Stratasys Finishing Touch User manual

www.stratasys.com | c-s[email protected]

Finishing Touch™ Smoothing Station

User Guide

September 2012

Part No. 108912-0001, Rev C

ii

Liability Statement

The information in this document is subject to change without notice.

Stratasys, Inc. makes no warranty of any kind with regard to this material, including,

but not limited to, the implied warranties of merchantability and fitness for a

particular purpose. Stratasys, Inc. shall not be liable for errors contained herein or for

incidental or consequential damages in connection with the furnishing, performance,

or use of this material.

possession are restricted by an agreement with Stratasys per software copyright. No

part of this document may be photocopied, reproduced or translated into another

language without the prior written consent of Stratasys, Inc.

All drawings and information herein are the property of Stratasys Inc. All

unauthorized use and reproduction is prohibited.

Trademark Acknowledgments

Stratasys is a registered trademarks of Stratasys, Inc.

Finishing Touch and WaterWorks are trademarks and service marks of Stratasys Inc.

in the United States and other countries.

Windows NT, Windows 2000, and Windows XP are registered trademarks of

Microsoft Corporation.

Weld-On is a registered trademark of IPS Corporation.

Super Glue is a registered trademark of Super Glue Corporation.

Teflon is a registered trademark of DuPont.

MicroCare is a registered trademark of MicroCare Corporation.

All other product names are the property of their respective owners.

Notice

Information in this User Guide is subject to change without notice.

Stratasys Incorporated

7665 Commerce Way

Eden Prairie, MN 55344 USA

952.937.3000

Fax: 952.937.0070

www.stratasys.com

Printed in the United States of America

iii

Revision Log

Finishing Touch Smoothing Station User Guide

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 Finishing Touch

Smoothing Station is designed to be safe and reliable smoothing system.

Access to areas of the system are potentially dangerous.

Safe Environment

• Connect equipment to a grounded facility power source. Do not defeat

or bypass the ground lead.

• Know the location of equipment branch circuit interrupters or circuit

breakers and how to turn them on and off in case of emergency.

• Know the location of fire extinguishers and how to use them. Use only

ABC type extinguishers on electrical fires.

• Know local procedures for first aid and emergency assistance.

• Use adequate lighting at the equipment.

• Maintain the recommended range of temperature and humidity in

equipment area.

• Do not use this product in an environment containing volatile or

flammable compounds.

Rev Date Description of Changes

A April 2010 First release of this document.

B May 2011 Added Supplemental Information chapter (Limited

Warranty Statement).

C September 2012 Updated Formatting.

iv

Safe Human Interface

• Use proper lifting techniques when moving or installing the

equipment.

Hazard Classifications

Be aware of the following hazard classification used in this user guide.

Warning: Indicates a potentially hazardous situation that may result in

death or serious injury.

Note: Always read and adhere to safety statements, and be aware of the

following safety signs located on the system.

Biohazard. The biohazard sign indicates that the material is hazardous to

the environment. Gloves and eye/face protection must be used around

this material.Use proper disposal practices in accordance with local

ordinances.

v

Table of Contents

Introduction ______________________________________________________ 1-1

Specifications ________________________________________________________ 1-2

Overview_____________________________________________________________ 1-3

Smoothing Fluid Reservoir __________________________________________ 1-4

Water Separator __________________________________________________ 1-4

Smoothing Chamber ______________________________________________ 1-5

Cold/Dry Chamber________________________________________________ 1-5

Front Panel _______________________________________________________ 1-5

Programmable Logic Controller (PLC) ______________________________ 1-5

Cooling/Heating System ___________________________________________ 1-6

Compressor ___________________________________________________ 1-7

Lower Primary Cooling Coils ____________________________________ 1-7

Upper Fin Coils_________________________________________________ 1-7

Exhaust Fan ___________________________________________________ 1-7

Heaters _______________________________________________________ 1-7

Foot Switch____________________________________________________ 1-7

Panel Controls ________________________________________________________ 1-8

On/Off Switch_____________________________________________________ 1-9

Start Button _______________________________________________________ 1-9

Stop Button _______________________________________________________ 1-9

Fluid Status Light___________________________________________________ 1-9

System Fault Light ________________________________________________ 1-10

System Status Light _______________________________________________ 1-10

Shut Down Status Light____________________________________________ 1-10

Safety ____________________________________________________________ 2-1

Safety ________________________________________________________________ 2-2

Drain and Vent Smoothing Station Prior to Service___________________ 2-2

Potential Health Effects ____________________________________________ 2-2

First Aid Measures _________________________________________________ 2-2

Inhalation _____________________________________________________ 2-2

Skin Contact __________________________________________________ 2-2

Eye Contact___________________________________________________ 2-2

Ingestion ______________________________________________________ 2-2

Environmental Safety__________________________________________________ 2-3

Spill Clean Up _____________________________________________________ 2-3

Handling and Storage _____________________________________________ 2-3

Handling ______________________________________________________ 2-3

Storage _______________________________________________________ 2-3

Waste Disposal ____________________________________________________ 2-4

Personal Protection ___________________________________________________ 2-4

Eye/Face Protection_______________________________________________ 2-4

Protective Clothing________________________________________________ 2-4

vi

Equipment Modification ___________________________________________ 2-4

Installation and Setup _____________________________________________ 3-1

Site Requirements _____________________________________________________ 3-2

Space Requirements ______________________________________________ 3-2

Environmental Requirements_______________________________________ 3-2

Electrical Requirements____________________________________________ 3-3

Compressed Air Requirements _____________________________________ 3-3

Exhaust Vent Requirements ________________________________________ 3-4

Consumables _____________________________________________________ 3-5

Smoothing Station Fluid ________________________________________ 3-5

Installing the System __________________________________________________ 3-6

Inspect Crate for Damage_________________________________________ 3-6

Required Tools and Equipment _____________________________________ 3-6

Forklift Truck Requirements _________________________________________ 3-6

Unpacking the System _____________________________________________ 3-7

Remove Shipping Crate________________________________________ 3-7

System Connections __________________________________________________ 3-8

Filling the Reservoir _______________________________________________ 3-10

Power On Process ________________________________________________ 3-11

Power Off Process ________________________________________________ 3-11

Prior to Smoothing Parts___________________________________________ 3-12

WaterWorks _________________________________________________________ 3-13

Support Material Removal ________________________________________ 3-13

Smoothing Operation ________________________________________________ 3-14

Masking _________________________________________________________ 3-15

Smoothing the Parts ______________________________________________ 3-15

Repeatability ____________________________________________________ 3-16

Post Finishing Tips _________________________________________________ 3-16

Post Finish Painting Tips ___________________________________________ 3-16

Recommended Burnishing Process ________________________________ 3-17

Effects of High Temperature_______________________________________ 3-17

Troubleshooting ___________________________________________________ 4-1

Troubleshooting_______________________________________________________ 4-2

Frequently Asked Questions ________________________________________ 4-2

System Will Not Start When the Cycle Start Button is Pressed ______ 4-2

Refrigeration Not Cooling or Does Not Have Inadequate Cooling 4-2

Excessive Frost or Ice on the Fin Coils ____________________________ 4-2

Smoothing Chamber Does Not Have Vapor or Vapor is Falling ___ 4-3

Troubleshooting Chart _____________________________________________ 4-4

Status Lights ___________________________________________________ 4-4

Ordering Supplies _____________________________________________________ 4-5

Smoothing Station Fluid ________________________________________ 4-5

Supplemental Information _________________________________________ 5-1

Stratasys Limited Warranty Statement __________________________________ 5-1

Finishing Touch Smoothing Station User Guide 1-1

Chapter 1: Introduction

This chapter describes the Stratasys Finishing Touch Smoothing

Station and its component functions, and device specifications.

Specifications________________________________________________________ 1-2

Overview ____________________________________________________________ 1-3

Smoothing Fluid Reservoir __________________________________________ 1-4

Water Separator___________________________________________________ 1-4

Smoothing Chamber ______________________________________________ 1-5

Cold/Dry Chamber ________________________________________________ 1-5

Front Panel________________________________________________________ 1-5

Programmable Logic Controller (PLC) ______________________________ 1-5

Cooling/Heating System ___________________________________________ 1-6

Compressor ___________________________________________________ 1-7

Lower Primary Cooling Coils ____________________________________ 1-7

Upper Fin Coils _________________________________________________ 1-7

Exhaust Fan____________________________________________________ 1-7

Heaters________________________________________________________ 1-7

Foot Switch ____________________________________________________ 1-7

Panel Controls _______________________________________________________ 1-8

On/Off Switch _____________________________________________________ 1-9

Start Button _______________________________________________________ 1-9

Stop Button _______________________________________________________ 1-9

Fluid Status Light ___________________________________________________ 1-9

System Fault Light_________________________________________________ 1-10

System Status Light _______________________________________________ 1-10

Shut Down Status Light ____________________________________________ 1-10

1-2 Introduction

Specifications

Area Specification

System Size 52.5 in. (133.35 cm) long X 46.0 in. (116.84 cm) high X 32 in.

(81.28 cm) deep.

System Size Crated 59.5 in. (151.13 cm) long X 58.5 in. (148.59 cm) high X 43in.

(109.22 cm) deep.

Weight 400 lbs. (181.44 kg) uncrated

~600 lbs. (~ 272.16 kg) crated

Electrical Rating 200-240 VAC 50/60Hz, 20 amp (dedicated circuit), single

phase

Compressed Air Requirements 5 SCFM @ 80 psi (minimum)

Regulatory Compliance CE

Noise Emission <60 dB

Operating Environment The smoothing station is for indoor use at temperatures from

60°F (15.6°C) to 85°F (29.4°C)

Humidity:<65% non-condensing

Maximum altitude of up to 10761 ft. (3280 m)

Compatible FDM Materials ABS-P400

ABS-M30

ABS-M30I

ABSplus

ABSI

Exhaust Requirement 4 in. (102 mm) to outside

Finishing Touch Smoothing Station User Guide 1-3

Overview

The Stratasys Finishing Touch Smoothing Station is a proven method to

dramatically reduce, and in many cases eliminate the need for manual

post finishing. When used with a bead blaster burnishing station, FDM

ABS models can be finished to injection-molded quality in a short period

of time. See “Recommended Burnishing Process” on page3-17 for details.

Major components of the smoothing station includes the following:

Figure 1-1: Major Components (Front View)

When smoothing parts, it is important to remember that the better the

parts look before the smoothing process, the higher the quality of part

you will get after smoothing.

• Smoothing Fluid Reservoir • Cooling/Heating System

• Water Separator • Front Panel

• Smoothing Chamber • Programmable Logic Controller (PLC)

• Cold/Dry Chamber

Cold/Dry Chamber

Cooling System

Smoothing Chamber

Front Panel

Programmable Logic

Controller (PLC)

(behind Front Panel)

1-4 Introduction

Figure 1-2: Major Components (Back View)

Smoothing Fluid Reservoir

Located in the back of the system, the smoothing fluid reservoir is a

7-gallon container that holds the smoothing solution. There is a low level

float inside the tank that indicates when it is time to add solution.

Water Separator

Located next to the smoothing fluid reservoir, the water separator

removes water from the smoothing solution. This occurs as the solution

enters the separator after being cycled through the smoothing chamber.

The separator works on the principle that the smoothing solution is

heavier than water and that the two will not mix with each other. The

lighter water floats on top of the solution and is siphoned off through the

P-trap over flow tube and into an external collection container. Follow

local guidelines and regulations concerning safety and disposal of

drained water.

Smoothing Fluid Reservoir

Water Separator

Finishing Touch Smoothing Station User Guide 1-5

Smoothing Chamber

The smoothing chamber is located under the smoothing lid and is where

parts are smoothed. The smoothing solution is heated from the bottom of

the chamber. Once hot, the vapor from the solution fills the chamber until

it is collected by the cooling coils at the top of the chamber. The collected

fluid is then recycled back into the separator and then into the smoothing

fluid reservoir.

Cold/Dry Chamber

The cold/dry camber is located next to the smoothing chamber. This

chamber provides hanging racks for parts that are drying or are cooling.

The manual sliding lid should be drawn closed across both the cold/dry

chamber and the smoothing chamber when not actively smoothing parts.

Keep this lid closed for safety and for cooling parts.

Front Panel

The front panel of the system contains all of the operator interface

switches and indicator lights. Located behind the panel is the main

electrical box.

Programmable Logic Controller (PLC)

Located in the main electrical box, the PLC controls the entire operation of

the system.

Figure 1-3: Programmable Logic Controller

1-6 Introduction

Cooling/Heating System

The cooling/heating system is comprised of the following components:

• Compressor

• Lower Primary Cooling Coils

• Upper Fin Coils

• Exhaust Fan

• Heaters

Figure 1-4: Cooling/Heating System Components

Compressor

Lower Primary Cooling Coils

Upper Fin Coils

Exhaust Fan

Heaters

Finishing Touch Smoothing Station User Guide 1-7

Compressor

A ¾ horse semi-hermetic compressor cools the system. The vents on the

panels of the smoothing station must be kept free of obstructions to allow

for free air movement through the compressor.

Lower Primary Cooling Coils

These coils are located beneath the air driven smoothing chamber lid.

They create a cold air blanket over the top of the smoothing chamber. This

cold air blanket keeps the smoothing solution vapor contained within the

smoothing chamber. They also are the collection point for the smoothing

vapor as it is cooled as it changes back into a liquid for recycling back into

the smoothing fluid reservoir.

Upper Fin Coils

Located over both the smoothing chamber and the cool/dry chamber

these coils cool the surfaces of the parts prior to exposing them to the

vapor in the smoothing chamber. They also collect any smoothing

solution vapor that is out gassed during the drying process.

Exhaust Fan

Located at the bottom of the cool/dry chamber, the exhaust fan removes

any out gassed vapors collected in the chamber. The exhaust must be

directed to an unobstructed area that is located outside of the building.

The process works on the principle that the smoothing solution vapor is

approximately 4 times heavier than air. This causes the vapor to sink to

the bottom of the chamber.

Heaters

The smoothing station has two temperature controlled silicon pad heaters

located on the bottom of the system. The temperature of the heaters are

factory set and should not be adjusted except by qualified service

personnel.

Foot Switch

The foot switch, located on the floor, activates an air driven linear actuator

to open the lid covering the smoothing chamber. When the foot switch is

pressed, the PCL resets the over all timer on the system. If the switch is not

pressed within a four hour period, the system assumes that no activity has

taken place and goes into a shutdown mode.

1-8 Introduction

Panel Controls

The front panel controls of the smoothing station includes the following:

• On/Off Switch

• Start Button

• Stop Button

• Fluid Status Light

• System Fault Light

• System Status Light

• Shut Down Status Light

Figure 1-5: Front Panel Control Components

On/Off

System Status Light

Start

Stop

System Fault

Fluid Status

Switch

Shut Down

Status Light

Button

Light

Finishing Touch Smoothing Station User Guide 1-9

On/Off Switch

The main power breaker on/off switch activates power to the system.

Start Button

Pressing the momentary start switch activates the smoothing station

operation cycle. Once pressed, an internal timer automatically causes the

system to shutdown if the foot switch for the air activated smoothing lid

has not been pressed within a four hour time period.

Stop Button

The momentary stop button initiates the cycle shutdown procedure. The

smoothing station operation cycle can be restarted by pressing the start

button.

Once the stop button is pressed (or a four hour time period has elapsed

without the lid over the smoothing chamber being opened) the red

indicator light will begin flashing indicating that the system is in a

shutdown mode. When the shutdown cycle is complete, the red shutdown

light will remain in a steady on state. This indicates that the system has

shutdown.

Fluid Status Light

When this amber fluid status light is rapidly flashing, there is not enough

fluid is flowing into the vapor chamber. This condition also may indicate

that the fluid valve is not closing properly.

When the amber fluid status light is on steady, there is low fluid in the

storage container. Adding solution to the smoothing reservoir will cause

the light to turn off.

1-10 Introduction

System Fault Light

The system fault light will illuminate indicating there is a fault in the

system. Refer to the “Troubleshooting Chart” on page4-4 for details.

System Status Light

When the system is ready to begin smoothing parts, the green system

status light will be illuminated. When the stop button is pressed, the light

will turn off.

Shut Down Status Light

Once the stop button is pressed (or four hours have elapsed without the

lid over the smoothing chamber being opened), the red shut down light

will begin flashing. The flashing indicates that the system is shutting

down. When the shutdown cycle is complete, the light will remain steady

on indicating that the system shutdown is complete.

Finishing Touch Smoothing Station User Guide 2-1

Chapter 2: Safety

This chapter describes the Stratasys Finishing Touch Smoothing

Station general safety information along with environmental safety

and personal protection concerns.

Safety _______________________________________________________________ 2-2

Drain and Vent Smoothing Station Prior to Service ___________________ 2-2

Potential Health Effects ____________________________________________ 2-2

First Aid Measures__________________________________________________ 2-2

Inhalation _____________________________________________________ 2-2

Skin Contact___________________________________________________ 2-2

Eye Contact ___________________________________________________ 2-2

Ingestion ______________________________________________________ 2-2

Environmental Safety _________________________________________________ 2-3

Spill Clean Up _____________________________________________________ 2-3

Handling and Storage _____________________________________________ 2-3

Handling ______________________________________________________ 2-3

Storage _______________________________________________________ 2-3

Waste Disposal ____________________________________________________ 2-4

Personal Protection___________________________________________________ 2-4

Eye/Face Protection _______________________________________________ 2-4

Protective Clothing ________________________________________________ 2-4

Equipment Modification ___________________________________________ 2-4

2-2 Safety

Safety

Drain and Vent Smoothing Station Prior to Service

Allow the smoothing solution to cool before draining. Make sure that all

solution is drained from the smoothing chamber and the chamber is well

ventilated prior to performing any work in the chamber. This includes

cleaning the chamber.

Potential Health Effects

• Avoid inhaling vapors because dizziness and weakness can occur.

• Skin contact may cause severe irritation with burning, redness,

swelling, pain or rash.

• Eye contact may cause severe eye irritation with tearing, pain or

blurred vision.

• Do not ingestion any solutions associated with the smoothing station.

First Aid Measures

Inhalation

If inhaled, move to fresh air. If not breathing, give artificial respiration. If

breathing is difficult, give oxygen. Call a physician.

Skin Contact

Flush skin with water after contact. Wash contaminated clothing before

reuse.

Eye Contact

In case of contact, immediately flush eyes with plenty of water for at least

15 minutes. Call a physician.

Ingestion

If swallowed, do not induce vomiting. Immediately give two glasses of

water. Never give anything by mouth to an unconscious person. Call a

physician.

Under no circumstances should any smoothing solution be poured

on the ground or down a sewer drain. Always follow local guidelines

and regulations concerning the disposal of smoothing solution.

Read and understand the Material Safety Data Sheet (MSDS)

associated with the smoothing solution.

Finishing Touch Smoothing Station User Guide 2-3

Environmental Safety

Spill Clean Up

• Immediately evacuate the area and provide maximum ventilation,

especially in low places where heavy vapors might collect.

• Only personnel equipped with proper equipment should be permitted

in the area.

• Soak up with sawdust, sand, oil dry or other absorbent material.

• After all visible traces, including vapors, have been removed,

thoroughly wet vacuum the area.

• Do not flush solution into a sewer.

• If area of the spill is porous, remove as much contaminated earth and

gravel, etc. as necessary and place in closed containers for disposal.

• Consult the MSDS in case of an accidental spill and then proceed with

clean up accordingly.

Handling and Storage

Always follow directions printed on the outside of the container.

Handling

Do not inhale vapors emitted from the container. Avoid contact with eyes,

skin or clothing. Wash thoroughly after handling. Keep container tightly

closed.

Storage

Store solution in a clean and dry area. Do not allow stored product to

exceed 125° F (52° C) in temperature to prevent leakage or potential

rupture of container from pressure and expansion. Protect from freezing

temperatures. If the solvent is stored below 14° F (-10° C), mix prior to use.

Refer to the MSDS for specific details.

Under no circumstances should any smoothing solution be poured

on the ground or down a sewer drain. Always follow local guidelines

and regulations concerning the disposal of smoothing solution.

2-4 Safety

Waste Disposal

Treatment, storage, transportation, and disposal must be in accordance

with applicable Federal, State/Provincial, and local regulations.

Personal Protection

Use only with adequate ventilation. Vapors are heavier than air, posing a

hazard of asphyxia if they are trapped in enclosed or low places.

Eye/Face Protection

Wear safety glasses. Where splash potential exists, wear chemical splash

goggles.

Protective Clothing

Wear appropriate protective clothing and gloves to avoid potential skin

contact.

Equipment Modification

Protection provided by the equipment may be impaired if not used in the

manner specified in the instructions.

Under no circumstances should any smoothing solution be poured

on the ground or down a sewer drain. Always follow local guidelines

and regulations concerning the disposal of smoothing solution.

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Stratasys Finishing Touch User manual

Stratasys Finishing Touch User manual

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