and then up behind the bracket in the corner gap. FORTUS 360mc/400mc Service Manual 5-94...
  • Page 218 Plug the thermocouple wiring into the MIO board. Power up the system and verify that oven temperature control functions properly. (See “System Power Up” on page 5-9.) Install the panels. (See “Panel Installation” on page 5-7.) FORTUS 360mc/400mc Service Manual 5-95...

  • Page 219: Oven Thermal Circuit Breaker

    Remove the thermal breaker (3) from the breaker mount by removing the retaining nut and bracket (14mm open end wrench. Figure 5-65: Thermal Breaker Installation 1. Sensor Bracket 2. Clamps 3. Breaker 4. Nut and Bracket Breaker and Sensor Bracket FORTUS 360mc/400mc Service Manual 5-96...

  • Page 220: Oven Thermal Circuit Breaker Installation

    Press the circuit breaker button to make sure it is reset. Move oven blankets back into place and reinstall nuts previously removed. Power up the system. (See “System Power Up” on page 5-9.) Install the right upper side panel. (See “Panel Installation” on page 5-7.) FORTUS 360mc/400mc Service Manual 5-97...

  • Page 221: Oven Heaters

    Remove one nut that secures the heater cable clamp using a 7/16-inch wrench. (See Figure 5-67.) Loosen the two screws (Phillips screwdriver) on the wiring harness clamp so the heater wiring is loose in the clamp. Figure 5-67: Wiring Harness Clamps Wiring Harness Clamp Heater Cable Clamp FORTUS 360mc/400mc Service Manual 5-98...
  • Page 222 (3X) Lower the platen to the lowest position. Remove one mounting nut through the waste chute funnel access hole. (See Figure 5-69.) Figure 5-69: Waste Chute Funnel Access Waste Chute Funnel Access Hole Mounting Nut FORTUS 360mc/400mc Service Manual 5-99...
  • Page 223 Remove the remaining six mounting screws (T-25 Torx wrench) that attach the oven heater assembly to the chassis of the system. Place a build sheet on the platen to protect it from being damaged by the oven heater assembly. FORTUS 360mc/400mc Service Manual 5-100...
  • Page 224 Remove the two nuts securing the electrical connections on the defective heater(s). (See Figure 5-72.) Remove the two mounting screws securing the defective heater(s) to the oven heater assembly and remove heater(s) from the system. (See Figure 5-74 FORTUS 360mc/400mc Service Manual 5-101...
  • Page 225 Figure 5-72: Oven Heaters Mounting Screws (2X) Heater Electrical Wiring Connections Oven Heater Plate FORTUS 360mc/400mc Service Manual 5-102...

  • Page 226: Oven Heaters Installation

    Position the heater wiring in the wiring harness clamp and then tighten the two screws (Phillips screwdriver). Make sure not to pinch the wiring. Using one nut (7-16-inch wrench), attach the heater cable clamp to the oven. FORTUS 360mc/400mc Service Manual 5-103...

  • Page 227: Oven Blanket (Right Side)

    Remove the two bottom nuts and washers that hold the oven blanket to the oven. Also, remove one nut, washer and cable clamp that hold the oven blanket to the oven. (See Figure 5-73.) FORTUS 360mc/400mc Service Manual 5-104...
  • Page 228 Manually lower the Z stage to the bottom of its travel. Remove the remaining four nuts and washers that hold the oven blanket to the oven. (See Figure 5-74.) FORTUS 360mc/400mc Service Manual 5-105...
  • Page 229 Figure 5-74: Upper Oven Blanket Removal Remove Nuts and Washers Maneuver the oven blanket away from the remaining four oven studs and then discard the oven blanket. FORTUS 360mc/400mc Service Manual 5-106...

  • Page 230: Oven Blanket (Right Side) Installation

    UPS is not powered off. Remove the upper and lower left side panels. (See “Panel Installation” on page 5-7.) Remove the eight nuts (7/16-inch wrench) and washers that hold the oven blanket to the oven. (See Figure 5-75.) FORTUS 360mc/400mc Service Manual 5-107...

  • Page 231: Oven Blanket (Left Side) Installation

    • Install the new blanket in the reverse order of the steps above. Taking care not to rip or tear the new oven blanket on any of the oven studs. Also, check to make sure the Z stage is not rubbing against the oven blanket. FORTUS 360mc/400mc Service Manual 5-108...

  • Page 232: Tip Sensor/Tip Sensor Cable

    Remove the terminal contact screw (7/64-inch hex key) that attaches the tip sensor cable to the sensor. Figure 5-76: Tip Sensor Replacement Route the Wire Through the Hole in the Body of the Sensor Terminal Connection Screws Cable Clamp Route Cable Through the Back of the Oven FORTUS 360mc/400mc Service Manual 5-109...

  • Page 233: Tip Sensor/Cable Installation

    Z stage support arm. Feed the tip sensor cable under the cable clamp. Caution: Use care when tightening cable clamp. Do not pinch the tip sensor cable between the clamp and the system frame. FORTUS 360mc/400mc Service Manual 5-110...
  • Page 234 Power up the system. (See “System Power Up” on page 5-9.) Perform an AutoCal Tips Calibration. (See “AutoCal Tips” on page 6-5.) Perform an XYZ Tip Offset Calibration. (See “XYZ Tip Offset” on page 6-6.) FORTUS 360mc/400mc Service Manual 5-111...

  • Page 235: Filament Path

    Disconnect the interface cable from the filament drive. Support the filament drive from the underside. Remove the detent lever from the affected filament drive (3/4-inch open end wrench). FORTUS 360mc/400mc Service Manual 5-112...
  • Page 236 Make sure the washers and springs on the alignment rods do not fall into the system. Remove washers and springs from the filament drive alignment rods. Save the washers and springs for re-assembly. Disconnect the filament tube from the filament drive. Save the tube for re-assembly. FORTUS 360mc/400mc Service Manual 5-113...

  • Page 237: Filament Drive Installation

    Guide the filament tube up through the center hole in the filament drive support, while sliding the filament drive into position. Figure 5-79: Filament Drive Filament Tube Washer (2X) Interface Cable Connection Spring (2X) Alignment Pin (2X Detent Lever FORTUS 360mc/400mc Service Manual 5-114...
  • Page 238 Install the LED fascia panel. There are 3 screws that use a 5/32-inch hex key and 2 screws that use a 1/8-inch hex key. Power up the system. (See “System Power Up” on page 5-9.) Perform the filament load time test. (See “Filament Drive Load Time Test” on page 8-8.) FORTUS 360mc/400mc Service Manual 5-115...

  • Page 239: Y Block

    Remove the Y block mounting screws using a 5/32-inch hex key and remove the Y block from the system. Figure 5-80: Y Block and Fix Labels Filament Tubes From Canisters Mounting Screws Push In To Release Tube Filament Tube To Head Air Dryer Tube FORTUS 360mc/400mc Service Manual 5-116...

  • Page 240: Y Bock Installation

    Y block. The tubes should stay attached. Install the middle back panel. (See “Panel Installation” on page 5-7.) Power up the system. (See “System Power Up” on page 5-9.) FORTUS 360mc/400mc Service Manual 5-117...

  • Page 241: Internal Air Components

    Remove four vacuum pump mounting nuts (7/16-inch wrench open end wrench) from the underside of the mounting bracket. Remove the pump from the system. Figure 5-82: Vacuum Pump Vacuum Tube Connection Electrical Connector Vacuum Pump Mounting Nuts (4X) FORTUS 360mc/400mc Service Manual 5-118...

  • Page 242: Internal Vacuum Pump Installation

    Make sure the vacuum tubes are securely fastened to the fittings. Install the upper and lower right side panels. (See “Panel Installation” on page 5-7.) Power up the system. (See “System Power Up” on page 5-9.) FORTUS 360mc/400mc Service Manual 5-119...

  • Page 243: Internal Air Compressor

    Disconnect the air tubes from the quick disconnect compressor fitting. Remove the four air compressor mounting nuts (7/16-inch wrench) from the underside of the mounting bracket. Remove the compressor from the system. Figure 5-83: Air Compressor Air Tube Connection Electrical Connection FORTUS 360mc/400mc Service Manual 5-120...

  • Page 244: Internal Air Compressor Installation

    Install the upper and lower left side panels. (See “Panel Installation” on page 5-7.) Power up the system. (See “System Power Up” on page 5-9.) Adjust air pressure and air flow. (See “Air Pressure and Air Flow Adjustment” on page 6-34.) FORTUS 360mc/400mc Service Manual 5-121...

  • Page 245: Calibrations

    Chapter 6: Adjustments and Calibrations This chapter describes the hardware calibration and adjustment procedures for the Fortus 360mc/400mc systems. Calibrations__________________________________________________________ 6-2 Autohome XYZ ____________________________________________________ 6-2 Z Zero Calibrations _________________________________________________ 6-3 Manual Z Zero Calibration ______________________________________ 6-3 Auto Z Zero Calibration _________________________________________ 6-4...

  • Page 246: Autohome Xyz

    X and Y axis will move to their end of travel positions. Procedure From the Main Menu on the operator control panel select: Operator Control > Calibrate > Autohome XYZ. Allow the system home. Homing will complete automatically. FORTUS 360mc/400mc Service Manual...

  • Page 247: Z Zero Calibrations

    Figure 6-1: Manual Z Zero Calibration Model Tip Build Sheet Model Tip Reflection Select Set Z Stage = 0 and press enter. Run the Auto Z Zero Calibration. (See “Auto Z Zero Calibration” on page 6-4). FORTUS 360mc/400mc Service Manual...

  • Page 248: Auto Z Zero Calibration

    From the Main Menu on the operator control panel select: Operator Control > Calibrate > Set Z Stage Zero > Auto Z Zero Calibrate. Allow the system to perform the calibration. If the calibration fails perform the Manual Z Zero Calibration. (See “Manual Z Zero Calibration” on page 6-3.) FORTUS 360mc/400mc Service Manual...

  • Page 249: Tip Offset Calibrations

    From the Main Menu on the system go to: Operator Control > Calibrate > AutoCal Tips. The system will proceed to run the calibration (approximately 5 minutes) and will display “Calibration Done” when it has completed. FORTUS 360mc/400mc Service Manual...

  • Page 250: Xyz Tip Offset

    • The X and Y values found on the calibration job must be at or under 2 or 0.002 in. (0.05 mm) to be within tolerance. • In order to continue to the Z offset value the X and Y must be at or under 2 or 0.002 in. (0.05 mm). FORTUS 360mc/400mc Service Manual...
  • Page 251 The support road is not entered at the Zero, so an adjustment will be needed. Model Road The support road is best entered between the model roads at the 6, indicating an adjustment of X = 0.006. Centered FORTUS 360mc/400mc Service Manual...
  • Page 252 Measure the thickness of the support layer on each side of the square with a caliper or micrometer. Measure in the center of each side. Measuring near the corners will result in inaccurate values. Figure 6-5: Support Road Measurement Points Measure Support Road Here FORTUS 360mc/400mc Service Manual...
  • Page 253 (0.254 mm). If the measured value was 0.012 in, the following would be the calculation: 0.010 - 0.012 = -0.002 Since -0.002 is outside the -0.0005 in. and +0.0005 in. range, the -0.002 value would be entered as the adjustment to the Z offset value. FORTUS 360mc/400mc Service Manual...

  • Page 254: Ppu/Scaling Calibration

    The tolerance for the PPU part is 5.000 in. ± 0.005 in. (127mm ±0.127 mm). If the measurements are both within tolerance the calibration is complete. If either measurement is not within the specified tolerance, continue to step 9. FORTUS 360mc/400mc Service Manual 6-10...
  • Page 255 Press Enter. Press the “Menu” key one time to return to the Machine Setup menu. Select Save Machine Setup Parameters. Return to step 4. Repeat the process until a PPU part is built within tolerance. FORTUS 360mc/400mc Service Manual 6-11...

  • Page 256: Adjustment

    The coupling and pulley should rotate freely on the lead screw shaft. While holding the loosened pulley in place, turn the lead screw with a 3/8-inch open end wrench until the Z end plate contacts the lower hard stop. FORTUS 360mc/400mc Service Manual 6-12...
  • Page 257 Perform an Autohome XYZ (Operator Control > Calibrate > AutoHome XYZ). Place a new build sheet on the platen and verify that proper vacuum is reached. Perform an Auto Z Zero. (Operator Control > Calibrate > Set Z Stage Zero > Auto Z Zero Calibrate). FORTUS 360mc/400mc Service Manual 6-13...
  • Page 258 LR: 0.002 LL: -0.010 Insert the measure flatness values into the platen level calculator (available on the Stratasys Website); use the output values to make adjustments to the platen leveling screws. (See Figure 6-8 on page 6-15 for adjustment locations.)
  • Page 259 ± 0.015-inch (0.381 mm) of the center value. Make sure to rotate the build sheet 180 degrees or flip it over before running measure flatness a second time. Continue to procedure “Upper Z Stage Hard Stop Adjustment” on page 6-16. FORTUS 360mc/400mc Service Manual 6-15...

  • Page 260: Upper Z Stage Hard Stop Adjustment

    It allows the motor drives to operate when the oven door is open. Keep head and hands clear of the oven area when the Z Stage is moving. FORTUS 360mc/400mc Service Manual 6-16...
  • Page 261 (0.001-inch or 0.025 mm) to avoid damage to the head. Unlock Door <E> >Set Distance = 0.001 in <E> Set Z Stage = 0 <E> 0.010) *Move Z STag.Z<9> -Z<3> FORTUS 360mc/400mc Service Manual 6-17...
  • Page 262 Check the adjustment by pulling on the paper between the bolt heads and Z Stage End Plate. • The paper should move with moderate pressure applied. • The paper must not tear. • Readjust the stop bolts if necessary to achieve the proper tension on the paper. FORTUS 360mc/400mc Service Manual 6-18...

  • Page 263: Head Filament Alignment

    Check the filament for bends (or an S-shape) through the path. • No bending is permitted. • Centerline of pulleys should match centerline of switch block and liquefier tip. Figure 6-12: Head Filament Alignment Liquifier Misaligned Good Alignment Switch Block Misaligned FORTUS 360mc/400mc Service Manual 6-19...
  • Page 264 “Head Installation” on page 5-20.) Perform an Autocal Tips (Operator Control > Calibrate > AutoCal Tips). (See “Tip Offset Calibrations” on page 6-5.) Perform an XYZ Tip Offset. (See “XYZ Tip Offset” on page 6-6). FORTUS 360mc/400mc Service Manual 6-20...

  • Page 265: Head Filament Presence Detect Switch Adjustment

    Switch From the 360mc/400mc Sensors States menu, verify the state of the filament switch is “sensed” or “not sensed” with the 0.050” Allen wrench in place. See page 4-17 for a sample Sensor States menu. FORTUS 360mc/400mc Service Manual 6-21...
  • Page 266 Verify that the state of the switch is “sensed”. Rotate the Allen wrench slowly and observe the state of the switch to ensure that it does not change and remains “sensed”. Repeat for the opposite side. FORTUS 360mc/400mc Service Manual 6-22...

  • Page 267: Belt Tension Gauge Setup

    Tighten the clamp screw (7/64-inch hex key) to hold the gauge in place. Do not over tighten the clamp screw. Rotate the dial face to zero the large gauge. Figure 6-15: Tension Gauge Zero Setting Adjustment Screw Zero Gauge Block FORTUS 360mc/400mc Service Manual 6-23...

  • Page 268: Xy Gantry Belt Tension

    • Make sure the fixture is square with the belt. Figure 6-16: X Drive Belt Tension Check Head Positioned to the Left Front Position of the Tension Gauge Right Belt Clamp/Tensioner Left Belt Clamp/Tensioner Front of System FORTUS 360mc/400mc Service Manual 6-24...
  • Page 269 Y High Y Low X High X Low Y High Y Low Room Temp 85° (ABSi ABS-M30 ABS-M30i) 85° (ASA) 100° (Nylon 12) 110° (PC-ABS) 145° (PC) 190° (Ultem* 9085) 225° (PPSF) For Spring # 109544-0001 FORTUS 360mc/400mc Service Manual 6-25...
  • Page 270 • The fixture plunger should contact the belt between the belt teeth. • Make sure the fixture is square with the belt. Figure 6-17: Y Drive Belt Tension Check Rear Belt Clamp/Tensioner Head Positioned to the Right Front Front Belt Clamp/Tensioner Position of the Tension Gauge FORTUS 360mc/400mc Service Manual 6-26...
  • Page 271 • If tension is within the specification continue to step 17. • If tension is not within the specification return to step 10. If belt tension was adjusted, run the PPU/Scaling Calibration. (See “PPU/Scaling Calibration” on page 6-10.) FORTUS 360mc/400mc Service Manual 6-27...

  • Page 272: Z Stage Belt Tension

    • Tension fixture pins must be on flat side of belt, plunger must be on toothed side of belt. • The fixture plunger should contact the belt between the belt teeth. • Make sure the fixture is square with the belt. FORTUS 360mc/400mc Service Manual 6-28...
  • Page 273 Remove the belt tension gauge. Move the Z drive belt from left to right several times to equalize the tension throughout the belt. Recheck the Z belt tension and adjust as necessary until the belt tension is within specification. FORTUS 360mc/400mc Service Manual 6-29...

  • Page 274: Tip Wipe Height Adjustment

    If course adjustment is not necessary go to step 8. If course adjustment is necessary, perform the following steps: Loosen the fine height adjustment screw lock nuts on the underside of tip wipe support bracket. (See Figure 6-20 on page 6- 31.) FORTUS 360mc/400mc Service Manual 6-30...
  • Page 275 (See Figure 6-21 on page 6-32.) Turn the fine height adjustment screw to adjust the flicker height. Proper height adjustment is shown in Figure 6-21 on page 6-32. FORTUS 360mc/400mc Service Manual 6-31...
  • Page 276 They should only make contact with the metal tips protruding from the tip shield as the head moves back and forth. Figure 6-21: Flicker/Brush Height Adjustment Flicker/Brush Assembly Reinstall the upper waste chute funnel. Verify the operation of the flicker/brush assemblies while running a part. FORTUS 360mc/400mc Service Manual 6-32...

  • Page 277: Quick Adjust Tip Wipe Assembly

    Reinstall the upper waste chute funnel. Verify the operation of the flicker/brush assemblies while running a part. Figure 6-22: Flicker/Brush Assembly with Tip Wipe Support Bracket Model Support Adjustment Adjustment Screw Screw FORTUS 360mc/400mc Service Manual 6-33...

  • Page 278: Air Pressure And Air Flow Adjustment

    Adjust the air flow to 3.5 to 4.0 SCFH. (See Figure 6-23.) Figure 6-23: Air Pressure and Flow Adjustments Flow Control Pressure Regulator Figure 6-24: Air Pressure Gauge Pressure Gauge Install the lower left side panel. (See “Panel Installation” on page 5-7.) FORTUS 360mc/400mc Service Manual 6-34...

  • Page 279: Z Homing Switch Adjustment

    Position the switch mounting bracket so there is a light drag on the shim as the shim is moved back and forth between the roller and the switch body. Tighten the switch bracket mounting screws. Use the shim to re-check the adjustment and readjust if necessary. FORTUS 360mc/400mc Service Manual 6-35...
  • Page 280 Close the oven door. Perform several AutoHome XYZ functions to verify correct switch operation (Operator Control > Calibrate > AutoHome XYZ). Perform an Auto Z Zero Calibration. (See “Auto Z Zero Calibration” on page 6-4). FORTUS 360mc/400mc Service Manual 6-36...

  • Page 281: Tip Air Deflector Adjustment

    Teflon tip shield. (See Figure 6-26.) Tighten the 4 mounting screws. Figure 6-26: Tip Air Deflector Adjustment Mounting Screws (2 in Front and 2 in Back) Support Tip at Active Position Support Tip at Inactive Position FORTUS 360mc/400mc Service Manual 6-37...

  • Page 282: Interlock Switch And Sensor Adjustments

    Procedure The Fortus 360mc/400mc systems uses three door sensors to activate two locking solenoids for the oven door, top front gantry door, and the top door (the top door uses a mechanical interlock with the top front gantry door).

  • Page 283: Tip Sensor Location/Setting Position

    With the model tip centered over the tip sensor plunger, select Set Loc to set the current position as the new tip sensor location. Press Menu to move up one level in the display menu. Select Save Machine Setup Parameters. Flip the tip sensor plunger back to its normal operating position. FORTUS 360mc/400mc Service Manual 6-39...

  • Page 284: Purge Location/Setting Position

    Install the Flicker/Brush assemblies, the purge ledge, and the upper waste chute funnel. Allow for thermal stabilization. (See Table 2-7 on page 2-16.) Run a small test part. Verify the tips are being cleaned properly and that the purged material is going into the waste chute. FORTUS 360mc/400mc Service Manual 6-40...

  • Page 285: Troubleshooting

    Part download failed__________________________________________ 7-22 Material load failed ___________________________________________ 7-23 Loss of extrusion (LOE) _________________________________________ 7-26 Operation: Condition _____________________________________________ 7-29 Odor/Burning _________________________________________________ 7-29 Error Messages______________________________________________________ 7-30 UI Messages ______________________________________________________ 7-30 UI HELP Messages_________________________________________________ 7-31 CFG File ERROR Messages_________________________________________ 7-32 FORTUS 360mc/400mc Service Manual...

  • Page 286: How To Use This Guide

    How to Use this Guide General Information Who Should Use This Guide? This troubleshooting guide is for use by Stratasys representatives - including Stratasys field service engineers and authorized distributor service representatives. This document is not intended for customer use.

  • Page 287: Definition Of Terms

    Filament Slip (Spin Out) Head motor chews a divot into the filament and spins freely. CFG File File uploaded to workstation with the Administration ìFile Cabinetî button. Contains several running logs of system operation. FORTUS 360mc/400mc Service Manual...

  • Page 288: System Problems

    Verify that the oven thermal breaker is not active (open). Using a meter, verify that 24V DC is present at both (connected) thermal breaker spade connections. An open (popped) oven thermal breaker may indicate a failed oven blower. FORTUS 360mc/400mc Service Manual...

  • Page 289: System Will Not Power Down

    Verify the BE controller version is 2.10.1 or above. Check the serial cable connection between the UPS and computer. Replace the UPS, as it’s possible that AC Line Loss is not being sensed or transmitted to the computer by the UPS. FORTUS 360mc/400mc Service Manual...

  • Page 290: System Powers Down Unexpectedly

    Power up the system - allow to run for 1 to 2 hours. Check the battery level in UPS status. • For Model 5125 UPS: if lower than 48V DC, the UPS batteries are failing. Replace the UPS. FORTUS 360mc/400mc Service Manual...

  • Page 291: Computer

    User interface is unresponsive (system locked up) Attempt to restart the system via power down/power up. Try and download the CFG file for examination at Stratasys Support. Computer unable to restart properly This assumes there is AC power to the computer. If boot failure messages on UI indicate “Failure to Update I/O”, verify that the...

  • Page 292: Vacuum

    Verify that the XY and Z belt tensions are correct and that there are no failed path components. Verify that the three servo amplifiers on the MIO board do not indicate an error red LED. Check output of 24/48V DC power supply for correct DC voltage. FORTUS 360mc/400mc Service Manual...

  • Page 293: Autocal Tip Failed

    Z= -0.020 anytime during calibration. Also may occur if switch is tripped, but the Z value is negative or zero. Possible causes: • User forgot to put the cone back in the block. • User forgot to install a tip. FORTUS 360mc/400mc Service Manual...
  • Page 294 If Model tip cannot find switch: Select Maintenance > Administration > Field Service > Service Procedures > Move Head > Set Cal Position to locate tip start position over sensor. Upper hard stops may be too low. (See “Adjustment” on page 6- 12.) FORTUS 360mc/400mc Service Manual 7-10...
  • Page 295 (< 4 mils). Verify that liquefier L brackets are not bent. Verify that there is no debris on support liquefier block stops. Make sure head is secured to the system. FORTUS 360mc/400mc Service Manual 7-11...

  • Page 296: Build Failures

    Verify oven door is closed and correctly recognized by system. Check oven temperature with an external thermal probe: (1). If an external oven thermal probe reading is higher than the UI reading: • Replace thermocouple. FORTUS 360mc/400mc Service Manual 7-12...
  • Page 297 Shock or fire may result if incorrect wire is used. Possible faulty heater element(s). Test the heater elements: Always replace heater elements as a pair - replace the entire bank. (1). Power the system down. FORTUS 360mc/400mc Service Manual 7-13...
  • Page 298 • Individually check resistance from ground wire of bank C across each of the six heater bank wires. • All readings should indicate an OPEN circuit (infinite resistance). • If NOT OPEN, element OR harness is faulty. FORTUS 360mc/400mc Service Manual 7-14...

  • Page 299: Part Build Stopped

    Single Servo Amp LED is Red. • Swap servo amp locations on the MIO board with one that is green (enabled): If problem remains at the amp’s position, replace motor. If problem remains with servo amp, replace MIO board. FORTUS 360mc/400mc Service Manual 7-15...

  • Page 300: Operation: Failure

    Check LEDs on cassette board - should be ‘On’. Check for filament dust in canister drive block. UI HELP message: Pause was caused by: Filament broken at head. This message appears when one of the head switches becomes open during building. FORTUS 360mc/400mc Service Manual 7-16...

  • Page 301: Part Quality

    Part quality Many of these issues are subjective and may require AE to look at or build the part at Stratasys, Inc. The part’s CMB file and STL file may be required. Support material is difficult to remove.
  • Page 302 Check filament load time. Wobble on side surfaces. Belt tensions loose or worn gantry components. Verify that all gantry Y-rail screws are secure. Verify head mount plate is secure and head is fastened correctly. FORTUS 360mc/400mc Service Manual 7-18...
  • Page 303 Bead width not consistent at raster turn-arounds. Raster bead widths vary up to 4 mils on 10 slice. Bad tip High pull force canister Worn filament drive Bad temperature at head Bad motor at head FORTUS 360mc/400mc Service Manual 7-19...
  • Page 304 Some flow conditions create larger seams, especially on cylindrical geometry, contour fill and part sparse. Check for large filament diameter or partially plugged tip. Verify that the customer used the default build style in Insight. Open seams Some flow conditions create open seams. FORTUS 360mc/400mc Service Manual 7-20...
  • Page 305 When using the Modify Z Zero function, User Placement must be set off and the oven temperature must remain within 10 degrees of the oven setpoint or an Auto Z zero will occur at next part start erasing a modified Z Zero parameter. FORTUS 360mc/400mc Service Manual 7-21...

  • Page 306: Operation: Failure

    Eliminate possible site network problems by using a laptop computer or workstation connected directly to the system with a crossover network cable. Verify that the network board is properly seated inside the computer. Replace the network board or the computer. FORTUS 360mc/400mc Service Manual 7-22...

  • Page 307: Material Load Failed

    • support filament drives are not causing the problem. (2). If LEDs are lit, replace the filament drive block. Observe the canister drive gears. If they’re not turning and power is good to cassette board, replace the drive block assembly. FORTUS 360mc/400mc Service Manual 7-23...
  • Page 308 UI. Check for liquefier clamping: Check torque on clamping screws. Check for foreign material between liquefier blocks, which may prevent correct clamping. Check for a bent or damaged extrusion tip. FORTUS 360mc/400mc Service Manual 7-24...
  • Page 309 Some switch blocks have burrs that may have no effect on loading, but may inhibit unloading. Remove gear cover and remove any dust or debris in the gears. FORTUS 360mc/400mc Service Manual 7-25...

  • Page 310: Loss Of Extrusion (Loe)

    Verify that the size of the tip matches with tip size indicated on Verify that tip life has not exceeded maximum tip odometer. Verify that the correct tips were installed for the material being used. Verify that the tips were installed correctly. Check tip-to-tip calibration. FORTUS 360mc/400mc Service Manual 7-26...
  • Page 311 Check CFG file for unplug retries. Check for head blower failure. Check for plugged tip. (See “Operation: Failure” on page 7-22.) Check temperature control. (See “Operation: Failure” on page 7- 22.) FORTUS 360mc/400mc Service Manual 7-27...
  • Page 312 Check for a plugged tip, temperature control, and liquefier clamping. (See “Operation: Failure” on page 7-22.) Check if the heads spring screw became loose (spring loaded drive pulley pinch force is too weak). FORTUS 360mc/400mc Service Manual 7-28...

  • Page 313: Operation: Condition

    An odor will occur when heating to PPSF temperatures. Lower temperature material stuck in the oven will burn at PPSF temperatures causing an odor. • Check head liquefiers with external thermometer. If external thermometer temperature reading on liquefier does not match UI temperature for liquefier, replace the head. FORTUS 360mc/400mc Service Manual 7-29...

  • Page 314: Error Messages

    ERROR 10 – Sheet Too Thick - tip encountered Check the sheet thickness. Also refer to: friction at pre-position level. “Operation: Failure” on page 7-22 “Part build stopped” on page 7-15 ERROR 17 – Following error in Z Check upper hard stop. FORTUS 360mc/400mc Service Manual 7-30...

  • Page 315: Ui Help Messages

    See X or Y Movement failure below and blocked. “Part build stopped” on page 7-15 Pause was caused by: Filament broken at “Part build stopped” on page 7-15 canister. Pause was caused by: Filament broken at head. FORTUS 360mc/400mc Service Manual 7-31...

  • Page 316: Cfg File Error Messages

    Check motor connections from motor to MIO and MIO to motor control amp. Swap amps on the MIO between motor control amps for Z and Y or X. Failure follows AMP: Replace MIO board. Failure follows motor: Replace motor. FORTUS 360mc/400mc Service Manual 7-32...

  • Page 317: Preventive Maintenance

    Chapter 8: Preventive Maintenance This chapter describes the preventive maintenance procedures for the Fortus 360mc/400mc systems. PM Procedure Checklist ______________________________________________ 8-2 Preventive Maintenance Procedures __________________________________ 8-2 Lubricate the X Y Gantry Guide Rods _______________________________ 8-2 Lubricate Z Stage__________________________________________________ 8-3 Head Cable Inspection ____________________________________________ 8-5...

  • Page 318: Pm Procedure Checklist

    PM Procedure Checklist PM Checklists are available from the Stratasys website. There is a 12 month PM checklist to be completed every 12 months. In addition to the 12 month checklist, there is a 24 month supplemental checklist to be completed in addition to the 12 month checklist every 24 months.

  • Page 319: Lubricate Z Stage

    Use a clean dry towel to remove old grease from the left and right side Z stage lead screws. Apply a bead of Super Lube to each Z lead screw. Cycle the Z axis up and down several times to distribute the lubricant. FORTUS 360mc/400mc Service Manual...
  • Page 320 Figure 8-2: Z Stage Lubrication Make sure the Super Lube is Squeezed into the Threads of the Lead Screw Apply Krytox Through the Grease Ports on the Pillow Blocks (4X) Lubricate the Z stage guide rod bearings with Krytox grease There are four grease fittings on each side of the Z stage;...

  • Page 321: Head Cable Inspection

    Loosen the connector screws to disconnect the head cable from the head. Make sure the cable exits the energy chain between the 6th and 7th links. Figure 8-3: Head Cable Routing Model Support Vac-U-Flex Filament Filament Tubing Head Cable Tube Tube FORTUS 360mc/400mc Service Manual...
  • Page 322 If necessary, shorten the cable length by pulling the excess cable into the system cabinet. • Slack should be removed from the back channel of the system. • Allow the excess cable to hang free above MIO board. Connect the cable to the head. FORTUS 360mc/400mc Service Manual...

  • Page 323: Filament Drive Inspection

    Install the seal and inspection plate. A new seal must be used if the old seal was damaged during removal. Install and tighten the inspection plate mounting screws. Reinstall the filament drive into the system. (See “Filament Drive Installation” on page 5- 114.) Repeat the procedure for remaining filament drives as necessary. FORTUS 360mc/400mc Service Manual...

  • Page 324: Filament Drive Load Time Test

    • Over 2.5 minutes: Unacceptable. Repair as necessary. Clean the Y blocks, replace filament tube, or replace filament drive. Unload the material canister from the bay that was tested. Reconnect the filament tube(s) to the head. FORTUS 360mc/400mc Service Manual...

  • Page 325: Internal Air Compressor Filters

    • Install the new exhaust muffler. Figure 8-6: Puregas Filters Intake Filter Exhaust Muffler Air Filter Elements Install the left side panels. (See “Panel Installation” on page 5-7.) Power up the system. (See “System Power Up” on page 5-9.) FORTUS 360mc/400mc Service Manual...

  • Page 326: Internal Vacuum Pump Filters Replacement

    Replace the exhaust filter: Remove the exhaust filter assembly from the vacuum pump. Apply liquid thread sealant or sealing tape to threads of new filter assembly. Install and tighten new filter assembly onto vacuum pump. FORTUS 360mc/400mc Service Manual 8-10...
  • Page 327 Insert the new filter element into the filter assembly if required. Thread the plastic bowl onto the filter assembly. Install the right side panels. (See “Panel Installation” on page 5-7.) Power up the system. (See “System Power Up” on page 5-9.) FORTUS 360mc/400mc Service Manual 8-11...

  • Page 328: Cleaning Oven Door Glass

    Check the platen for scratches or damage and replace if necessary. Check the platen O-ring for nicks, tears, or other damage and replace if necessary. Check the platen vacuum screen for damage and replace if necessary. FORTUS 360mc/400mc Service Manual 8-12...

  • Page 329: Schematics

    PCI Communication Cable 103047_____________________________ 9-29 24/48V to IO Cable 103049 ____________________________________ 9-30 Power Switch/UPS Vacuum Pump Cable 103050 ________________ 9-31 24/48V Power Supply Cable 103054 ____________________________ 9-32 Contactor Control Cable 103610-0002 _________________________ 9-33 Door/Hood Vane Switch 104466 _______________________________ 9-34 FORTUS 360mc/400mc Service Manual...
  • Page 330 Door Cover Solenoid 105569 __________________________________ 9-35 Bay Communication Jumper 105570___________________________ 9-36 Vacuum Switch 105571 _______________________________________ 9-37 Door Switch 105572 ___________________________________________ 9-38 External Air Diagram______________________________________________ 9-39 FORTUS 360mc/400mc Service Manual...
  • Page 331 Schematics Block Diagram FORTUS 360mc/400mc Service Manual...

  • Page 332: Cable Wiring Diagrams

    Cable Wiring Diagrams Left/Right Fan Bay Cables 101266 FORTUS 360mc/400mc Service Manual...

  • Page 333: Light Blower Cable 101325

    HEAD 3 POS UMNL BLOWER CUT SLEEVE BACK 2" USE THE CRIMP TOOL SPECIFIED BY THE COMPONENT MANUFACTURER FOR EACH CONTACT FROM SPADES ATTACH LABEL WITH STRATASYS PART NUMBER SPADE 4 LEFT USE ITEM 6 WHERE NEEDED LIGHTS SPADE 5 1-1/4"...

  • Page 334: Rs485 Cable Pic Bus 101342

    RS485 Cable PIC Bus 101342 FORTUS 360mc/400mc Service Manual...

  • Page 335: Oven Heater Cable 101428

    Oven Heater Cable 101428 2621 FORTUS 360mc/400mc Service Manual...

  • Page 336: Cassette Interface Cable 101470 Sheet 1 Of 2

    Cassette Interface Cable 101470 Sheet 1 of 2 FORTUS 360mc/400mc Service Manual...
  • Page 337 Cassette Interface Cable 101470 Sheet 2 FORTUS 360mc/400mc Service Manual...

  • Page 338: Z Limit Switch Cable 101471

    Z Limit Switch Cable 101471 FORTUS 360mc/400mc Service Manual 9-10...

  • Page 339: Cassette Led Cable 101472

    Cassette LED Cable 101472 FORTUS 360mc/400mc Service Manual 9-11...

  • Page 340: Display Internal Cable 101473

    Display Internal Cable 101473 FORTUS 360mc/400mc Service Manual 9-12...

  • Page 341: Display Switch Interface Cable 101474

    Display Switch Interface Cable 101474 FORTUS 360mc/400mc Service Manual 9-13...

  • Page 342: Rj45 Communication Cable 101515

    RJ45 Communication Cable 101515 FORTUS 360mc/400mc Service Manual 9-14...

  • Page 343: Door Switch Solenoid Cable 101543

    Door Switch Solenoid Cable 101543 FORTUS 360mc/400mc Service Manual 9-15...

  • Page 344: Display Interface Cable 101786

    Display Interface Cable 101786 FORTUS 360mc/400mc Service Manual 9-16...

  • Page 345: Motor Cable 102349

    (SEE NOTE 6) ALPHA WIRE 6368 OR BELDEN WIRE 8340 NOTE 6 NON DRAIN WIRE CABLE TYPES WILL ATTACH WIRE FROM CONNECTOR FIRMLY TO BRAIDED DRAIN SHIELD. ENSURE PROPER CONNECTION TO GROUND WITH CONTINUITY TEST. FORTUS 360mc/400mc Service Manual 9-17...

  • Page 346: Y Motor Cable 102350

    (SEE NOTE 6) ALPHA WIRE 6368 OR BELDEN WIRE 8340 NOTE 6 NON DRAIN WIRE CABLE TYPES WILL ATTACH WIRE FROM CONNECTOR FIRMLY TO BRAIDED DRAIN SHIELD. ENSURE PROPER CONNECTION TO GROUND WITH CONTINUITY TEST. FORTUS 360mc/400mc Service Manual 9-18...

  • Page 347: Z Motor Cable 102351

    DDS 5/7/02 (SEE NOTE 6) ALPHA WIRE 6368 OR BELDEN WIRE 8340 NOTE 6 NON DRAIN WIRE CABLE TYPES WILL ATTACH WIRE FROM CONNECTOR FIRMLY TO BRAIDED SHIELD. ENSURE PROPER CONNECTION TO GROUND WITH CONTINUITY TEST. FORTUS 360mc/400mc Service Manual 9-19...

  • Page 348: Head Umbilical Cable 102628

    Head Umbilical Cable 102628 FORTUS 360mc/400mc Service Manual 9-20...

  • Page 349: Signal Motor Driver Board Cable 102630

    Signal Motor Driver Board Cable 102630 FORTUS 360mc/400mc Service Manual 9-21...

  • Page 350: Power Motor Drive Board Cable 102631

    Power Motor Drive Board Cable 102631 FORTUS 360mc/400mc Service Manual 9-22...

  • Page 351: Filament Sensor Cable 102997

    Filament Sensor Cable 102997 FORTUS 360mc/400mc Service Manual 9-23...

  • Page 352: Mio Ac Board Interface Cable 103027

    MIO AC Board Interface Cable 103027 FORTUS 360mc/400mc Service Manual 9-24...

  • Page 353: Top Hood Switch Solenoid Cable 103029

    Top Hood Switch Solenoid Cable 103029 FORTUS 360mc/400mc Service Manual 9-25...

  • Page 354: Thermal Fuse Cable 103031

    Thermal Fuse Cable 103031 FORTUS 360mc/400mc Service Manual 9-26...

  • Page 355: Twin Tower Tip Wipe Comp Cable 103033

    Twin Tower Tip Wipe Comp Cable 103033 FORTUS 360mc/400mc Service Manual 9-27...

  • Page 356: Computer Ups Power Cable 103046

    Computer UPS Power Cable 103046 FORTUS 360mc/400mc Service Manual 9-28...

  • Page 357: Pci Communication Cable 103047

    PCI Communication Cable 103047 FORTUS 360mc/400mc Service Manual 9-29...

  • Page 358: 24/48V To Io Cable 103049

    24/48V to IO Cable 103049 FORTUS 360mc/400mc Service Manual 9-30...

  • Page 359: Power Switch/Ups Vacuum Pump Cable 103050

    Power Switch/UPS Vacuum Pump Cable 103050 FORTUS 360mc/400mc Service Manual 9-31...

  • Page 360: 24/48V Power Supply Cable 103054

    24/48V Power Supply Cable 103054 FORTUS 360mc/400mc Service Manual 9-32...

  • Page 361: Contactor Control Cable 103610-0002

    Contactor Control Cable 103610-0002 FORTUS 360mc/400mc Service Manual 9-33...

  • Page 362: Door/Hood Vane Switch 104466

    Door/Hood Vane Switch 104466 FORTUS 360mc/400mc Service Manual 9-34...

  • Page 363: Door Cover Solenoid 105569

    Door Cover Solenoid 105569 FORTUS 360mc/400mc Service Manual 9-35...

  • Page 364: Bay Communication Jumper 105570

    Bay Communication Jumper 105570 FORTUS 360mc/400mc Service Manual 9-36...

  • Page 365: Vacuum Switch 105571

    Vacuum Switch 105571 FORTUS 360mc/400mc Service Manual 9-37...

  • Page 366: Door Switch 105572

    Door Switch 105572 FORTUS 360mc/400mc Service Manual 9-38...

  • Page 367: External Air Diagram

    Existing pressure gauge 10243801 FTG, Y 3X 1/4" Tube SCHEMATIC, 108953-0001 FTG, NIPPLE 3/8OD PNEUMATIC 400MC 207161-0001 Filter bracket 108956-0001 VALVE, SOLENOID 230VAC w/ AMP connector P. LEAVITT 5/21/10 104284-0001 FTG, STR 1/4" NPTM 3/8" Tube FORTUS 360mc/400mc Service Manual 9-39...
  • Page 368 FORTUS 360mc/400mc Service Manual 9-40...
  • Page 369 Display Panel Installation ____________________________________ 10-29 Computer______________________________________________________ 10-30 Computer Removal _________________________________________ 10-30 Computer Installation _______________________________________ 10-31 Calibration and Adjustment_________________________________________ 10-33 Linear Compensation ___________________________________________ 10-33 X and Y Belt Tension Settings ____________________________________ 10-36 Component Adjustment ________________________________________ 10-37 FORTUS 360mc/400mc Service Manual 10-1...
  • Page 370 Filament Dryer Air Pressure and Air Flow _______________________ 10-44 Interlock Switch and Sensor Adjustments ______________________ 10-46 XY Gantry PPU/Scaling Calibration (alternate method) ____________ 10-51 Air Conversion Procedures _________________________________________ 10-58 External Air______________________________________________________ 10-58 Internal Air ______________________________________________________ 10-70 FORTUS 360mc/400mc Service Manual 10-2...

  • Page 371: Specifications

    Vantage: 50.24 in. (1277 mm) wide x 34.4 in. (874 mm) deep x 76.75 in. (1950 mm) high Titan: 50.25 in. (1277 mm) wide x 34.75 in. (883 mm) deep x 78 in. (1981 mm) high Weight 1600 pounds (726 kg) shipping weight FORTUS 360mc/400mc Service Manual 10-3...

  • Page 372: Liquefier Tip Specifications

    The Titan system is capable of using: High strength polycarbonate material (PC and medical grade PC- ISO); ABS, ABSi and PC-ABS - used with WaterWorks supports; Polyphenylsulfone (PPSF), which has the highest strength, heat, and chemical resistance. FORTUS 360mc/400mc Service Manual 10-4...
  • Page 373 Because other factors can affect tip life, the material amounts are only approximates. For Vantage - Table 10-2 shows the available material and tips. Table 10-3 shows the tip life. FORTUS 360mc/400mc Service Manual 10-5...
  • Page 374 T12 WW ABSi T12 WW ABSi T12 WW ABSi T20* PC-ABS T12 WW PC-ABS T12 WW PC-ABS T12 WW PC-ISO PC-ISO *The same T20 Tip is used for Model Material and for SR10 Support Material. FORTUS 360mc/400mc Service Manual 10-6...
  • Page 375 Tip Life is directly related to the amount of material that passes through the tip. The amounts listed above are approximates of how much material will pass through a tip before the tip will need to be replaced. Because other factors can affect tip life, the material amounts are only approximates. FORTUS 360mc/400mc Service Manual 10-7...

  • Page 376: Tip Identification And Slice Height

    Tip Slice Height information is provided in Table 10-4. Table 10-4: Slice Height Model Tip Slice Height 0.005 inch (0.127 mm) 0.007 inch (0.178 mm) 0.010 inch (0.254 mm) 0.013 inch (0.330 mm) FORTUS 360mc/400mc Service Manual 10-8...

  • Page 377: Material Build Temperatures

    330° C (626° F) 110° C (230° F) PC and PC-ISO 390° C (734° F) 145° C (293° F) PPSF 405° C (761° F) 225° C (437° F) Temperatures are automatically set by the modeler. FORTUS 360mc/400mc Service Manual 10-9...

  • Page 378: Removal And Replacement

    Slide the blade of a small, flat blade screwdriver between the ‘hook and lock’ strips at each corner of the door while pulling the outer-glass away from the door. Figure 10-2: Vantage Oven Door Glass FORTUS 360mc/400mc Service Manual 10-10...
  • Page 379 Mark the oven (back) side of the inner-door glass with washable marker or tape. Loosen and remove the inner-door glass frame screws (T25 Torx). Carefully lift the glass frame from the glass. Carefully lift the inner-glass from the door. FORTUS 360mc/400mc Service Manual 10-11...
  • Page 380 Figure 10-3: Titan Oven Door Glass FORTUS 360mc/400mc Service Manual 10-12...

  • Page 381: Oven Door Window Installation

    Install (do not tighten) the outer frame screws - except the one for the ground strap (upper right corner). Install (do not tighten) the inner frame screws (hex head). Tighten the outer and inner frame screws. Install the door latch assembly. FORTUS 360mc/400mc Service Manual 10-13...
  • Page 382 Visually check the door latch and switch alignment. (See “Interlock Switch and Sensor Adjustments” on page 10-46.) For Titan, check the operation of the manual door latch release. Check the operation of the latch and switch assembly from the operator’s panel.Y FORTUS 360mc/400mc Service Manual 10-14...

  • Page 383: Y Bridge

    Loosen and remove eight Y bridge mount bolts (3/16-inch hex key), eight shoulder screws (3/16-inch hex key) and eight spring washers. (Figure 10-4 on page 10-15) Lift the Y bridge from the system. Figure 10-4: Y Bridge Mounting Hardware FORTUS 360mc/400mc Service Manual 10-15...

  • Page 384: Y Bridge

    Figure 10-5: Location of X-Axis Hard Stop Bolt Torque (16) retaining screws (8 with wavy washers and 8 with socket heads). • Torque the screws without the wavy washers first. Carefully remove the squaring fixture. FORTUS 360mc/400mc Service Manual 10-16...
  • Page 385 Tighten remaining screws/bolts on X-axis pillow blocks. Remove the squaring fixtures. Install the X-axis hard stop bolt - apply medium strength threadlocker to threads. If the X-axis guide rods were removed, tighten the X-axis guide rod mounting screws: FORTUS 360mc/400mc Service Manual 10-17...
  • Page 386 Attach the energy chain, energy cable, and filament tubes to head. Place head in operating position. (See “Place Head in the Operating Position” on page 5- 14.) Adjust Air Deflector. (See “Z Homing Switch Adjustment” on page 6-35.) FORTUS 360mc/400mc Service Manual 10-18...

  • Page 387: X-Axis Guide Rod / Pillow Block

    The center screw and the two screws in the third position from each end are shorter screws that hold the guide rod to the rail - they do not need to be removed. Remove the guide rods and support rails from system. FORTUS 360mc/400mc Service Manual 10-19...

  • Page 388: X-Axis Guide Rod / Pillow Block

    Figure 10-7: X-Axis Guide Rod/Bearing Installation Position Guide Rod assemblies for installation. Install, but do not tighten, Guide Rod mounting screws. Do not use medium strength threadlocker on Guide Rod mounting screws. Grease Bearing assemblies. (Figure 10-7) FORTUS 360mc/400mc Service Manual 10-20...
  • Page 389 For Titan/Vantage: Guide Rod mounting screws for both X Guide Rods are tightened during Y bridge is installation. (See “Y Bridge Installation” on page 10-16.) Install Y bridge. (See “Y Bridge Installation” on page 10-16.) FORTUS 360mc/400mc Service Manual 10-21...

  • Page 390: Y-Axis Guide Rod Assembly

    Remove the Air Deflector - loosen and remove 4 retaining screws (7/64-inch hex key). (Figure 10-8) Remove the X-axis heat shield - loosen and remove 4 retaining screws (5/32-inch hex key). Figure 10-8: Air Deflector and X-Axis Heat Shield FORTUS 360mc/400mc Service Manual 10-22...
  • Page 391 Figure 10-10: Y Carriage Pillow Blocks Install Y Carriage with Energy Chain mounting bracket holes are in the front, left position (as viewed from the front of the system). Turn the Y bridge right-side up. FORTUS 360mc/400mc Service Manual 10-23...
  • Page 392 (6 for each rod - 7/64-inch hex key). (Figure 10-11) Figure 10-11: Y-Axis Guide Rod Assembly Remove the Y-axis guide rods, support rails and pillow blocks as an assembly. Individual part replacement is not allowed. FORTUS 360mc/400mc Service Manual 10-24...

  • Page 393: Y-Axis Guide Rod Installation

    Slide Y carriage to screw position 5 - tighten screws at position 5. Slide Y carriage to screw position 2 - tighten screws at position 2. Slide Y carriage to screw position 4 - tighten screws at position 4. FORTUS 360mc/400mc Service Manual 10-25...
  • Page 394 Install the air deflector using 4 mounting screws. Do not use threadlocker and do not tighten screws at this time. Install Y bridge. (See “Y Bridge Installation” on page 10-16.) FORTUS 360mc/400mc Service Manual 10-26...

  • Page 395: Electronic Components

    The Display is not attached to the cover. Disconnect the Display interface cable from the bottom of the Display assembly. Loosen and remove the 4 Display mount screws (5/32-inch hex key) - remove the Display. FORTUS 360mc/400mc Service Manual 10-27...
  • Page 396 Disconnect the Display interface cable from the Display assembly. Loosen and remove the 6 Display mounting nuts from the back of the Display assembly (11/32-inch open end wrench). Remove the Display assembly. Figure 10-13: Vantage Display Panel Removal FORTUS 360mc/400mc Service Manual 10-28...

  • Page 397: Display Panel Installation

    Connect interface cable to side of Display Panel assembly. Close/Install right side panels. (See “Panel Installation” on page 5-7.) Power up the system to verify display panel operation. (See “System Power Down/ Power Up” on page 5-8.) FORTUS 360mc/400mc Service Manual 10-29...

  • Page 398: Computer

    Remove computer from the system. Slide the computer to the back of the modeler until the mounting screw heads are positioned within the large opening of the keyhole slots. Carefully lift the computer away from the mount. FORTUS 360mc/400mc Service Manual 10-30...

  • Page 399: Computer Installation

    Check the PPU Values. (See “Linear Compensation” on page 10-33.) Perform Tip to Tip calibration. (See “Tip Sensor Location/Setting Position” on page 6- 39.) Check the purge position. (See “Air Pressure and Air Flow Adjustment” on page 6-34.) FORTUS 360mc/400mc Service Manual 10-31...
  • Page 400 Install the left side panels. (See “Panel Installation” on page 5-7.) Figure 10-14: Computer Plug Locations Power Cord - Secured with Bracket 4 Interface Connections 2 Ribbon Connectors Mounting Screws - 4 Locations FORTUS 360mc/400mc Service Manual 10-32...

  • Page 401: Calibration And Adjustment

    • PPU values will be reset to defaults of 9000, 4500. Build the appropriate PPU part. • Select Maintenance > Administration > Field Service (Password) > Service Jobs to Build. • Choose the appropriate PPU part for the material being used. FORTUS 360mc/400mc Service Manual 10-33...
  • Page 402 Measure and record the length of the three Y-axis dimensions. • Record the dimensions as X1, X2, X3. Figure 10-15: PPU Part - Linear Compensation X Dimensions Y Dimensions Input the measured values of X1, X2, X3, Y1, Y2, and Y3. FORTUS 360mc/400mc Service Manual 10-34...
  • Page 403 Measure the PPU part dimensions (Figure 10-15). Part must cool for a minimum of 30 minutes before taking measurements. Use a dial or digital caliper to take measurements. Measured dimensions must be within limits per Table 10-6 FORTUS 360mc/400mc Service Manual 10-35...

  • Page 404: And Y Belt Tension Settings

    -55 to -65 -45 to -55 Vantage X Belt -80 to -90 -65 to -75 -60 to -70 -45 to -55 Vantage Y Belt -75 to -85 -55 to -65 -50 to -60 -40 to -50 FORTUS 360mc/400mc Service Manual 10-36...

  • Page 405: Component Adjustment

    For models with a Hinged Waste Chute Door (Titan Only) Figure 10-16 on page 10-39. Remove the waste chute door assembly. • Open the waste chute door. • Loosen and remove the 4 waste chute door assembly mounting screws. FORTUS 360mc/400mc Service Manual 10-37...
  • Page 406 Use the adjustment screw to set the correct tip wipe height. • Position the model tip wipe so that it is lightly touching the model tip. (5). Remove the purge bucket. (6). Tighten the mount nuts and mount screw. FORTUS 360mc/400mc Service Manual 10-38...
  • Page 407 Figure 10-16: Tip Wipe Adjustment - Titan with Door FORTUS 360mc/400mc Service Manual 10-39...
  • Page 408 Figure 10-17: Tip Wipe Adjustment - Titan with Bucket and All Vantage Perform several tip purge and wipes for the model and support tips. After each purge and wipe, the tips should be clean and free of purged material. FORTUS 360mc/400mc Service Manual 10-40...

  • Page 409: Tip Clean Position / Purge Location

    (Figure 10-18 Figure 10-19). X-axis - align the model tip with the center of the high step of the wiper squeegee. Y-axis - align the model tip 2/3 of the way forward along the purge ledge. FORTUS 360mc/400mc Service Manual 10-41...
  • Page 410 X-axis - align the model tip 1 inch (25 mm). Figure 10-20: X-Axis Clean Position - NO Purge Ledge Front view of tip wipe assembly Model tip Position to approximate center of high step on the orange wiper X-axis position FORTUS 360mc/400mc Service Manual 10-42...
  • Page 411 Perform several tip purge and wipes for the model and support tips. Make sure purged material drops into the waste chute during the tip wipe. After each purge and wipe, the tips should be clean and free of purged material. FORTUS 360mc/400mc Service Manual 10-43...

  • Page 412: Filament Dryer Air Pressure And Air Flow

    Tighten the locknut. Re-check the air pressure, adjust again if necessary. For systems with Puregas dryer: Turn the adjustment knob to set the air pressure as required. Re-check the air pressure, adjust again if necessary. FORTUS 360mc/400mc Service Manual 10-44...
  • Page 413 Turn the adjustment knob on the air flow meter to set the air flow. • For Puregas air dryer, pull knob down to unlock, turn to adjust, then push knob up to lock in place. Close/install right side lower door/panel. FORTUS 360mc/400mc Service Manual 10-45...

  • Page 414: Interlock Switch And Sensor Adjustments

    (3). Tighten the plunger lock nuts. (4). Open and close the door several times to check plunger alignment. Close the top hood. From the Main Menu, select Maintenance > Administration > Field Service (Password) > FORTUS 360mc/400mc Service Manual 10-46...
  • Page 415 • Plunger must be long enough to depress and actuate the switch. Adjust the plunger as necessary to meet the alignment requirements. (1). Remove the plunger cover (T25 Torx). (2). Loosen the plunger lock nuts (9/16 inch wrench). (3). Adjust the plunger as necessary. FORTUS 360mc/400mc Service Manual 10-47...
  • Page 416 Observe the door latch while actuating it from the operator’s panel. If the latch fails to operate from the panel, there is an electrical problem with the release circuit - repair accordingly. FORTUS 360mc/400mc Service Manual 10-48...
  • Page 417 • The flag should be centered between the sensor vanes. Adjust the flag as necessary to meet the alignment requirements. (1). Loosen the flag mount screws (T25 Torx). (2). Position the flag within the sensor vanes. (3). Tighten the flag mount screws. FORTUS 360mc/400mc Service Manual 10-49...
  • Page 418 Open and close the door several times to check the flag alignment. (5). Re-adjust as necessary. Figure 10-25: Vantage Door Sensor Flags Top Lid Flag Vantage Oven Door Flag (2 Views) Top Door Flag Vantage FORTUS 360mc/400mc Service Manual 10-50...

  • Page 419: Xy Gantry Ppu/Scaling Calibration (Alternate Method)

    Place the magnet extension fixture on the left side frame member. Manually move the Y bridge with fixture assembly into a position where the dial indicator rod is just short of touching the magnet extension fixture. FORTUS 360mc/400mc Service Manual 10-51...
  • Page 420 00.000 *PPU Values Current: 9012. New: Set the Set Distance increment to 0.001 inch (0.0254 mm). >Set Distance = 0.001 *Move Head: +X<6> -X<4< +Y<2> -Y<8> *Move Z Stage: +Z<9> -Z<3> *Current: X:0.000 Y:0.000 Z:0.000 FORTUS 360mc/400mc Service Manual 10-52...
  • Page 421 Set the Set Distance increment to 1.0 inch (2.54 cm). Press 6 on the keypad 5 times to move the gantry 5 inches (12.7 cm) to the right (back to the dial indicator zero reference). Zero the dial indicator. FORTUS 360mc/400mc Service Manual 10-53...
  • Page 422 Do not lean on the frame while performing measurement. The frame can flex and cause an inaccurate reading. Install the top door/hood interlock bypass fixture (Figure 10-27 on page 10-52). From the display panel, select Set Y PPU. FORTUS 360mc/400mc Service Manual 10-54...
  • Page 423 9012. New: Note the amount of actual travel on the dial indicator up to the 4th digit after the decimal point (value is needed in a later step). Move the cursor to Enter Measured Distance: FORTUS 360mc/400mc Service Manual 10-55...
  • Page 424 Measure the part for correct dimensional accuracy in X and Y (Figure 10-29). Measurement must be 5.000 inch (12.7 cm) ± 0.005 inch (0.127 mm) X and Y. Repeat the procedure until the part is in specification. FORTUS 360mc/400mc Service Manual 10-56...
  • Page 425 Figure 10-29: Measure 5 Inch Scaling Part in X and Y Measurement for X and Y must be 5.000 inch (12.7 cm) Measure ± 0.005 (0.127 mm) Location for X FORTUS 360mc/400mc Service Manual 10-57...

  • Page 426: Air Conversion Procedures

    Air Conversion Procedures External Air Follow the procedure below to convert a Fortus 360mc/400mc system from internal air to external air or a stand-alone external air compressor. Tools and Materials Required • Basic service tools Figure 10-30: External Air Components...
  • Page 427 Power down the system and then remove power to the system. (See “System Power Down/Power Up” on page 5-8.) Remove both lower side panels from the system and set them aside. (See “Panel Removal” on page 5-6.) FORTUS 360mc/400mc Service Manual 10-59...
  • Page 428 Air Hose Connector with Bracket Attach the 85 inch air line to the air hose connector. Feed the air line through system to the left hand side. The free end will be connected in step 23. FORTUS 360mc/400mc Service Manual 10-60...
  • Page 429 Rotate Vacuum Switch 90° Before After Install the “Y” connector and connect a 49 inch length of 3/8 inch vacuum line. Route the vacuum line through the system. It will be attached later in step 28. FORTUS 360mc/400mc Service Manual 10-61...
  • Page 430 Discard the air line connected from the compressor to the filter assembly. Figure 10-37: Wire Tie Location Clip and Remove Wire Ties Disconnect the compressor motor power cable connector. Figure 10-38: Compressor Connector Compressor Connector FORTUS 360mc/400mc Service Manual 10-62...
  • Page 431 Disconnect the air line from the filter assembly to the air dryer. Remove two screws that attach the filter bracket to the filter assembly. Discard the filter assembly and bracket, but retain the screws. Figure 10-40: Filter Bracket Removal Filter Bracket (Retain Screws) Discard Filter Assembly FORTUS 360mc/400mc Service Manual 10-63...
  • Page 432 Mount the filter bracket assembly to the system chassis using two screws removed in step 16. Figure 10-41: Filter Bracket Mounting Filter Assembly Filter Bracket Connect the filter assembly cable connector to the compressor cable connector. Wire tie loose wires to the compressor wire harness. FORTUS 360mc/400mc Service Manual 10-64...
  • Page 433 Cable Connector Install a 13 inch length of 1/4-inch air line from the Purgas filter to the 90° elbow on the filter assembly. Figure 10-43: Purgas Filter Purgas Filter Air Filter Air Line Assembly Inlet FORTUS 360mc/400mc Service Manual 10-65...
  • Page 434 AC electrical enclosure with one screw. Figure 10-45: Cable Clamp Installation Cable Clamp Use a wire tie to attach the 85 inch length of 3/8-inch air line to an open hole in the system cross member as shown. FORTUS 360mc/400mc Service Manual 10-66...
  • Page 435 Make sure that the vacuum generator or wire ties do not make contact with the Z-stage belt or pulley. Do not over tighten the wire ties. FORTUS 360mc/400mc Service Manual 10-67...
  • Page 436 Remove one screw from the bottom of the electrical enclosure. Install one cable clamp (included in kit) to hold the muffler air line and then secure the clamp to the AC electrical enclosure with one screw. FORTUS 360mc/400mc Service Manual 10-68...
  • Page 437 Using the pressure regulator on the filter assembly, adjust the air pressure to 50 psi (± 2 psi). Adjust the air flow to 3.5 to 4.0 SCFH. Install both lower side panels on the system. FORTUS 360mc/400mc Service Manual 10-69...

  • Page 438: Internal Air

    Internal Air Follow the procedure below to convert a Fortus 360mc/400mc system from external air to self-contained internal air. Tools and Materials Required • Basic service tools Figure 10-51: Internal Air Components 3/8-in. and 1/4-in. Filter Bracket Air/Vacuum Lines Filter Assembly...
  • Page 439 Discard Cable Clamps Discard External Air Line, Muffler, and Muffler Line Remove (and retain for later use) the 13 inch length of 1/4-inch air line from the Purgas filter to the 90° elbow on the filter assembly. FORTUS 360mc/400mc Service Manual 10-71...
  • Page 440 Remove and discard the external air filter assembly, but retain the two hex key screws used to hold the bracket to the chassis and the two Phillips screws used to mount the air filter to the bracket. Figure 10-55: External Air Filter Removal External Air Filter FORTUS 360mc/400mc Service Manual 10-72...
  • Page 441 Attach the filter bracket (supplied in kit) to the filter assembly (supplied in kit) using the two Phillips screws that were previously removed in step 6. Figure 10-57: Filter Bracket to Filter Attachment Filter Bracket Filter Assembly FORTUS 360mc/400mc Service Manual 10-73...
  • Page 442 Attach the 13 inch length of 1/4-inch air line (previously removed in step 5.) from the Purgas filter to the 90° elbow on the filter assembly. Figure 10-59: Purgas Air Line Attachment Reused 13 Inch Length of Air Line FORTUS 360mc/400mc Service Manual 10-74...
  • Page 443 Connect the air compressor power cable to the main wire harness. Make the wiring and air line neat and then secure the wiring and air line with wire ties. Figure 10-61: Air Compressor Connection Connect Air Compressor Secure Wires Power Cable with Wire Ties FORTUS 360mc/400mc Service Manual 10-75...
  • Page 444 Connect power to the system and then power on the system. Using the pressure regulator on the filter assembly, adjust the air pressure to 38 psi (± 2 psi) and flow to 3.5 to 4.0 SCFH. Install both lower side panels on the system. FORTUS 360mc/400mc Service Manual 10-76...

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