Stratasys Dimension 768/Elite Manuals

Manuals and User Guides for Stratasys Dimension 768/Elite. We have 3 Stratasys Dimension 768/Elite manuals available for free PDF download: Service Manual, Site Preparation Manual, Quick Start Manual

Stratasys Dimension 768/Elite Service Manual (713 pages)

Brand: Stratasys | Category: 3D Printers | Size: 13 MB

Table of Contents

4
- Safety
  
  10
- Hazard Classifications
  
  10
- Product Safety Symbols
  
  10
- Safety Devices
  
  10
Electronics Overview

12
- Dimension 768 and Elite Specifications
  
  14
- What Happens When
  
  15
  - Powering up
    15
  - Powering down
    15
  - Loading Material
    15
  - Making a Part
    16
  - A System Error Occurs
    16
- Gen 1 Electronics
  
  17
  - 186 Processor Board
    17
  - 186 Microprocessor Overview
    17
    
    Dual Port Memory Interface
    17
    
    X,Y,Z Axis Control
    17
    
    Filament Motor Control
    18
    
    Chamber Temperature Control
    18
    
    Liquefier Temperature Control
    18
    
    Actuators, Switches & Optical Sensors
    19
    
    Safety Devices
    19
    
    Watch Dog Timer (WDT)
    19
    
    186 Board Layout
    20
    
    Reset Button
    20
    
    Dip Switches
    20
    
    Memory
    21
    
    Led's
    21
  - Single Board Computer
    22
  - Power Distribution Board (PDB)
    24
  - Motor Driver Board
    26
    
    Overview
    26
    
    Power/Voltages
    26
- Gen 2 Electronics
  
  28
  - Electronics Overview
    28
  - Controller Board
    29
    
    Overview
    29
    
    Voltage Generation
    29
    
    Dual Port Memory Interface
    29
    
    X, Y, Z Axis Control
    29
  - Filament Motor Control
    29
  - Temperature Control
    29
  - Liquefier Temperature Control
    29
  - Actuators, Switches & Optical Sensors
    31
  - Safety Devices
    31
  - Controller Board Layout
    31
  - Reset Button
    32
  - Dip Switches
    32
  - Memory
    33
  - Leds
    34
  - Power Distribution Board (PDB)
    35
  - Chamber Temperature Control
    36
  - Test Points
    36
- Gen 3 Electronics
  
  40
  - Electronics Overview
    40
  - Controller Board
    41
  - Overview
    41
  - Voltage Generation
    41
  - Dual Port Memory Interface
    41
  - X, Y, Z Axis Control
    41
  - Filament Motor Control
    41
  - Temperature Control
    41
  - Liquefier Temperature Control
    41
  - Actuators, Switches & Optical Sensors
    43
  - Safety Devices
    43
  - Controller Board Layout
    43
  - Reset Button
    44
  - Dip Switches
    44
  - Memory
    45
  - Leds
    45
  - Single Board Computer
    46
  - Power Distribution Board (PDB)
    47
  - Chamber Temperature Control
    48
  - Test Points and Led's
    48
Software

52
- Software Architecture
  
  53
- Datastat
  
  55
- Catalystex Help
  
  56
- Maraca Help
  
  58
- System Software
  
  64
Troubleshooting

66
- Troubleshooting a System Malfunction
  
  68
  - Overview
    68
    
    Testing the 186 Processor Board
    68
    
    Testing the Hard Drive and SBC
    69
    
    Final Test
    69
- Fault Determination Codes
  
  71
- Cycling Power
  
  71
- Diagnosing Loss of Extrusion
  
  72
- Clogged Tip
  
  73
- Service Troubleshooting
  
  74
- Code Errors
  
  75
  - Major Codes
    75
  - Major Codes with Minor Codes
    76
    
    Controller Abort Minor Errors (Code: 14, XX)
    76
    
    Starting up Failed Minor Errors (15.XX)
    88
    
    Controller Load Failed Minor Errors (17.XX)
    88
    
    Temperature Failed to Regulate Minor Errors (18.XX)
    89
    
    Controller Initialization Failed Minor Errors (19.XX)
    90
    
    Door Unlatch Failed (20.XX)
    90
    
    Controller Communications Failed Sub Errors (22.XX)
    90
    
    Unique Device Name Error (23.XX)
    90
- Non-Code Errors
  
  91
  - Build Error" Displayed on LCD
    92
  - Tip Depth Is Incorrect
    92
  - Corrupted Upgrade" Displayed on LCD
    92
  - Cartridge Invalid or Empty" Displayed on LCD
    92
  - Door Latch
    92
  - Door Open" Displayed on LCD
    93
  - Download
    93
  - Loss of Extrusion (LOE)
    93
  - Lights
    94
  - Material/Unload Error
    94
  - Network Communication
    95
  - Pauses During Build
    96
  - What Happens During Power up / Boot
    97
  - Power up / Boot
    98
  - Can't Find Home - Check Modeling Base" Displayed on LCD
    99
  - Power down
    100
  - System very Slow to Reach Temperature
    100
  - Calibration Issues
    100
  - Z Calibration Failure
    100
  - Noise
    102
- Part Quality Troubleshooting
  
  103
  - Embedded Support Strands in Model
    103
  - Brown Streaks (Burn Marks)
    104
  - Loss of Extrusion (LOE)
    105
  - Model Embedded in to Support
    106
  - Moisture in Material
    107
  - Open Seams
    108
  - Part Curling
    109
  - Part Fell over
    110
  - Part Shifting
    111
  - Rough Surface Quality
    112
  - Rough Quality All over
    113
  - Model Strands on Parts
    114
  - Witness Marks
    114
  - Wavy Surface
    115
  - Wavy Parts
    116
  - Under Fill
    117
  - Material Sagging on Curved Parts
    118
  - Fused Layers
    119
  - Z Layers Inconsistent
    120
- Hyperterminal
  
  121
Service Procedures

138
- Exterior Components
  
  146
  - Rear Door
    146
    
    Removing the Rear Door
    146
    
    Installing the Rear Door
    147
  - Side Panels
    148
    
    Removing the Side Panels for Serial Numbers Less than P04746
    148
    
    Installing the Side Panels for Serial Numbers Less than P04746
    149
    
    Removing the Side Panels for Serial Numbers Greater than P04746
    149
    
    Installing the Side Panels for Serial Numbers Greater than P04746
    149
  - Front Bezel
    150
    
    Removing the Front Bezel
    150
    
    Installing the Front Bezel
    157
  - Display Panel
    158
    
    Removing the Display Panel
    158
    
    Installing the Display Panel
    160
  - Door Solenoid
    161
    
    Removing the Door Solenoid
    161
    
    Installing the Door Solenoid
    162
  - Door Sensor
    163
    
    Removing the Door Sensor
    163
    
    Installing the Door Sensor
    164
- Gen 3 Electrical Components
  
  165
  - Power Distribution Board (PDB)
    165
    
    Removing the Power Distribution Board
    166
    
    Installing the Power Distribution Board
    174
  - Controller Board
    175
    
    Removing the Controller Board
    176
    
    Installing the Controller Board
    179
  - Single Board Computer (SBC)
    180
    
    Removing the IDE Single Board Computer
    181
    
    Installing the IDE Single Board Computer
    183
    
    Removing the SATA Single Board Computer
    184
    
    Installing the SATA Single Board Computer
    186
  - Hard Drive
    187
    
    Removing the IDE Hard Drive
    187
    
    Installing the IDE Hard Drive
    189
    
    Removing the SATA Hard Drive
    190
    
    Installing the SATA Hard Drive
    191
  - Electronics Bay Cooling Fan
    193
    
    Removing the Electronics Bay Cooling Fan
    193
    
    Installing the Electronics Bay Cooling Fan
    194
  - 24 VDC Power Supply
    195
    
    Removing the 24 VDC Power Supply
    195
    
    Installing the 24 VDC Power Supply
    198
  - VDC Power Supply (SST Only)
    200
    
    Removing the 120 VDC Power Supply
    200
    
    Installing the 120 VDC Power Supply
    202
  - 5/12 VDC Power Supply
    203
    
    Removing the 5/12 VDC Power Supply
    203
    
    Installing the 5/12 VDC Power Supply
    205
  - Line Filter Board
    206
    
    Removing the Line Filter Board
    206
    
    Installing the Line Filter Board
    208
  - AC Input
    209
    
    Removing the AC Input
    209
    
    Installing the AC Input
    211
  - Circuit Breaker
    212
    
    Removing the Circuit Breaker
    212
    
    Installing the Circuit Breaker
    215
- Gen 2 Electrical Components
  
  216
  - Power Distribution Board (PDB)
    216
    
    Removing the Power Distribution Board
    217
    
    Installing the Power Distribution Board
    224
  - Controller Board
    225
    
    Removing the Controller Board
    226
    
    Installing the Controller Board
    229
  - Single Board Computer (SBC)
    230
    
    Removing the Single Board Computer
    231
    
    Installing the Single Board Computer
    234
  - Hard Drive
    235
    
    Removing the Hard Drive
    235
    
    Installing the Hard Drive
    237
  - Electronics Bay Cooling Fan
    238
    
    Removing the Electronics Bay Cooling Fan
    238
    
    Installing the Electronics Bay Cooling Fan
    239
  - 24 VDC Power Supply
    240
  - VDC Power Supply (SST Only)
    245
  - 5/12 VDC Power Supply
    248
  - Line Filter Board
    251
  - AC Input
    254
  - Circuit Breaker
    257
- Gen 1 Electrical Components
  
  261
  - Power Distribution Board (PDB)
    261
  - 186 Processor Board
    265
  - Single Board Computer (SBC)
    270
  - VDC Piggyback Power Supply
    273
  - 24 VDC Power Supply
    280
    
    Removing the 24 VDC Power Supply
    280
  - Dual 48 VDC Power Supplies (SST Only)
    293
  - Motor Driver Board (MDB)
    299
  - Hard Drive
    304
  - Line Filter
    310
    
    Removing the Line Filter
    310
    
    Installing the Line Filter
    313
  - AC Input
    314
    
    Removing the AC Input
    314
    
    Installing the AC Input
    317
  - Circuit Breaker
    318
    
    Removing the Circuit Breaker
    318
    
    Installing the Circuit Breaker
    320
- Head Components
  
  321
  - Head Cooling Fan
    321
    
    Installing the Head Cooling Fan
    324
  - Head Temperature Snap Switch
    325
    
    Removing the Head Temperature Snap Switch
    325
    
    Installing the Head Temperature Snap Switch
    327
  - BST Swivel Head
    329
    
    Removing the BST Swivel Head
    329
    
    Installing the BST Swivel Head
    333
  - SST Swivel Head
    334
    
    Removing the SST Swivel Head
    334
    
    Installing the SST Swivel Head
    339
  - TC Amp Board
    340
    
    Removing the TC Amp Board for SST
    340
    
    Installing the TC Amp Board for SST
    343
    
    Removing the TC Amp Board for BST
    343
  - Umbilical Cable
    346
    
    Removing the Umbilical Cable
    346
    
    Installing the Umbilical Cable
    358
  - Z Foam Level Sensor
    359
    
    Removing the Z Foam Level Sensor
    359
    
    Installing the Z Foam Level Sensor
    360
  - Z Foam Level Assembly
    361
    
    Removing the Z Foam Level Assembly
    361
    
    Installing the Z Foam Level Assembly
    362
  - Chamber Thermal Snap Switch
    363
    
    Removing the Chamber Thermal Snap Switch for Cable Drive XY Table
    363
    
    Installing the Chamber Thermal Snap Switch for Cable Drive XY Table
    364
    
    Removing the Chamber Thermal Snap Switch for Belt Drive XY Table
    365
    
    Installing the Chamber Thermal Snap Switch for Belt Drive XY Table
    367
- XY Table Cable Drive Components
  
  368
  - EOT (End of Travel) Limit Switch
    368
    
    Removing the X EOT Switch
    368
    
    Installing the X EOT Switch
    369
  - BOT (Home) Sensor
    370
    
    Removing the X BOT Sensor
    370
    
    Installing the X BOT Sensor
    372
  - Y EOT (End of Travel) Limit Switch
    373
    
    Removing the y EOT Switch
    373
    
    Installing the y EOT Switch
    375
  - Y BOT (Beginning of Travel) Sensor
    376
    
    Installing the y BOT Sensor
    378
  - XY Table Assembly (Cable Drive)
    379
    
    Removing the XY Table Assembly
    379
    
    Installing the XY Table Assembly
    387
- XY Table Belt Drive Components
  
  394
  - BOT (Home) Sensor (Belt Drive)
    394
    
    Removing the X BOT Sensor
    394
    
    Installing the X BOT Sensor
    396
  - EOT (End of Travel) Sensor (Belt Drive)
    397
    
    Removing the X EOT Sensor
    397
    
    Installing the X EOT Sensor
    399
  - Motor (Belt Drive)
    400
    
    Removing the X Motor
    400
    
    Installing the X Motor
    402
  - Motor Belt (Belt Drive)
    403
    
    Removing the X Motor Belt
    403
    
    Installing the X Motor Belt
    407
  - Drive Belt (Belt Drive)
    411
    
    Removing the X Drive Belt
    411
    
    Installing the X Drive Belt
    413
  - Y BOT (Home) Sensor (Belt Drive)
    415
    
    Removing the y BOT (Home) Sensor
    415
    
    Installing the y BOT (Home) Sensor
    417
  - Y EOT (End of Travel) Sensor (Belt Drive)
    418
    
    Removing the y EOT Sensor
    418
    
    Installing the y EOT Sensor
    420
  - Y Motor (Belt Drive)
    421
    
    Removing the y Motor
    421
    
    Installing the y Motor
    423
  - Y Motor Belt (Belt Drive)
    424
    
    Removing the y Motor Belt
    424
    
    Installing the y Motor Belt
    425
  - Y Drive Belt (Belt Drive)
    427
    
    Removing the Right Side y Drive Belt
    427
    
    Installing the Right Side y Drive Belt
    433
    
    Removing the Left Side y Drive Belt
    437
    
    Installing the Left Side y Drive Belt
    442
  - Y Pulley (Belt Drive)
    446
    
    Removing the Right Side y Pulley
    446
    
    Installing the Right Side y Pulley
    449
    
    Removing the Left Side y Pulley
    452
    
    Installing the Left Side y Pulley
    455
  - Y Drive Assembly (Belt Drive)
    459
    
    Removing the y Drive Assembly
    459
    
    Installing the y Drive Assembly
    465
  - XY Table Assembly (Belt Drive)
    471
    
    Removing the XY Table Assembly
    471
    
    Installing the XY Table Assembly
    484
- Z Stage Components
  
  490
  - Thermostat Snap Switch
    490
    
    Removing the Thermostat Snap Switch
    490
    
    Installing the Thermostat Snap Switch
    493
  - Tip Wipe Assembly
    494
    
    Replacing the Flicker Blade
    494
    
    Replacing the Brush
    495
- Z Stage Components - 3 Lead Screw
  
  496
  - Chamber Thermocouple (3 Lead Screw)
    496
    
    Removing the Chamber Thermocouple
    496
    
    Installing the Chamber Thermocouple
    498
  - Chamber Heaters (3 Lead Screw)
    499
    
    Removing the Left Side Chamber Heaters
    499
    
    Installing the Left Side Chamber Heaters
    502
    
    Removing the Right Side Chamber Heaters
    503
    
    Installing the Right Side Chamber Heaters
    506
  - Z Switches (3 Lead Screw)
    507
    
    Removing the Z BOT (Home) Switch
    507
    
    Installing the Z BOT (Home) Switch
    511
    
    Removing the Z EOT Switch
    513
    
    Installing the Z EOT Switch
    517
  - Z Jam Sensor (3 Lead Screw)
    519
    
    Removing the Z Jam Sensor
    519
    
    Installing the Z Jam Sensor
    522
  - Z Motor Belt (3 LS)
    523
    
    Removing the Z Motor Belt
    523
    
    Installing the Z Motor Belt
    526
  - Z Stage Motor (3 Lead Screw)
    531
    
    Removing the Z Motor
    531
    
    Installing the Z Motor
    535
  - Z Stage Bearings (3 Lead Screw)
    541
    
    Removing the Z Stage Bearings
    541
    
    Installing the Z Stage Bearings
    550
  - Z Foam Retainers
    558
    
    Removing the Z Foam Retainers
    558
    
    Installing the Z Foam Retainers
    558
- Z Stage Components (1 Lead Screw)
  
  560
  - Chamber Thermocouple (1 Lead Screw)
    560
    
    Removing the Chamber Thermocouple
    560
    
    Installing the Chamber Thermocouple
    562
  - Chamber Fans (1 Lead Screw)
    563
    
    Installing the Left Side Chamber Fans
    565
    
    Removing the Right Side Chamber Fans
    566
    
    Installing the Right Side Chamber Fans
    568
  - Chamber Heaters (1 Lead Screw)
    569
    
    Removing the Left Side Chamber Heater
    569
    
    Installing the Left Side Chamber Heater
    571
    
    Removing the Right Side Chamber Heater
    572
    
    Installing the Right Side Chamber Heater
    574
  - Z Jam Sensor (1 Lead Screw)
    575
    
    Removing the Z Jam Sensor
    575
    
    Installing the Z Jam Sensor
    578
  - Z Sensors (1 Lead Screw)
    579
    
    Removing the Z BOT (Home) Sensor
    579
    
    Installing the Z BOT (Home) Sensor
    581
    
    Removing the Z EOT Sensor
    581
    
    Installing the Z EOT Sensor
    583
  - Z Motor Belt (1 Lead Screw)
    584
    
    Removing the Z Motor Belt
    584
    
    Installing the Z Motor Belt
    587
  - Z Motor (1 Lead Screw)
    588
    
    Removing the Z Motor
    588
    
    Installing the Z Motor
    590
  - Z Stage Assembly - 1 LS
    591
    
    Removing the Z Stage Assembly
    591
    
    Installing the Z Stage Assembly
    600
- Receiver Components
  
  607
  - Galvanized Receiver Assembly
    607
    
    Removing the Galvanized Receiver Assembly
    607
    
    Installing the Galvanized Receiver Assembly
    612
  - Galvanized Receiver Plate
    613
    
    Removing the Galvanized Receiver Plate
    613
    
    Installing the Galvanized Receiver Plate
    615
Calibrations & Adjustments

616
- Tip Depth Calibration
  
  617
  - Leveling the Liquefier
    619
- Tip Offset Calibration
  
  623
- Y Lash
  
  626
- Part Based Calibration
  
  627
- Tensioning the XY Cable Table
  
  632
- Leveling the XY Table (Cable Drive)
  
  638
- Leveling the XY Table (Belt Drive for 3 LS)
  
  644
- Tensioning the X & y Motor Belts (Belt Table)
  
  646
- Tensioning the X & y Drive Belts (Belt Table)
  
  650
- Leveling the XY Table (Belt Drive)
  
  663
- Adjusting Z BOT (Home) Switch
  
  668
- Get/Send Calibration Files
  
  672
- Z Tray Leveling (Cantilever Z Stage, Foam)
  
  674
  - Leveling the Z Platen
    676
  - Aligning Single Lead Screw Z Stage
    679
- Preventive Maintenance
  
  680
- Daily Maintenance
  
  681
- Startup Kit
  
  681
- Weekly Maintenance
  
  682
- Quarterly Maintenance
  
  682
- As Needed Maintenance
  
  683
- Index
  
  684
- 120/240 VAC Jumper Configuration
  
  702
- Appendix
  
  702
- Fuse Specifications
  
  703
- Device Voltages
  
  704
- Hard Drive Installation Checklist
  
  705
- XY Table Installation Checklist
  
  706
- Head Installation Checklist
  
  707
- Pre-Installation Checklist
  
  708
- System Installation Checklist
  
  709
- Training Checklist
  
  710
- Required Tool List
  
  712

Stratasys Dimension 768/Elite Site Preparation Manual (12 pages)

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Stratasys Dimension 768/Elite Quick Start Manual (7 pages)

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Stratasys Dimension 768/Elite Manuals

Stratasys Dimension 768/Elite Service Manual (713 pages)

Table of Contents

Table of Contents

Safety

Hazard Classifications

Product Safety Symbols

Safety Devices

Electronics Overview

Dimension 768 and Elite Specifications

What Happens When

Gen 1 Electronics

Gen 2 Electronics

Gen 3 Electronics

Software

Software Architecture

Datastat

Catalystex Help

Maraca Help

System Software

Troubleshooting

Troubleshooting a System Malfunction

Fault Determination Codes

Cycling Power

Diagnosing Loss of Extrusion

Clogged Tip

Service Troubleshooting

Code Errors

Non-Code Errors

Part Quality Troubleshooting

Hyperterminal

Service Procedures

Exterior Components

Gen 3 Electrical Components

Gen 2 Electrical Components

Gen 1 Electrical Components

Head Components

XY Table Cable Drive Components

XY Table Belt Drive Components

Z Stage Components

Z Stage Components - 3 Lead Screw

Z Stage Components (1 Lead Screw)

Receiver Components

Calibrations & Adjustments

Tip Depth Calibration

Tip Offset Calibration

Y Lash

Part Based Calibration

Tensioning the XY Cable Table

Leveling the XY Table (Cable Drive)

Leveling the XY Table (Belt Drive for 3 LS)

Tensioning the X & y Motor Belts (Belt Table)

Tensioning the X & y Drive Belts (Belt Table)

Leveling the XY Table (Belt Drive)

Adjusting Z BOT (Home) Switch

Get/Send Calibration Files

Z Tray Leveling (Cantilever Z Stage, Foam)

Preventive Maintenance

Daily Maintenance

Startup Kit

Weekly Maintenance

Quarterly Maintenance

As Needed Maintenance

Index

120/240 VAC Jumper Configuration

Appendix

Fuse Specifications

Device Voltages

Hard Drive Installation Checklist

XY Table Installation Checklist

Head Installation Checklist

Pre-Installation Checklist

System Installation Checklist

Training Checklist

Required Tool List

Stratasys Dimension 768/Elite Site Preparation Manual (12 pages)

Table of Contents

Stratasys Dimension 768/Elite Quick Start Manual (7 pages)

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