Stratasys Prodigy Plus User manual

User Guide

2

Prodigy Plus User Guide

Notice

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

STRATASYS, INC. MAKES NO WARRANTY OF ANY KIND WITH REGARD TO THIS

MATERIAL, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF

MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. Stratasys, Inc. shall

not be liable for errors contained herein or for incidental or consequential damages in

connection with the furnishing, performance, or use of this material.

This equipment has been tested and found to comply with the limits for a Class A digital

device, pursuant to part 15 of the FCC Rules. These limits are designed to provide

reasonable protection against harmful interference when the equipment is operated in a

commercial environment. This equipment generates, uses and can radiate radio

frequency energy and, if not installed and used in accordance with the instruction

manual, may cause harmful interference to radio communications. Operation of this

equipment in a residential area is likely to cause harmful interference in which case the

user will be required to correct the interference at his own expense.

Changes or modifications to the Prodigy Plus system not expressly approved by

Stratasys, the party responsible for compliance, could void the user’s authority for use.

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. Printed in the USA.

Prodigy Plus, Insight and Waterworks are trademarks of Stratasys, Inc.

Stratasys is a registered trademark of Stratasys, Inc.

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

respective companies.

October 2005

The Prodigy Plus system conforms with the following standards, in

accordance with the EU Machinery, Low Voltage and Electromagnetic

Compatibility Directives: EU 89/392/EEC, EU 98/37/EEC, EU 73/23/EEC

amended by 93/68/EEC, EU 89/336/EEC

3

Prodigy Plus User Guide

Introduction

Prodigy Plus is designed with ultimate simplicity in mind. Prodigy

Plus enables you to build parts quickly, even if you’ve never used a

modeler before. Its display panel prompts you to press a few keys

to get you modeling quickly.

The system models with ABS plastic, so modeled parts are strong

and durable. ABS also ensures you’ll be able to drill, tap, sand, and

paint your creations.

Prodigy Plus is an innovative combination of proprietary hardware,

software, and material technology.

Congratulations…

you’ve made a smart choice!

4

Prodigy Plus User Guide

5

Prodigy Plus User Guide

Table of Contents

Introduction................................................................................3

Installation Checklist.................................................................9

Overview...................................................................................11

Finding More Information.......................................................13

Setting up Prodigy Plus................................................................ 13

Using Prodigy Plus....................................................................... 13

Consumables.........................................................................14

Setup.........................................................................................15

Workspace.............................................................................15

Unpacking..............................................................................16

Power Connections................................................................17

Powering On Prodigy Plus ........................................................... 18

Powering Off Prodigy Plus ........................................................... 19

Cycling Power .............................................................................. 20

Setting Network Addresses....................................................20

Installing Software..................................................................22

CD-ROM Software Contents........................................................ 22

Workstation Requirements........................................................... 23

Operation..................................................................................25

Display Panel and Keypad.....................................................25

Inserting a Plastic Modeling Base..........................................26

Loading Material.....................................................................27

Unloading Material.................................................................31

Verifying Tip Depth.................................................................31

Building a Test Part................................................................33

Sending Your CAD File to the System...................................33

Building a Part from Your CMB File .......................................35

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Prodigy Plus User Guide

Machine Chamber Light.........................................................35

Pausing Build .........................................................................36

Resuming Build from Pause Mode.........................................36

Resuming Operations from Standby Mode............................36

Canceling a Job......................................................................37

Removing a Completed Part..................................................37

WaterWorks............................................................................38

Maintenance.............................................................................43

Startup Kit Tools.....................................................................43

Daily Maintenance..................................................................44

Empty Purge Container................................................................ 44

Remove Debris Buildup ............................................................... 44

Weekly Maintenance..............................................................44

Vacuum Build Chamber............................................................... 44

Quarterly Maintenance...........................................................45

Axis Maintenance......................................................................... 45

Axis Lubrication............................................................................ 45

Clean fan filter.............................................................................. 46

Tip Cleaning Assembly ................................................................ 46

As Needed Maintenance........................................................47

Chamber Lamp ............................................................................ 47

Tip Shroud.................................................................................... 48

Troubleshooting.......................................................................53

Troubleshooting Checklist......................................................53

Fault Determination Codes.....................................................54

Loss of Extrusion....................................................................55

Diagnosing Loss of Extrusion....................................................... 55

Recovering From Loss of Extrusion............................................. 56

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Prodigy Plus User Guide

Table of Procedures

To unpack the machine: ............................................................16

To prepare all power connections:.............................................17

To cycle power:..........................................................................20

To set the network addresses:...................................................20

To install Insight:........................................................................24

Verifying the controller software version:...................................24

To reuse a plastic modeling base:.............................................26

To load material cartridges:.......................................................27

To unload material cartridges:...................................................31

To verify tip depth:.....................................................................32

To build a test part:....................................................................33

To send a “job” to Prodigy Plus: ................................................33

To build a part:...........................................................................35

To read the display panel while building:...................................35

To continue operation from Standby mode:...............................36

To cancel a job: .........................................................................37

To remove a completed part:.....................................................37

To remove a completed part from the plastic modeling base:...38

To check the part and water level:.............................................40

To remove the part from the tank: .............................................40

To rinse or soak parts:...............................................................40

To dry parts:...............................................................................41

To change the solution in the tank:............................................41

To dispose of the soluble concentrate:......................................41

Soluble Solution Drain Effluent..................................................42

Neutralization.............................................................................42

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Prodigy Plus User Guide

To clean the fan filter: ................................................................46

To replace the extrusion head’s tip cleaning assembly: ............46

To replace the chamber lamp:...................................................47

To diagnose loss of extrusion: ...................................................55

To recover from loss of extrusion:..............................................57

Clearing drive block obstructions: ..........................................60

Clearing the support liquefier inlet tube:.................................61

Clearing the model liquefier inlet tube:...................................62

9

Prodigy Plus User Guide

Installation Checklist

This guide is designed to help you set up and configure your new

Prodigy Plus modeling system. The following steps include easy-

to-follow instructions.

 Step 1 Workspace 15

 Step 2 Unpacking 16

 Step 3 Power Connections 17

 Step 4 Powering On Prodigy Plus 18

 Step 5 Setting Network Addresses 20

 Step 6 Loading Material 27

 Step 7 Installing Software 22

 Step 8 Building a Test Part 33

 Step 9 Removing a Completed Part 37

 Step 10 Sending Your CAD File to the System 33

 Step 11 Building a Part from Your CMB File 35

 Step 12 Powering Off Prodigy Plus 19

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Prodigy Plus User Guide

Overview

Prodigy Plus builds models, including internal features, directly

from CAD .stl files. The system builds three-dimensional parts by

extruding a bead of ABS plastic through a computer-controlled

extrusion head, producing high quality parts that are ready to use

immediately after completion. With three layer resolution settings,

you can choose to build a part quickly for design verification, or you

can choose a finer setting for higher quality surface detail.

Figure 1: Prodigy Plus front view

Z-Axis Table

Tip Cleaning

Assembly

Plastic Modeling

Base

Purge Containe

r

Display Pane

l

Power Switc

h

Context-sensitiv

e

display and keys

Extrusion

Head

Extrusion

Tips

Guide Rods

Lead Screw

Model Material

Cartridge

Support Material

Cartridge

12 Overview

Prodigy Plus User Guide

The Prodigy Plus system consists of two main components — the

machine itself and Insight, the preprocessing software that runs on

a Windows NT, Windows 2000, or Windows XP platform.

Prodigy Plus’s build envelope measures 203 x 203 x 305 mm (8 x 8

x 12 in). Each material cartridge contains 922 cc (56.3 cu. in.) of

usable material — enough to build continuously for about four days

without reloading.

Overview 13

Prodigy Plus User Guide

Finding More Information

Several references are available for use with Prodigy Plus.

Setting up Prodigy Plus

Prodigy Plus User Guide

Step-by-step instructions for

installing, setting up and operating

the Prodigy Plus system.

Using Prodigy Plus

Insight Online Users Guide

Simple operating instructions for

Insight are online. You can access

them at any time by clicking Help.

You can also print the Insight

instruction file, (approximately six

pages).

Insight Training CD

For more detailed training on the

many advanced features within

Insight, a training CD may be

purchased.

World Wide Web

Additional information is available at:

http://www.stratasys.com

14 Overview

Prodigy Plus User Guide

Consumables

This section lists all replaceable consumables used by the Prodigy

Plus modeling system.

Part Number Description

Modeling Material

340-20000 White ABS Filament Cartridge

340-20200 Black ABS Filament Cartridge

340-20300 Red ABS Filament Cartridge

340-20400 Blue ABS Filament Cartridge

340-20500 Green ABS Filament Cartridge

340-20600 Yellow ABS Filament Cartridge

WaterWorks Support Material/Concentrate

340-30200 WaterWorks Support Cartridge

300-00600 WaterWorks Soluble Concentrate (12 bottles)

Modeling Base

340-00200 Plastic Modeling Base (qty. 24)

Miscellaneous

300-00100 Krytox Grease

540-00101 Tip Cleaning Kit (1 brush, 5 flickers)

540-10000 Tip Shroud

300-01100 ABS Glue (case of 12)

340-02000 24 V 20 W Halogen Bulb (qty. 4)

To order consumables for your Prodigy Plus system, contact:

North America: Stratasys, Inc.

Consumable Orders

+1.800.937.3010 (US toll-free)

+1.952.906.2727 (fax)

consumables@stratasys.com

International: Your regional distributor

Prodigy Plus User Guide

Setup

Workspace

Observe the following when placing Prodigy Plus in its operating

location:

• Prodigy Plus has an approximate weight of 128 kg (282

lbs.) and requires a table capable of safely supporting 300

lbs.

• System Dimensions:

864 x 686 x 1041 mm (34 x 27 x 41 in)

Four-inch minimum space behind unit for air circulation

• Dedicated outlet requirements:

110-120 VAC, 60 Hz, 15 A min. (20 amp recommended)

–or–

220-240 VAC, 50/60 Hz, 7 A min. (10 amp recommended)

• Temperature: 18–32°C (65-90°F)

• Relative Humidity: 30-80%, Non-condensing

• Ethernet 10/100 Base T network

• Network patch cable with RJ45 connectors

• Optional UPS for power interruptions (brown-out

conditions):

Rated Power – 2200 VA

Output Power – 1600 watts

16 Setup

Prodigy Plus User Guide

Unpacking

This section describes the recommended procedures for

unpacking and preparing Prodigy Plus for its first use.

To unpack the machine:

1. Before unpacking machine, use a forklift to move it near its

intended location.

2. Remove the plastic banding from around the cardboard,

and slide the cardboard up and off the pallet.

3. Using the forklift, place the unit in its final location.

4. Cut and remove the cable ties that secure the extrusion

head to the Z-axis frame (see Figure 2).

Figure 2: Cable ties securing the extrusion head to the Z-axis frame

WARNING

Before powering on Prodigy Plus, if you

have not yet done so, cut and remove the

plastic cable ties that secure the extrusion

head to the Z-axis frame (see Figure 2).

The machine will be damaged if powered

on while the head is tied to the frame.

Setup 17

Prodigy Plus User Guide

5. After uncrating and removing the cable ties, inspect the

machine and report any shipping damage to the carrier.

Power Connections

This section discusses the procedure for preparing all power

connections for the machine.

Prodigy Plus is provided with two power cords: one for 110 V and

one for 220 V.

To prepare all power connections:

1. Connect the male end of the supplied power cord directly

into a grounded electrical outlet, as shown in Figure 3

below. If using a UPS, connect the cord directly into the

UPS.

Figure 3: Connecting to a grounded electrical outlet

Important

Before connecting power to the machine,

ensure that the circuit breaker located in the

rear of the machine is in the off (down)

position.

WARNING

Connect the cord directly into the

receptacle or UPS. Do not use an

extension cord or power strip.

18 Setup

Prodigy Plus User Guide

2. Connect the female end of the power cord directly into the

rear of the cabinet.

3. Switch the circuit breaker to the on (up) position.

The machine is now ready for powering on.

Powering On Prodigy Plus

To power on Prodigy Plus, simply flip the large red power switch on

the lower right side of the machine (see Figure 4). Prodigy Plus

boots up in three to seven minutes.

Figure 4: Location of Power Switch

WARNING

Prodigy Plus’s build chamber and

extrusion-head tip get very hot! The

chamber and head tip reach temperatures

of approximately 75° C (167° F) and 280° C

(536° F) respectively. Use the leather safety

gloves provided in the Startup Kit when

working inside the machine.

Setup 19

Prodigy Plus User Guide

Note

If the machine was off and is at room temperature, it

requires approximately 30 minutes to warm up before

you can perform any functions. Temperatures are

factory-preset and not adjustable. The panel displays

the head and envelope temperatures while Prodigy Plus

is warming up and cooling down.

Note

For safety, the head and platen does not move while the

chamber door is open. During warm-up and operation, a

solenoid triggers the door lock. The door can be opened

only when Prodigy Plus is not building a part, getting

ready to build a part, or in pause status.

Powering Off Prodigy Plus

Note

If the system is powered off during a build, the part will

be lost. You should complete the current build and

unload the material before a planned power-off.

If you wish to power-off Prodigy Plus, simply flip the large red

power switch on the lower right side of the cabinet (see Figure 4 on

page 18). You can do this at any time without harming the machine.

No other steps are necessary. If this is done while the machine is

building a part, the part will be lost. System cooling fans continue to

operate for several minutes ensuring a safe, systematic power

down and cooling of the system.

Note

For extended non-use periods, unload the material

cartridges and then power off the system.

20 Setup

Prodigy Plus User Guide

Cycling Power

Situations may occur that require completely shutting off and then

restarting the Prodigy Plus system. This section discusses the

procedure for cycling the electrical system.

To cycle power:

1. Flip the power switch located at the lower right side of the

cabinet (Figure 4 on page 18) to the OFF (down) position.

Wait for the machine to completely power down.

2. Flip the circuit breaker located on the rear of the cabinet to

the OFF (down) position.

3. Wait ten seconds and then flip the circuit breaker to the ON

(up) position.

4. Flip the power switch to the ON (up) position.

5. Wait 15 minutes for the system to prepare itself for normal

operation.

Setting Network Addresses

You will need to set up your network addresses before sending files

from the workstation to Prodigy Plus. If this has not been done

already follow the steps below. Ask your IT department for your

network addresses before beginning this process.

If your IT department requires a NIC MAC address to assign a

static IP address:

1. From Idle or Ready to Build, press Maintenance.

Press Next until the panel displays Setup Maintenance.

2. Read the serial number and the NIC MAC address from

the display.

3. Press Next to return to Idle or Ready to Build.

To set the network addresses:

1. From Idle or Ready to Build, press Maintenance.

The panel then displays System Maintenance and

displays the software version.

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Stratasys Prodigy Plus User manual

Stratasys Prodigy Plus User manual

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