3D Systems ProJet 4500 User manual

Installation Guide
ProJet® 4500
3D Printer

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3D Systems, Inc.
TABLE OF CONTENTS
1. SYMBOL DEFINITIONS.................................................................................................................................................................... 3
2. DESCRIPTIONS................................................................................................................................................................................ 3
3. PREREQUISITES.............................................................................................................................................................................. 3
4. EQUIPMENT .................................................................................................................................................................................... 3
5. OVERVIEW ......................................................................................................................................................................................4-6
6. UNCRATE AND INSPECT THE PRINTER ...................................................................................................................................... 7
7. MOVE INTO LOCATION ..................................................................................................................................................................10
8. UNPACK and INSPECT ACCESSORIES and SUPPIES................................................................................................................11
9. INSPECT INTERIOR of PRINTER ...................................................................................................................................................13
10. INSTALLATION SCRIPT and FLUID LOADING PROCEDURE ..............................................................................................18-30
11. CONFIRMING PRINT HEAD and OPERATION ............................................................................................................................31
12. ASSEMBLE THE GREASE GUN .............................................................................................................................................33-34
13. LUBRICATE THE PISTON SCREW ..............................................................................................................................................36
14. LUBRICATE THE SLOW AXIS .................................................................................................................................................37-38
15. LOAD CORE .................................................................................................................................................................................39
16. INSTALL SOFTWARE ...................................................................................................................................................................40
17. REPLACE ALL COVERS ..............................................................................................................................................................42
18. SETUP 3D PRINTER FOR CUSTOMER BUILD ...........................................................................................................................42
19. MAKING ELECTRONIC CONNECTIONS .....................................................................................................................................42
20. SUBMIT INFORMATION ................................................................................................................................................................43

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SYMBOL DEFINITIONS
The following symbols are used on the 3D printer and in this manual.
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DESCRIPTION
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This procedure describes how to install a 3D Printer at a customer site. This procedure is intended to be performed by an installer trained
to install a 3D Systems ProJet®4500 3D Printer.
General Caution: User should take care to avoid possible damage to equipment.
Hot Surface: User should use care when working near or on the labeled item.
High Voltage: User should use appropriate electrical safety precautions.
PREREQUISITES
• Installer/trainer must have been trained by 3DSystems in proper installation methods and practices.
• 3D Printer must be at the customer’s facility.
• Customer must have all necessary site prep completed. This includes any power, network, partitions or other work.
• The customer must designate a computer that will be used for 3DPrint®software and control the 3D Printer.
• It is suggested the customer set up a specic work area for using the 3DPrint®software and control the 3D Printer - typically this
would include a table or two, the computer workstation, and shelves for supplies and printed parts.
EQUIPMENT / PARTS REQUIRED
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• 3D Printer and its accompanying Starter Kit and Accessories Kit.
• Recommended Dealer Tools (See 3DS Central for List).
• Heavy Duty wire cutters (to remove metal straps).
• 9/16” Hex socket (to remove the fasteners on the pallet).
• Scissors (to remove shrink wrap).
• Phillips screwdriver (to remove panels).
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OVERVIEW
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Installation and training is a two-day process.
Always follow all instructions in this manual. The following overview may also be used as a checklist to conrm that all installation and
training steps have been conducted.
Important Note – Powering Up
When powering up the printer, always be sure the power has been off at least sixty (60) seconds before power is once again applied.
This allows all the internal circuitry, processors, motors, etc. to completely reset before power is applied.
DAY ONE - INSTALLATION
Installation Item
Thoroughly inspect crate for any shipping damage - Immediately notify the shipping company of
anything unusual.
Relocate the printer to its pre-determined installation space.
Unpack Accessories Kit and conrm that all items are present.
Install 3DPrint & 3DEdit Pro Software.
Register the 3DEdit Pro Software.
Register customer for an account on 3DS Central.
Remove all exterior panels and inspect interior of printer - Immediately notify 3D Systems of any-
thing unusual.
Physically check all electrical and uid connectors for secure attachment.
Connect printer to power and power-up.
Follow the Installation Script on printer LCD and Fluid Loading Procedures in this manual.
- Make network connections.
- Load rst set of Binder into printer.
- Perform Manual Fluid Advance Procedure to bring Binder into Fast Axis.
- Perform Level Sensor Test Procedure.
- Complete binder lling by performing Automatic Advance Procedure.
- Conrmation of correct head lling / additional Head Purging if needed.
Add remaining sets of Binder Cartridges.
Printer Lubrication
- Assemble Grease Gun.
- Lubricate Piston Screw.
- Lubricate Slow Axis.
Load Core.
Conrmation of powder spreading/Fill Bed.
Replace all covers.
Run small test build.
Remove and clean test build and check for quality.

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DAY TWO - CUSTOMER TRAINING
Training Item
Teach removal of part / gross core removal
- Explain the importance of the post-build curing time
- Gross core removal utilizing the User Hose
- Raising/lowering of Build Plate using Control Knob
- Stress that any foreign material vacuumed will be recycled into Feeder
Teach ne Core removal
- Changing Cleaning Station from printing to cleaning
- Adjustment of air pressure using Control Knob
- Use of tools such as soft brushes
- Stress importance of keeping foreign materials out of Cleaning Station
Teach post-build cleaning of the priinter
- Vacuum all powder from deck and Fast Axis
- Empty broken material from Debris Separator
- Clean excess powder from the Fast Axis Rails
- Replacement of Suction Wiper with Spare (stress importance of skin/eye protection)
- Cleaning of removed wiper by soaking in IPA
DAY ONE - CUSTOMER TRAINING
Training Item
Teach the 3DPrint Software
- Selecting a printer
- Importing Parts
- Navigating the views
- Transformations (select, scale, rotate, copy, paste, delete)
- Build button and checking consumable levels
Teach customer the printer hardware - explain the purpose of the following components:
- Binder Cartridges
- Service Station (incl. Suction Wiper)
- Fast Axis Module (incl. Head Carriage, Spreader Roller, Snow Plows)
- Feeder
- User Hose & Debris Separator
- Front & Rear Overows
- Infrared Heater
Teach pre-build steps
- Checking consumable levels
- Adding Binder
- Using Vacuum and User Hose to add core
- Replacing Waste Tray
- Prep Build Chamber
Run a large overnight build (4” tall or more)

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DAY TWO - CUSTOMER TRAINING (continued)
Training Item
Teach periodic maintenance procedures
- Cleaning Debis Separator Filter
- Lubrication of Piston Screw
- Lubrication of Slow Axis
- Resetting the Maintenance Reminders in the 3DPrint Software
Conrm understanding of 3DPrint (customer sets up their own build using skills learned on day 1)
Teach Advanced 3DPrint Features
- Create Fixture
- Collision Detection and Layer view
- Edit in 3DEdit Pro (show customer how to access tutorial videos)
- Conrm understanding of build button and checking consumable levels
Run another large build
Introduce customer to 3DS Central website. Familiarize them with the following sections:
- ProJet 4500 User Manuals
- ProJet 4500 Firmware and Software Downloads
- Community Section; Best Practices, Webinars & Forum
Answer any remaining questions that the customer may have
DAY TWO - WRAPPING UP
Installation Item
Complete and submit the Installation Report on 3DS Central (activates warranty)

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UNCRATE
UNCRATE and INSPECT the PRINTER
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The 3D Printer is shipped on a wooden pallet with a cardboard cover. Uncrating consists of removing the cover and rolling the printer off
the pallet.
Visually inspect the exterior of the crate for any damage incurred during shipping. Notify the shipping carrier immediately if anything is
evident at this point. DO NOT proceed with the installation until you have discussed the damage with the carrier and 3DS Service.
1. Position the crate where there will be enough room to accomodate the
pallet base, the ramps and unloaded printer.
2. Open the ap on the end of the box and remove
Power Cord and any documentation

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4. Pull out the foam blocks at the top of the printer.
3. Cut metal straps and remove top cover of crate
4. Detach the ramps using a 9/16 socket. Remove the ramps.

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5. Pry up and remove the supports from the front and rear of the
system. Mount the ramps to the holes in the base of pallet
6. Remove the foam pads from the front of the printer.
7. Use the 9/16” socket wrench to remove the bolts securing the four
(4) hold-down brackets.
NOTE: Carefully roll the printer down the ramps. It is recommended to
use two people.

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8. Remove all shrink-wrap and bubble-wrap from the printer.
MOVE INTO LOCATION
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Work with the customer to determine the best location for the printer, considering such factors as ease of access and proximity to the
necessary power and network connections.
Roll the printer to its nal location, going slowly over bumps such as oor expansion joints. Get help when going down or up ramps.
INSPECT EXTERIOR OF PRINTER
Visually inspect the exterior of the printer for any damage incurred during shipping. Notify 3D Systems Service immediately if anything
is evident at this point. DO NOT proceed with the installation until you have discussed the damage with Service.

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ACCESSORIES KIT
Please ensure that each of the following items are packaged in your ProJet®4500 accessories kit. The Accessories Kit is located in a
box inside the Cleaning Station.
UNPACK and INSPECT ACCESSORIES and Supplies
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ProJet® 4500 Accessories Kit Contents
Part Number Description Quantity UoM √
22-16446 3DEdit Pro License 1 Ea.
361320-00 ProJet 4500 Service Station Wiper 2 Ea.
361533-00 Debris Separator 1 Ea.
22-16853 Part Tray 3 Ea.
22-10249 Phillips Screwdriver 1 Ea.
22-16011 Pick, 90 deg 1 Ea.
22-10295 Needle-nose Vacuum Attachment 1 Ea.
22-10297 Crevice Vacuum Attachment 1 Ea.
22-10298 Brush Vacuum Attachment 1 Ea.
22-10637 Needle, 16 Gauge 1 Ea.
22-10638 Needle, 18 Gauge 1 Ea.
22-13017 Wash Bottle, 8oz for IPA 1 Ea.
22-13087 Brush – 2” 1 Ea.
22-14902 Brush – Double sided 1 Ea.
22-14903 Brush – Toothbrush 1 Ea.
22-14904 Brush – ¼” 1 Ea.
22-16081 Grease Gun 1 Ea.
22-15235 Super Lube Grease 1 Ea.
22-15782 Ethernet Cable, Blue 1 Ea.
22-05363 Oil Bottle w/Needle Top 1 Ea.
22-31491 Mirror 1 Ea.
22-05363 Oil Bottle 1 Ea.
22-16752 Nitrile Gloves 1 Ea.
362537-00 Tyvek Sleeves 1 Ea.
22-16533 Safety Gloves 1 Ea.
362118-00 Mercury Test Paper 10 Ea.
362279 Scraper Bar Cleaning Brush 5 Ea.
361320 4500 Service Station Wiper 2 Ea.

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STARTER KIT
1. Unpack the Consumables . Check that all items are present and undamaged. Place everything neatly in a location convenient to the
printer.
NOTE: Use the packing list to make sure that all Starter Kit items have been received.
2. Unpack the accessories and use the checklist inside the lid of the box to conrm that all items are present.
Regular CSK:
• VisiJet C4 Spectrum Core 5kg container (4)
• VisiJet C4 Spectrum Clear 800 mL cartridge (4)
• VisiJet C4 Spectrum Cyan 300 mL cartridge (4)
• VisiJet C4 Spectrum Magenta 300 mL cartridge (4)
• VisiJet C4 Spectrum Yellow 300 mL cartridge (4)
• Waste Tray (4)
Super CSK:
• VisiJet C4 Spectrum Core 5kg container (8)
• VisiJet C4 Spectrum Clear 800 mL cartridge (8)
• VisiJet C4 Spectrum Cyan 300 mL cartridge (8)
• VisiJet C4 Spectrum Magenta 300 mL cartridge (8)
• VisiJet C4 Spectrum Yellow 300 mL cartridge (8)
• Waste Tray (8)

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INSPECT INTERIOR of PRINTER
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IMPORTANT: Initial installation of the printer should always be conducted with all external covers removed. Covers should not be rein-
stalled until all uids have been loaded and uid system has been conrmed free of leaks.
REMOVE COVERS
1. Lower Rear Cover:
Release the two handles. Cover will tilt towards you and
can be lifted clear.
2. Left and Right End Covers:
a. Have an assistant release the spring-loaded rod by pull-
ing as indicated.
b. As the assistant releases the rod, swing the bottom of
the end cover outwards and then lift up slightly to re-
move.
c. Repeat for the opposite end cover.

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3. Upper Rear Cover
Holding the upper and lower edges, lift the cover directly
upwards to disengage.
INSPECT “TIP AND TELL”
Check the “Tip and Tell” indicator inside the printer
IMPORTANT: If blue beads are present in the upper por-
tion of the indicator this indicates that the system has been
mishandled.
In this instance call 3D Systems Service Department im-
mediately. DO NOT proceed with the installation until you
have discussed this with Service.

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INSPECT INTERNAL CABLE, FLUID & VACUUM CONNECTIONS
3. Check all electrical and uid connections to Fluid
Reservoirs. Check all electrical and hose connections
to Feeder.
Cable and hose connections can come loose during shipping - It is important to conrm that all connections are properly in place before
applying power or adding uids.
1. Internal Box Connections
Loosen the four (4) screws that mount the E-box to the Printer
Chassis (not the screws that hold the E-Box cover on).
2. Tilt the E-Box outward until it comes to rest.
Check all cable connections to the E-Box to ensure that
they are securely connected.

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5. Check hose connections to Rotary Vacuum Valve.
6. Check electrical and uid connectons to pumps.
4. Check all electrical and hose connections to compressor
and negative-air system.

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NOTE: Leave all the covers off until the installation is complete.
7. Check uid connections where IGUS Chain meets the Fast
Axis.
8. Check all uid and air connections at Carriage and Print
Heads.

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INSTALLATION SCRIPT & FLUID LOADING PROCEDURE
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IMPORTANT: Although the Installation Script on the printer LCD will walk you through many of the installation steps, it is important to refer
back to these instructions often for additional information that is critical for successful installation.
All network connections must be approved by the customer or customer’s IT manager prior to installation.
The most common methods of connecting the 3D Printer are as follows:
• 3D Printer connected to ethernet network running DHCP with dedicated computer connected to same network.
• 3D Printer connected directly to dedicated PC - Static IP Addresses are used on both devices.
1. Connect the Power Cord to the EBox.
Note that the cord must rst be fed up through the opening in the bot-
tom of the printer (indicated by arrow). This is necessary to allow for
proper mounting of covers.
2. Connect Power Cord to AC main outlet.
NOTE: Most facilities have one (1) circuit breaker for ve (5) or six (6) outlets. It is best to not share the circuit that the 3D Printer is using
with other equipment sharing the circuit that might exceed the wattage of the supplying circuit breaker and cause it to trip.
Ideally, an outlet on a dedicated circuit should be used for the 3D Printer.

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4. INSTALLATION MODE. REFER TO INSTALLATION GUIDE is
displayed. Press CONTINUE
5. This alert message lets you know that the Network Cable should now
be connected.
Connect one end of a CAT-5 network cable to the Ethernet port on the
E-Box and the other to your network hardware or PC.
Click CONTINUE on LCD
3. Power on unit by ipping power switch on E-Box.

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7. This alert message explains the process of changing the current
conguration type.
Press CONTINUE.
8. REBOOT NOW? is displayed.
TO USE DHCP CONFIGURATION:
Select NO - The printer will now automatically be assigned an address.
You can now skip to step 9 of these instructions.
TO USE STATIC IP CONFIGURATION:
Select YES and then a screen appears informing you to immediately
press and hold the Control Knob as the printer reboots.
This process allows you to manuallyenter an IP address.
Perform the following steps: “A” through “E” on the next page.
6. This alert message indicates what the current network conguration
is set to (installs of new machines will always default to DHCP).
Press CONTINUE.