Connex Connex500 Installation and operation manual

DOC-13000 Rev. E 7–1
Operating & Maintaining the
Connex500/350 3-D Printer
StartingtheConnexPrinter ............................................................... 2
LoadingModelandSupportCartridges.......................................... 4
ProducingModels ............................................................................... 5
PrinterInterfaceColor Key.................................................................. 7
PrintingIndicators ................................................................................ 8
ResumingProductionAfterPrintinghasStopped......................... 9
ChangingtheModelMaterial ......................................................... 10
KeepingtheConnexPrinterinIdleMode..................................... 15
ShuttingDowntheConnexPrinter ................................................ 16
MaintainingtheConnexPrinter ..................................................... 18
RoutineMaintenanceSchedule......................................................... 18
CleaningthePrintHeads................................................................... 19
PatternTest........................................................................................... 21
ImprovingPrintQuality .................................................................... 22
CleaningandReplacingtheWiper................................................... 23
ReplacingtheRollerScraper(Knife) ................................................ 28
AligningthePrintHeads ................................................................... 30
CalibratingPrintHeads ..................................................................... 34
ReplacingPrint Heads........................................................................ 40
TestingandCalibratingtheUVLamps ........................................... 49
CalibratingtheLoadCells ................................................................. 51
ReplacingtheOdorFilter................................................................... 52
ReplacingtheUVLamps ................................................................... 52
Built‐inTests......................................................................................... 57
ReplacingtheWasteContainer ......................................................... 62
CleaningtheExteriorPanels ............................................................. 64

Operating & Maintaining the Connex500/350 3-D Printer
7–2 DOC-13000 Rev. E
Figure 7-1: The Connex500 3-D Printer
Starting the Connex Printer
1. Turnonthemainpowerswitch,locatedatthebackoftheConnex
printer.
Figure 7-2: Main power cable and switch
ThemainpowerswitchturnsontheConnexprinter,whichincludes
thebuilt‐inConnexcomputer.
Printer cover
Printing-materials &
storage compartment
CAUTION!
•Do not attempt to operate the Connex printer before being trained by
an Objet customer-support representative.
•Observe all safety warnings and follow the safety guidelines described
in chapter 2.

DOC-13000 Rev. E 7–3
Connex500/350 User Guide
2. Afterthecomputerboots,logintoWindowsandlaunchtheConnex
controlapplication:
•Onthecomputerdesktop,double‐clicktheConnexprintericon.
or—
•FromtheStartmenu,selectObjet > Connex500/350Connex500/350.
TheConnexprinterinterfacescreenopens(seefigure 7‐3).Allmonitoring
andcontrollingoftheConnexprinterisdonefromthisinterface.
Figure 7-3: Connex500 interface
A valid HASP key is required on the printer computer for the application to
open. This key should be installed during printer installation. If the
application does not open and a HASP message appears, contact your
dealer or Objet Customer Support.
Printer mode Current activity
Support material
cartridges
Display
toggle button
Pause button
Stop button
Online/offline
button
Model material
cartridges
Connex installations utilize one monitor for displaying both the computer
running Objet Studio / Job Manager and the computer installed inside the
printer. Make sure that the KVM (keyboard-video-mouse) switch is in the
correct position so that the Connex printer interface is displayed.

Operating & Maintaining the Connex500/350 3-D Printer
7–4 DOC-13000 Rev. E
Loading Model and Support Cartridges
Connexprintersusetwocartridgesofmodelmaterialandtwocartridgesof
supportmaterial,eachweighing3.6kilogramswhenfull.Agraphical
representationofthecartridgesandtheircurrentweightappearsinthe
printerinterface(seefigure 7‐3).
——
Important:Ifyouneedtoreplacethemodelmaterialcurrently
installedwithanothertype,see“ChangingtheModelMaterial”
onpage 7‐10.Otherwise,makesuretoreplacethemodel
cartridgewithonecontainingthesametypeofmaterial.
To load model and support cartridges:
1. OnthefrontoftheConnexprinter(seefigure 7‐1),pullopenthedoors
ofthestoragecompartment.
2. Ifyouarereplacingacartridge,graspitshandleandpullthecartridge
out,takingcarenottotwistorturnit.
3. Loadmodelandsupportcartridgesintotheirrespective
compartments—themodelcartridgeontheright,andthesupport
cartridgeontheleft.(Notethatthecartridgesonlyfitintotheircorrect
compartments.)
Youshouldfeelsomeresistance,asaneedlepiercesthecartridge.
4. ChecktheConnexprinterinterfacetomakesurethatthenewcartridge
isdetectedandthatitsweightisdisplayed(seefigure 7‐3).
5. Closethestorage‐compartmentdoor.
The printer uses RFID technology to automatically identify the material
cartridges. For this purpose, an RFID module is part of the printer hardware.
Tampering with this module will render the printer inoperable and may void
Objet warranties and service contracts.
Tips about replacing cartridges:
•You can replace material cartridges either before or during printing.
•You can replace partially used cartridges to avoid the need for replacing
them during printing.
•You can load partially used cartridges, as long as they contain more
than 100 grams of material.

DOC-13000 Rev. E 7–5
Connex500/350 User Guide
Producing Models
TheConnex500/350printerproducesmodelsbyprintingtrayfiles
preparedintheObjetStudioapplicationandsenttotheprinterfromthere.
Forinformationaboutpreparingmodelfilesforprinting,see”UsingObjet
Studio”orObjetStudioHelp.
To prepare the Connex printer for producing models:
1. MakesurethatthebuildtrayintheConnexprinterisemptyandclean.
Ifnot,removeoldmaterialwiththescraper,andcleanthetray
thoroughlywithcleaningfluid.
2. Makesurethatthereissufficientmodelandsupportmaterialloaded
intheprinter,asindicatedintheConnexprinterinterface(see
figure 7‐3).Youmaywanttoreplacethecartridgesofmodeland
supportmaterialcurrentlyloadedintheprintertoavoidtheneedfor
replacingthemduringprinting.
3. AtthebottomoftheConnexprinterinterface,clicktheredbuttonto
switchtheprintertoonlinemode.
Thecolorofthebuttonchangesfromredtogreen(seefigure 7‐4).If
thereisajobintheJobManagerqueue,itissenttotheprinter.
OntheConnexprinterinterface,theprintermodechangesfromIdletoPre‐
print,astheprinter’scomponentspreparethemselvesforproduction:
•Theprintblockisheated.
•TheUVlampsarepoweredandtheywarmup.
Whenprintingbegins,JobManagersendssevenslicestotheConnex
printer.ThisisthestandardbufferbetweentheJobManagerandthe
printer.Aseachsliceisprinted,theJobManagersendsanotherslicetothe
printer.
Dependingonthesizeofthemodel(s)tobeproduced,printingcantake
betweenseveralhourstoseveraldays.Aslongasthereisenoughmodel
andsupportmaterialinthesupplycartridges,printingproceeds
automaticallyuntilthejobisfinished.
Before beginning to produce models, it is recommended that you check the
current printing quality of the print heads by performing a pattern test (see
“Pattern Test” on page 21).
CAUTION: Use protective gloves when cleaning the build tray, and be
careful of the sharp edges of the scraper blade.
Forinstallingmaterialcartridgesandreplacingemptyones,see
“LoadingModelandSupportCartridges”onpage 7‐4.
Forchangingthetypeofmodelmaterialcurrentlyloaded,see
“ChangingtheModelMaterial”onpage 10.
During printing, the server computer must remain on and it must
communicate with the Connex printer. Do not log-off Windows until printing
is finished.

Operating & Maintaining the Connex500/350 3-D Printer
7–6 DOC-13000 Rev. E
TheConnex500/350printerusesoneortwomodel‐materialcartridgesand
onesupport‐materialcartridgetoproducemodels.Ifadditionalcartridges
areinstalledandtheyarenotneededforthecurrentprintjob,theprinter
interfaceindicateswhicharebeingused:
•Bluecartridge—usedfortheprintjob
•Graycartridge—notusedfortheprintjob
Youcanmonitorprinterstatusindicatorsbyswitchingtheprinterinterface
display.Todothis,clickthedisplaytogglebuttonintheprinterinterface
screen.
Figure 7-4: Connex printer indicators
Block temp.
in front of
support heads
Block temp.
behind
support heads
Waste weight
Display
toggle button
Printer set to
online mode
(green)
Temp. of each
support head
Chamber temp.
Left UV lamp
Right UV lamp
Block temp.
behind model
heads
Temp. of each
model head
Block temp. in
front of model
heads
Support/Model
material in print-
block reservoir
System
vacuum level
Pre-heating of
support & model
material

DOC-13000 Rev. E 7–7
Connex500/350 User Guide
Printer
Interface
Color Key
Thebackgroundcolorsintheprinterindicatorfieldstellyouataglance
whetherornotthevalueoritemissuitableorreadyforprinting.
•Green—suitable/readyforprinting
Forexample,infigure 7‐4:
Ambient—Theambienttemperatureoftheprintingchamberis
withintheacceptablerange.
HeadsLiquid—Thelevelofmodelandsupportmaterialintheprint‐
blockreservoirisOK.
HeadsVacuum—Thevacuumlevelinthesystemiswithinthe
acceptablerange.
•Red—notsuitableforprinting(orindicatesawarning)
Forexample,infigure 7‐4:
Waste—Theweightofthewastecontainerisgrams,morethan
allowedwhenbeginningaprintjob.(See“ReplacingtheWaste
Container”onpage 7‐62.)
•Blue—notready
Forexample,infigure 7‐4:
UVlamps—TheUVnoton.
Heads(°C)—Theheadshavenotreachedthetemperaturerequired
forprintingmodels(inprintingmode).
Thecolorofthematerialcartridgesdisplayedintheprinterinterface
indicateswhichcartridgesareactiveforthecurrent(ornext)printjob.
•Blue—activecartridges
•Gray—reservecartridges

Operating & Maintaining the Connex500/350 3-D Printer
7–8 DOC-13000 Rev. E
Printing
Indicators TheprinterinterfacescreenchangeswhenyousendaprintjobfromJob
Managertotheprinter,andtheprinterisonline(seefigure 7‐5):
•ThemodechangesfromPre‐printtoPrinting.
•Thespecificactivitybeingperformedisshowninthe“currentactivity”
field.
•Currentjob‐printinginformationisdisplayed.
•Theprintingprogressbarisdisplayed.
•TheStopandPausebuttonsareenabled.
Whentheweightofacartridgedropsbelow100grams,thedisplayofthe
materiallevelintheprinterinterfaceisred.
Figure 7-5: Connex printer interface during printing
Current Activity
Job information
Progress bar
Pause button
Stop button
Printer mode
Job information

DOC-13000 Rev. E 7–9
Connex500/350 User Guide
Resuming Production After Printing has Stopped
Iftheprintingprocessisinterruptedforanyreason,JobManagerstops
sendingslicestotheConnexprinter.
To continue printing the model:
1. Switchtheprintertoonlinemodebyclickingtheredbuttonatthe
bottomoftheConnexprinterinterface(seefigure 7‐3onpage 3).
Thebuttonchangesfromredtogreen(seefigure 7‐4onpage 6).
2. MakesurethatthecomputernetworkconnectingtheprinterandJob
Managerserverisactive.
3. IntheJobManagerinterface,clicktheResumeicon.
4. IntheContinuefromSlicedialogboxthatappears,confirmtheslice
number,aftercheckingtheConnexprinterinterface.
Figure 7-6: Connex printer interface after interrupted printing
Figure 7-7: Continue from Slice confirmation dialog box in server
(Job Manager) interface
5. If,foranyreason,thecorrectnumberdoesnotappearinthedialog
box,enterthenumberandclickOK.
Youcannotcontinueprintingthemodelif:
•ThenumberofthelastsliceprinteddoesnotappearintheConnex
printerinterface,eveniftheservercomputerdisplaystheContinuefrom
Sliceconfirmationdialogbox.
•Therewasarelativelylonginterruptioninprinting,evenifthe“last
slice”and“continuefromslice”indicatorsarecorrect.Thepartofthe
modelalreadyprintedmaydeformorshrink,andtheremightbea
visibledifferencebetweenitandthenewlyprintedpart.Theeffectsofa
printingstoppageonamodeldependonthemodelsizeandstructure,
modelmaterialused,ambienttemperatureandthelengthofthe
stoppage.
Printer mode
Last slice
printed

Operating & Maintaining the Connex500/350 3-D Printer
7–10 DOC-13000 Rev. E
If you cannot continue printing:
1. CanceltheprintjobinJobManager.
2. Removethepartiallyprintedmodelfromthebuildtray.
3. SendthejobtotheConnexprinteragain.
Changing the Model Material
Beforeproducingmodelsusingadifferenttypeofmodelmaterialthanis
currentlyinstalled,runtheMaterialReplacementwizardtoflushtheprint
blockandfeedtubes.
To replace the model material:
1. StarttheMaterialReplacementwizardfromtheOptionsmenu.
Figure 7-8: Starting the Material Replacement wizard from the Options menu
2. Intheopeningscreen,clickNext.
3. Iftheprintercoverisnotclosed,ascreenappearsinstructingyouto
closethecover.ConfirmthatitisclosedandclickNext.
You can stop and later resume printing from either the Connex printer
interface or the Job Manager interface, since both applications are updated
when you use these commands. However, after clicking the Pausebutton in
the printer interface, you can only resume printing from the printer interface.
You should carefully plan printing models with different model materials to
avoid unnecessary waste of the material loaded in the printer. The amount
of material flushed depends on the flushing cycle chosen and if you are
replacing one or both cartridges.