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.