POSTPROCESS DECI-SR007-02 User manual

PostProcess Technologies, Inc. • www.postprocess.com • REV A
DECI CE User Manual
Automated Support Removal System Original Instructions

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Copyright
Conventions
Copyright © 2018 by PostProcess Technologies Inc. “PostProcess”. All rights reserved. The information
disclosed herein is proprietary information owned by PostProcess. This information shall be used solely and
exclusively by employees and customers of PostProcess as documentation for the safe operation of
processing equipment provided by said company. The information herein shall be used by or disclosed to others
only for this purpose.
Published: September 2018
Disclaimer: The content of this guide is subject to change without prior notice. Please contact PostProcess for
the most current information. Items marked with an asterisk * have been identied as likely to be updated.
Picture on front cover is for illustrative purposes only and does not reect actual dimensions.
Draws attention to an operating procedure, practice, or condition, etc., that may result in injury or death if not
carefully observed or followed.
Draws attention to an operating procedure, practice, or condition, etc., that may result in damage to equipment if
not carefully observed or followed.
Draws attention to an operating procedure, practice, or condition, etc., that must be emphasized or provides
information to simplify procedures tasks.
Any time a screen or button is referenced the following formatting will be used.
Screens – References to a screen on a machine will be Bold and Italicized. References to gauges on a screen will
be italicized.
Buttons – References to a button that can be pressed or activated by an operator will be BOLD AND
CAPITALIZED.
Safety Pictograms
Use Nitrile Gloves
Lockout / Tagout
Consult Operator’s
Manual
Use Eye Protection
Electrical Hazard
Caution Hot Surface
Power On /
Power Off
Grounding /
IEC Earth Symbol
Arc Flash Hazard
NOTE
CAUTION
WARNING

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Table of Contents
Overview 5
Warnings, Cautions and Notes 5
Physical Description 7
1. Operation 9
1.1 Connecting Power to the DECI 9
1.2 Powering Up the DECI 10
1.3 Automatic Operation - Setup/Start 11
1.3.1 Auto Setup Controls 12
1.3.2 System Information 13
1.3.3 Features 14
1.3.4 Setting Auto-Temperature Operation 15
1.3.5 Setting Auto-Drain/Dose Operation 16
1.3.6 Recipe Management 16
1.3.7 Auto Run Mode 18
1.4 Manual Operation Screens 20
1.4.1 Manual Motion 22
1.5 Maintenance Operations 23
1.5.1 Filter Screen Maintenance 24
1.5.2 pH Sensor Maintenance 25
1.5.3 Dosatron Maintenance 26
1.6 Alarms and Warnings 28
1.6.1 Alarm Conditions 28
1.6.2 Warning Conditions 29
2. Dosatrons 30
2.1 Priming the Dosatrons 30
3. Troubleshooting 31
3.1 There is a decrease in water/detergent ow, or the ow has stopped. 31
3.2 The ALARM BUTTON is lit up and the DECI will not operate. 31
3.3 The DECI Controller touchscreen is not reacting properly. 31
3.4 Water or liquids are leaking inside of or around the DECI. 31
3.5 The internal passages of the part are not being fully cleaned. 31
3.6 The lter screen and particle lter have buildup or blockages. 32
3.7 The liquid temperatures are running too hot or too cold. 32
3.8 There is excess foam in the processing chamber. 32
3.9 The DECI is not stationary or stable 32
3.10 Where can I nd the DECI Serial Number? 32
4. Point of Contact 33
5. Revision History 33
6. Appendix A 34
Conguration Settings 34
Agitation Settings 35
Setup 38
7. Appendix B 46
Noise 46
Moving the Machine 46
Decommisioning and Disposal 47
Spare Parts List 47
CE Declaration of Conformity 48

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List of Figures
Figure 1. Location of Master Power Switch 9
Figure 2. Master Power Switch “ON” 9
Figure 3. Power Connector 9
Figure 4. Controller Screen, Power Button, and Emergency Stop Button 10
Figure 5. Automatic Operation Screen - Setup/Start 11
Figure 6. Auto Setup Screen 12
Figure 7. Hardware Status 13
Figure 8. System Information Screen 14
Figure 9. Features Enabling Screen 14
Figure 10. Auto-Temperature Conguration Screen 15
Figure 11. Recipe Save As Screen 16
Figure 12. Recipe Overwrite Warning Screen 17
Figure 13. Enter Recipe Name Screen 17
Figure 14. Recipe Selection Screen 17
Figure 15. Auto Run Screen 18
Figure 16. Auto Run Warning Screen 19
Figure 17. Home Screen 20
Figure 18. Manual Operations Screen 20
Figure 19. Manual Motion Screen 22
Figure 20. Filter Screen Maintenance Screen 23
Figure 21. pH Sensor 25
Figure 22. pH Sensor Maintenance Screen 25
Figure 23. Dosatron Maintenance Screen 26
Figure 24. Dosatrons 27
Figure 25. Alarms and Warnings Screen 28
Figure 26. Dosatrons Conguration 30
Figure 27. Caster with Ratchet 32
Figure 28. Conguration Screen 35
Figure 29. Level 1 Agitation Valve Conguration Screen 35
Figure 30. Agitation Valve Conguration Screen 36
Figure 31. Segments Screen 36
Figure 32. Run Time Screen 37
Figure 33. Taper Screen 37
Figure 34. Level 0 Screen 38
Figure 35. System Conguration Screen 38
Figure 36. Auto-Temperature Conguration Screen 39
Figure 37. Heater Conguration Screen 40
Figure 38. Heater Conguration Screen 2 41
Figure 39. Over Temperature Conguration Screen 41

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PostProcess Technologies detergents are specically formulated chemistry for maximized 3D printed support
removal efciency. It is recommended that the equipment be located in a well ventilated room. Specic
ventilation requirements can vary widely due to size of the install room, existing ventilation (positive or negative)
and differences in individual sensitivities to airborne scents or fragrances. For more information on the safe use
of PostProcess detergents refer to the SDS for the specic detergent used.
Overview
Warnings, Cautions and Notes
This User Manual is intended to explain the setup and operation of the DECI Support Removal
machine. Read this guide thoroughly before operating the DECI to ensure safe and efcient
operation. If a question is not answered in this guide, contact PostProcess for additional support.
The DECI applies patent-pending technology, including optimized energy through agitation in combination with
proprietary, eco-friendly detergents and heat to remove excess material deposited during 3D printing processes.
While the DECI is robust, care should be used during operation. When accessing the main chamber, gently open
and close the chamber door. Be careful when extracting nished parts to limit the amount of detergent that is
lost during the part removal process. Ensure no heavy materials are stored above the DECI that may fall and
damage it.
Failure to adhere to any of the warnings below could result in personal injury or damage to equipment.
Improper use of PostProcess equipment may void the warranty. Read thoroughly before operating
the machine. If the machine appears to be malfunctioning in any way, immediately PUSH the
EMERGENCY STOP button and refer to the Troubleshooting section of this guide on page 31. If the
issue is not able to be resolved, call PostProcess Support.
Caution should be used whenever working with industrial-powered equipment. If there is an emergency situation,
it is important to note that hitting the EMERGENCY STOP button does not turn off power to the DECI. It turns off
the DECI’s operating cycle only. To shut off power to the DECI, turn off the MASTER POWER SWITCH, located on
the front left panel of the DECI. (For a visual of the switch location, see Figure 1. Location of MASTER POWER
SWITCH)
GHS Hazards
Warnings
Ventilation

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Warnings, Cautions and Notes
• Do not operate the unit without proper grounding.
• Do not allow alcohol, gasoline or other ammable solutions near the machine. Doing so could
cause a re or explosion.
• Do not attempt to disassemble or repair the machine.
• Do not place the power cord in a location where it may come into contact with water or liquids.
• Connect the unit only to three-phase 400v power 50Hz.
• Use only PostProcess detergents. Do not add any other liquid solutions to the machine.
• Do not operate the machine without sufcient detergent in the tank.
• Do not touch the detergent with bare skin. Use nitrile gloves, laboratory-style
eyeglasses and other necessary personal protective equipment when performing
any operations including removing parts where skin could come into contact with
the detergent.
• When working with or near detergents, always wear nitrile gloves.
• Wear laboratory-style protective glasses.
• If bare skin comes in contact with detergent, thoroughly wash the body part with
soap and warm, clean water.
• It is recommended that an eyewash station is near the DECI and any detergent
storage areas.
Caution should be used whenever working with industrial-powered equipment.
If there is an emergency situation, it is important to note that hitting the
EMERGENCY STOP button does not turn off power to the DECI. It turns off the
DECI’s operating cycle only. To shut off power to the DECI, turn off the MASTER
POWER SWITCH, located on the left-side panel of the DECI.
Electrical Safety
Residual Risks
Foreseeable Misuse
The EMERGENCY STOP button should only be used in actual emergency situations. For any other
situation requiring the machine to be powered down, use the MASTER POWER SWITCH.
NOTE
The operating environmental temperature must be between 10°C and 40°C (50°F to 104 °F), and humidity
between 20% and 80% relative humidity, non-condensing.
Environmental Temperature and Humidity

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Physical Description
Envelope and Capacity
Internal Envelope Dimensions:
Length: .48 m Width: .7 m Height: .66 m
The maximum tank capacity is approximately 75.7 liters.
The maximum part weight for the xture is 22.7 kg.
Power and Electrical
Phases: 3 Voltage: 400 Amperage: 30
Cord: 5 wire Lapp ÖLFLEX® Gauge: 8
Plug: Hubbell HBL516P6W (1.83 m cord)
Recommended Connector or Receptacle:Hubbell HBLS530C6W* (Female Connector) or
Hubbell HBLS530R6W* (Female Receptacle) and BB2030N* (housing)
*Not supplied with machine
Size and Weight
External Dimensions (Doors Open):
Length: 1.13 m Width: 2.09 m Height: 2.54 m
External Dimensions (Doors Closed):
Length: 1.13 m Width: 1.03 m Height: 2.38 m
Note: This height is measured to a removable stack light. The maximum xed height (with stack light
removed) is 2.12 m.
Approximate Weights:
Empty: 317.5 kg Full: 453.6 kg
High Leakage Current - Earth connection essential before connecting supply. Incoming Primary Earth conductor
must be a minimum of 10mm2 CSA.
NOTE

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Dimension Drawings
Physical Description
Closed-door dimensions Open-door dimensions

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1. Operation
The DECI is delivered with an industrial power cord. Use only the power cord supplied by PostProcess with the
DECI. Connect the DECI only to 3-phase 400v power 50Hz. Do not place the power cord in a location where it
could come into contact with water or other liquid substances. It is recommended to keep the entire power cord
suspended above the oor surface.
The MASTER POWER SWITCH is located on the left side of the DECI in the upper right corner (Figure 1.
Location of Master Power Switch). Before connecting or disconnecting the DECI to a power outlet, or inserting
or removing the power cord, ensure the MASTER POWER SWITCH is in the horizontal “O” or OFF position (Figure
2. Master Power Switch “ON”).
When the power cord is connected to the DECI and plugged into a 3-phase 400v 50Hz power outlet, turn the
POWER switch 90 degrees clockwise to the vertical “I” or ON position. The DECI is now ready to be powered up.
Figure 1. Location of Master Power Switch Figure 2. Master Power Switch “ON”
To turn off the Master Power Switch grab
the handle and rotate counter clockwise
90° to the OFF position.
The Master Power Switch is located
on the left side in the upper right corner.
The DECI utilizes 400v 50Hz power
provided through an industrial power
cable/connector located on the upper
rear of the unit as shown in Figure 3.
Power Connector.
Figure 3. Power Connector
1.1 Connecting Power to the DECI

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1. Operation
The POWER button for the DECI is located to the lower left of the Controller Touchscreen (Figure
4. Controller Screen, Power Button, and Emergency Stop Button). To power up (or down) the
DECI, press the POWER button. If the POWER button is illuminated, the DECI is on.
Below the Controller Touchscreen on the right is the Emergency Stop button (shown below, right)
Figure 4. Controller Screen, Power Button, and Emergency Stop Button
If the DECI is not used for a period of time it may be necessary to run the heater in Manual Mode to bring the
detergent in the tank up to the appropriate operating temperature. Please see Section 1.4 Manual Operations for
more information on how to increase operating temperatures. For more information on how temperature impacts
post-processing, see Appendix A.
NOTE
CAUTION
If the DECI appears to be malfunctioning in any way, immediately PUSH the EMERGENCY STOP button and
refer to the Troubleshooting section of the Manual. If the issue is not able to be resolved, contact PostProcess
Support.
1.2 Powering Up the DECI

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1. Operation
To access the Automatic Operation screen (Figure 5. Automatic Operation Screen - Setup/Start), from the
Home screen press the AUTOMAT3D™ button. The cycle settings are selected on the Auto Setup screen. The
DECI will retain the settings from the previous cycle. If no changes need to be made, press the START icon to
begin the cycle. If new settings are required, see Section 1.3.1 Auto Setup Controls.
1.3 Automatic Operation - Setup/Start
The DECI is designed to be fully automatic and congured to
remove supports from the following 3D print technologies:
FDM, SLA, CLIP, Polyjet, and others. The DECI is engineered to
utilize an automated Volume Velocity Dispersion system that
is congurable based on a specic operational need. To learn
more please refer to DECI Conguration Settings.
The top side of the DECI houses the envelope (or chamber).
The envelope is roughly 47cm x 65cm x 74 cm (18” x 25 1/2” x
29”). The door utilizes a counterweight system to keep it open
once opened, yet caution should be used when reaching into the
chamber.
Figure 5. Automatic Operation Screen - Setup/Start
To begin the support removal cycle, press the POWER button to ON and wait for the Main Menu screen to display.
Whenever an operator is handling detergents, nitrile gloves and eye glasses should be worn.
NOTE

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1. Operation
1.3.1 Auto Setup Controls
Three settings can be congured on the Auto Setup screen (Figure 6. Auto Setup Screen). The settings must be
properly congured based on the unique properties of the parts to be processed by the DECI and are discussed
in greater detail below.
At the upper, left are four buttons that control the Agitation (Energy) Level by conguring the spray nozzles
to operate in a predetermined sequence. These settings are congured by PostProcess personnel during the
installation process. For detailed information about conguring the settings, see the DECI Appendix A.
Run Time - To set the desired run time for
the automatic cycle use the + / - to adjust
the Hours (Left) and Minutes (Right).
Temperature Control – Use the slider to set the desired
temperature of the detergent in the tank. The operator can
also use the + / - to adjust the temperature.
Figure 6. Auto Setup Screen
Press (4) for High Agitation – bottom spray nozzles and the upper narrow-angle nozzles all
operate for the highest agitation.
Press (3) for Medium Agitation– bottom spray nozzles, one upper narrow-angle nozzles and
the upper wide angle nozzles operate for higher agitation.
Press (2) for Low Agitation – spray nozzle conguration for low level combination of bottom
nozzles and upper nozzles.
Press (1) for Ultra-Low Agitation –bottom spray nozzles only.
The selected Agitation Level turns ORANGE while non-selected levels remain BLUE.

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1. Operation
After adjusting the settings to their appropriate levels for the part to be cleaned press the START button
on the left side of the screen (as shown above).
To select a Recipe having the desired settings (See Section 1.3.6 Recipe Management) press the
SELECT RECIPE button.
To save newly created Automatic Cycle settings as a Recipe for future use (See Section 1.3.6 Recipe
Management) press the SAVE RECIPE icon.
The icons on the right of the screen control access to basic functions.
1.3.2 System Information
The operator can access basic system information by pressing the INFORMATION button from any screen.
Figure 7. Hardware Status
LIGHT - Turns the chamber light on/off
HOME - Returns to the Home Screen.
INFO - For machine data.
CONFIGURATION - For basic system settings.
ALERTS - Displays Alarm conditions.
(See Section 1.6 Alarms and Warnings).

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When multiple pages are available, the screen will have a right/left arrow to allow navigation between the screens
(Figure 8. System Information Screen). To close the Information screens, press the X.
Figure 8. System Information Screen
1.3.3 Features
Figure 9. Features Enabling Screen
When the FEATURES button is pressed, the operator has access to basic operational functions . As shown in Figure
9. Features Enabling Screen the Features menu has three areas that can be adjusted.
Press the Xbutton
to exit the Features
screen. A conrmation
will display.
1. Operation
Press the RIGHT
ARROW to access
the Auto-Drain/Dose
Conguration Screen.

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Standby – Because heat is an important component of post-processing, the DECI has functionality built-in to
allow the detergent to be maintained at a certain temperature when the machine is not in use. The AUTO-
TEMPERATURE button should be enabled if the tank needs to be kept at a constant temperature between
cycles. If AUTO-TEMPERATURE is not enabled, the DECI tank heater will need to be run manually to bring the
temperature up to the desired level before starting the cycle.
Auto-Drain – When enabled, the tank will automatically drain after the completion of a user dened amount of
auto cycles.
Auto-Level - When enabled, the tank level will be monitored at a user dened interval. If the tank level drops
below a predened level the tank will be automatically dosed back to 100%. A message will appear to inform the
operator.’
Auto-pH - When enabled, the tank’s pH will be monitored. If the pH falls below the Minimum Operational pH Level
a warning will become active and the tank will be automatically drained and re-dosed to correct the pH level. A
message will appear to inform the operator.
Advanced Output – If enabled, system data is collected for PostProcess Support.
Light Stack Test – When pressed the light stack will illuminate so the operator can verify that the lights are
operational. The light stack should be tested at the beginning of each shift.
Power – When pressed a menu will appear for restarting the PC, shutting down the PC, or exiting the application.
1.3.4 Setting Standby Operation
Temp Setpoint – Use the slider bar to set the desired tank temperature for Auto-Temperature mode.
Temperature Check Wait Time – Sets the time between temperature checks while in Auto-Temperature mode.
Press the LEFT ARROW
to return to the
Features screen.
Figure 10. Auto-Temperature Conguration Screen
Once the AUTO-TEMPERATURE is enabled, the operator can adjust the Auto-Temperature Conguration settings.
To access the settings, press the “right arrow” from the Features Enabling Screen.
1. Operation
Press the Xbutton
to exit the Auto-
Temperature screen.
A conrmation will
display.

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1. Operation
1.3.5 Setting Auto-Drain/Dose Operation
Once AUTO-DRAIN or AUTO-DOSE is enabled, the operator can adjust Auto-Drain/Dose Conguration settings.
To access the settings, press the “right arrow” from the Auto-Temperature Conguration screen.
Number of Cycle Between Auto-Drain - Set the desired number of auto cycles that must run before Auto-
Draining occurs.
Auto-Level Check Wait Time - Sets the time between level checks during an auto cycle while Auto-Level is enabled.
Press the Xbutton on the far left to exit the
screen.
A conrmation will display.
Press the LEFT ARROW to return to Auto-
Temperature Conguration Screen.
Figure 11. Recipe Save As Screen
To Save a Recipe
Once an optimal agitation level, temperature, and duration have been discovered for a specic part being
nished, save those settings as a recipe for future use. First, press the SAVE button (Diskette icon) as shown in
Figure 11. Recipe Save As Screen.
1.3.6 Recipe Management
Through a trial and error process, as an operator becomes familiar with how certain settings react on a part
being nished, it is advisable to save the settings as a Recipe. Saving recipes can be a very useful tool in making
the nishing process more efcient.
It is recommended that the operator devise a system for identifying which recipes are optimal for each part
being nished. The easiest way to do this is by maintaining a spreadsheet.
NOTE

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Figure 12. Recipe Overwrite Warning Screen
Next, press any empty button to display the QWERTY keyboard, allowing you to enter in a recipe name.
1. Operation
If the operator selects a slot that already has a recipe stored, the warning screen as shown in Figure 12. Recipe
Overwrite Warning Screen will display.
NOTE
Figure 13. Enter Recipe Name Screen
When the operator selects an empty slot, the next step is to enter the name of the recipe using the Enter Recipe
Name screen (See Figure 13. Enter Recipe Name Screen) When nished, press the “check mark” to save the recipe.
To cancel, press the “x”.
Figure 14. Recipe Selection Screen
Using a Saved Recipe
As recipes are created for specic nishing cycles, they can easily be retrieved to quickly set the DECI for a cycle. To
access all of the saved recipes, click on the FOLDER button to display the recipes (Figure 14. Recipe Selection Screen).
Available saved recipes will be highlighted by BLUE buttons, while empty recipe slots are GRAY. Click on the desired
recipe and the DECI will load the saved settings and return the display to the Auto Setup screen.

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The Pressure Gauge icon
will display the current
pressure of the spray
valves in operation.
The CLOCK icon displays
the remaining time in the
cycle.
The pH icon will display
a current pH level of the
detergent in the main tank.
The SPRAY NOZZLES icon
displays the operational
spray valves.
The Temperature icon
will display the current
temperature of the
detergents in the tank.
Use the PAUSE button to
temporarily pause and use
the STOP button to abort
a cycle.
Once the desired settings have been selected, the DECI is ready for the cycle to be initiated. To start, press the RUN
button (Play icon) as shown in Figure 15. Auto Run Screen.
Figure 15. Auto Run Screen
1.3.7 Auto Run Mode
The last graphical element of the Auto Run screen displays the AGA Intensity Meter.
The AGA Intensity Meter is a graphic representation of the current energy output of
the system, based on the Agitation Algorithm.
1. Operation

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The DECI is designed to detect conditions at the start of an Auto Run cycle that may inhibit the performance of
the machine. These conditions are not yet at a critical stage but are presented to alert the operator to take action
in order to achieve maximum machine efciency.
The warning can be ignored and the cycle started by pressing the CONTINUE button (Figure 16. Auto Run
Warning Screen).
To take corrective action based on the warning that is presented, the operator can choose to drain the tank and
rell. To correct pH warnings, the operator can run a dosing cycle to raise the pH or add water to lower the pH.
For more information about Drain and Dose cycles refer to Section 1.4 Manual Operations. Once action is taken,
press the CONTINUE button to proceed.
After the Auto Run cycle has completed, the DECI will display a conrmation that the Automatic Run Has
Completed. Press the CHECK button to return to the Auto Run screen.
The control buttons for the cycle are shown left. As indicated, the PLAY
button is gray because the cycle is running. The two available control
buttons are PAUSE and STOP. To pause or stop the cycle for any reason,
press the corresponding button. Whenever the PAUSE or STOP button is
active, it will be gray, and the PLAY button will turn blue to show that it is
available.
Figure 16. Auto Run Warning Screen
1. Operation
If there is a question mark displayed next to the PLAY button (shown below), it is an indication that there is a
condition that is inhibiting the cycle from starting. For more information, press the question mark and a
message screen will display.
NOTE

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The rst available Manual Operations screen controls the Spray Valves, Temperature, and Mechanical Operations.
The screen components are identied in detail next.
1.4 Manual Operation Screens
Figure 18. Manual Operations Screen
The DECI can be operated in a completely manual mode. It is important to keep in mind that the congured
AUTO modes are all optimized for the most efcient operation of the support removal process. However, manual
mode may be preferred when an operator is working through trial and error scenarios with new printed parts.
From the HOME screen, press the MANUAL button to access the Manual Run screen (Figure 17. Home Screen
and Figure 18. Manual Operations Screen).
1. Operation
Figure 17. Home Screen