PVA Emergence PRO User manual

Emergence PRO™3D Printer
Operation Manual
Revision C
INNOVATION.PRECISION.EXCELLENCE.

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This document is based on information available at the time of its publication. While efforts
have been made to ensure the contents of this manual are accurate, the information
contained herein does not purport to cover all specific details or variations in hardware, or
to provide for every possible contingency in connection with installation, operation, or
maintenance. Features may be described herein which are not present in all hardware and
software systems. Precision Valve and Automation, Inc. assumes no obligation of notice to
holders of this document with respect to changes subsequently made.
Precision Valve and Automation, Inc. makes no representation or warranty, expressed,
implied, or statutory with respect to, and assumes no responsibility for the accuracy,
completeness, sufficiency, or usefulness of the information contained herein. No warranties
of merchantability or fitness for purpose shall apply.
This document, including the information contained herein, is the property of
Precision Valve and Automation, Inc. and is considered confidential and proprietary
information. It is delivered on the express condition that it not be used, disclosed, or
reproduced, in whole or in part, for any reason without prior written consent of
Precision Valve and Automation, Inc.
Copyright © 2019
Precision Valve and Automation, Inc.
All Rights Reserved.

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Table of Contents
Introduction ...................................................................................................... 6
PVA Contact Information ........................................................................................................6
Document History.....................................................................................................................6
Safety ..........................................................................................................................................7
Best Practices............................................................................................................................9
Getting Started ................................................................................................10
Unboxing...................................................................................................................................10
Local Ventilation Disclaimer ..................................................................................................11
Exhaust Flange Installation ..........................................................................................12
Initial Setup ..............................................................................................................................13
Setting Up the Printer....................................................................................................13
Setting Up the Emergence PRO™ Wireless Connection..........................................15
Connect Web Interface to Existing Network............................................................. 17
M587 Command ..............................................................................................................18
Change Web Interface to Client Mode....................................................................... 20
Emergence PRO™ Setup....................................................................................................... 24
Printer Tool Kit................................................................................................................ 24
Check Levelness of the Bed Relative to the Gantry............................................... 25
Adjust Bed Level .............................................................................................................27
Check Bed Levelness .................................................................................................... 29
Install and Gap Hot End .................................................................................................31
Remove Hot End............................................................................................................. 36
Load Filament ................................................................................................................. 36
Unload Filament ............................................................................................................. 39
Perform Test Prints ....................................................................................................... 39
Print...................................................................................................................41
Printer Control Screen...........................................................................................................41
Starting the Print ................................................................................................................... 43
MicroSD ............................................................................................................................ 43
Internet Upload............................................................................................................... 46

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G-code Files .................................................................................................................... 47
Run Test Prints...............................................................................................................48
Run G-Codes...................................................................................................................48
Monitoring the Print Process............................................................................................... 49
First Layer........................................................................................................................ 49
Next Layers ..................................................................................................................... 49
Opening the Door and Pausing the Print.................................................................. 49
Filament Break Detection System ............................................................................. 49
Helpful Recommendations............................................................................. 50
Best Practices......................................................................................................................... 50
Filament ............................................................................................................................... 50
Hot End............................................................................................................................. 50
Print Bed .......................................................................................................................... 50
Printer............................................................................................................................... 50
Cleaning and Maintenance ...................................................................................................51
Hot End Cleaning and Maintenance............................................................................51
Rail Maintenance.............................................................................................................51
Belt Maintenance ............................................................................................................51
Check for Quality.................................................................................................................... 52
Quality Checklist ............................................................................................................ 52
Quick Tips................................................................................................................................. 54
Changing Print Speed................................................................................................... 54
Changing Flow Rate ...................................................................................................... 54
Troubleshooting..................................................................................................................... 55
Probe Failed to Extend.................................................................................................. 55
Probe Failed to Trigger Error ....................................................................................... 55
Probe Unexpectedly Triggered Error......................................................................... 55
Under Extrusion ............................................................................................................. 55
Over Extrusion ................................................................................................................ 56
First Layer Not Sticking to Bed ................................................................................... 56
Print Sagging or Drooping............................................................................................ 56
Print Appears Cloudy .....................................................................................................57

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Layer Shift ........................................................................................................................57
Clogged Nozzle................................................................................................................57
Materials Errors ...............................................................................................................57
APPENDIX A ..................................................................................................... 58
Printing Terminology............................................................................................................. 58
APPENDIX B ..................................................................................................... 59
Printer Dimensions and Parts ............................................................................................. 59
X-/Y-Assembly................................................................................................................... 60
Z Assembly .......................................................................................................................61
Print Head.........................................................................................................................61
Technical Specifications and Warnings ............................................................................ 64
Warnings .......................................................................................................................... 64
APPENDIX E...................................................................................................... 65
Recommended Maintenance Schedule ............................................................................ 65
Table of Figures............................................................................................... 66
Warranty .......................................................................................................... 68
PVA Warranty Policy.............................................................................................................. 68

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Introduction
Before you operate this system, read the operation and setup manual. This will help you to
become familiar with the product and ensure successful operation.
If any questions or problems arise, contact PVA’s Technical Support department.
PVA Contact Information
Main Office PVA
One Mustang Drive
Cohoes, NY 12047
Tel [phone]
Fax [phone]
Website: rapidplaster.pva.net
Email: [email protected]et
Technical Support
Tel [phone]
Email: [email protected]
Document History
Revision
Revision Date
Reason for Changes
REV C
November 2020
Updated Getting Started and Print sections
REV B
July 2020
Emergence PRO™v2 Updates
REV A
December 2019
Initial Release
Note: All photographs and CAD model representations in this document are a “general
representation” of the system and its components. The actual appearance of the
system and its components can differ based upon customer specific configuration.

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Safety
Certain warning symbols are affixed to the machine and correspond to notations in this
manual. Before operating the system, identify these warning labels and read the notices
described below. Not all labels may be used on any specific system.
Always wear approved safety glasses when you operate or work near the
workcell.
Before you operate the system, read and understand the manuals provided
with the unit.
Never put hands or tools in areas with this symbol when the machine is in
operation. A dangerous condition may exist.
Read and understand the manuals provided with the unit before any repairs
or maintenance is done. Only a qualified individual should do service.
Use caution when there are pressurized vessels. Find and repair any leaks
immediately. Always wear appropriate safety equipment when you work
with pressurized vessels or vessels that contain chemicals.
Shear hazard from moving parts. Avoid contact.
Do not remove protective guarding.

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In situations where inattention could cause either personal injury or damage
to equipment, a warning notice is used.
Do not smoke near the machine. Always have a fire extinguisher available
for emergency use.
Before performing any repairs or maintenance to the system, turn off power
and lock out the power disconnect switch.
Warning notices are used to emphasize that hazardous voltages, current,
temperatures, or other conditions that could cause personal injury exist in
this equipment or may be associated with its use. Only qualified personnel
should enter areas designated with this symbol.
Laser light source present. Do not stare directly into the beam. Do not use in
the presence of highly reflective surfaces
Pinch hazard from moving parts. Avoid contact.
Hot surface. Avoid contact.
Warning, Ultraviolet (UV) light hazard. Do not look directly at the UV light
source.

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Best Practices
•Do not wear loose clothes or jewelry when you operate the printer
•Do not touch the print head while it is moving
•Immediately engage the Emergency Stop button if personnel is in danger
•Locate and define all safety labels on and around the printer before you turn the
machine “On”
•Dispose of all used parts and materials in accordance with local laws and
regulations
Safety is a joint responsibility between the OEM and the end-user. All precautions and
practices should be in accordance with local regulations.
Do Not: Use incompatible tools, remove door interlocks or bypass safety devices,
make custom mechanics or change material from the original design.

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Getting Started
Unboxing
1. Remove the packaging straps from the shipping crate.
2. Open the shipping crate by first taking the lid off and then removing the sides.
3. Remove plastic wrapping around the metal ramp and any additional items that may
be included.
Figure 1: Remove Plastic Wrapping
4. Remove the four metal plates around each of the wheels by removing the lag screws
using a 9/16” socket wrench.
Figure 2: Remove Metal Plates

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5. Secure the metal ramp to the wooden pallet on the side of the printer with lag
screws from prior step.
6. Offload the 3D printer using the metal ramp with two people -- one person in front
of the printer and one person in the back.
Figure 3: Secure Metal Ramp to Wooden Pallet and Move Printer
7. Move the printer to its location and position the printer on level ground.
8. To level the printer, lower the feet by turning the red knob on each leg to stabilize the
3D printer. Turning the knob to the left lowers the foot and turning the knob to the
right raises the foot.
Local Ventilation Disclaimer
IMPORTANT: End user should consult manufacturer safety data sheets to identify if
local ventilation is required for their application and proceed as recommended. For
composite materials please consult local regulations (OSHA PELs, NIOSH RELs, and/or
ACGIH) for the particular materials being used and monitor locally to identify if local
ventilation is required.

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Exhaust Flange Installation
If local ventilation is required, follow the steps below to install the exhaust flange.
Remove cover from exhaust flange mount in the top rear corner of the machine.
Figure 4: Remove Exhaust Flange Cover
Locate the 4-inch exhaust flange provided with the machine.
Figure 5: Exhaust Flange
Install exhaust flange through top hole and secure with 4 M6X1 hex nuts.
Figure 6: Secure Exhaust Flange

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Initial Setup
Setting Up the Printer
1. Remove additional packing material from the outside of the printer.
2. Remove the key tied to the handle on the front door. The key is for the back door.
3. Open the front door and remove the green metal bracket holding the extruder in place
by removing the mounting screws.
Figure 7: Remove Bracket from Front Door
4. Remove the two green brackets attached to the print bed.
Figure 8: Remove Brackets from Print Bed

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5. Unbox the nozzle brush from the box that is shipped with the printer.
Figure 9: Nozzle Brush Box
6. Install the nozzle brush in the hole on the front left of the print bed.
Figure 10: Install Nozzle Brush

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7. Connect the power cord in the back of the printer and plug the power cord into the
120/220V* power supply. *Refer to the machine serial tag.
Figure 11: Connect Power Cord
Setting Up the Emergence PRO™ Wireless Connection
The Emergence PRO™has 2.4GHz wireless network connection capability that allows you to
use the printer remotely with a computer. For the initial setup of the printer, you will need to
use this feature.
1. Turn on the printer using the on/off switch located near the power cord
connection (Figure 11). The printer control screen will start up on its own.
2. Via a laptop or PC, connect to the network matching your printer serial number
by pressing the WiFi icon.
3. Your printer serial number will automatically be broadcasted.
Figure 12: Connecting to Network

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Note: The serial number is listed on the label located in the upper right corner of the
back panel of the printer.
Figure 13: Serial Number
4. The password for the network is PVA12345. This should not be needed next time
you connect.
5. Once connected to the network, open Google Chrome web browser and type
11.22.33.44 into the address bar. This will bring you to the web interface.
Figure 14: Web Interface

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Connect Web Interface to Existing Network
There is an option to connect an existing 2.4 GHz WiFi network to the web interface.
Note: This option is not compatible with 5 GHz networks.
1. Reserve a dedicated IP address with your IT team or via your router.
•The process to do this will be specific to your network hardware and you may
need consult the manufacturer.
2. Use the steps outlined in Section 2.3.2 to connect to the Emergence PRO’s WiFi
network.
3. Once connected, access the Web Interface.
4. Navigate to the G-Code Console.
Figure 15: G-code Console

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M587 Command
The M587 command will be used to send your desired network information to the web
interface’s G-code console. The M587 command must include three components.
•S: Network SSID
oMust be enclosed in quotation marks
oCase-sensitive
•P: Network Password
oMust be enclosed in quotation marks
oCase-sensitive
•I: IP address to use when connected to this network (optional).
oThis should be the IP address that you previously reserved
oIf zero is entered or not specified, an IP address will be acquired via DHCP.
▪This will result in your network hardware assigning the available IP
addressed based on existing devices connected to the network.
The M587 command must be written in the following format:
M587 S”WIFI_NETWORK_NAME” P”PASSWORD” Ix.xxx.xx.xxx
Example:
Network SSID
TEST_Network
Network Password
Testing123
IP Address
1.160.10.240
Using the credentials listed above, the M587 command would be as follows:
M587 S”TEST_Network” P”Testing123” I1.160.10.240

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1. In the Send G-code field, enter the full M587 command.
2. Click Send. Once received by the printer, if formatted correctly, you will see the
M587 shown in green within the system messages.
Figure 16: Enter M587 Command
Additional Commands:
•To view stored networks, enter M587
•To see the current network connection and IP, enter M552
•To remove the network from memory, enter M588 S”NETWORK_NAME”
•To remove all networks from memory, enter M588 S”*”

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Change Web Interface to Client Mode
Confirm Network Connectivity
1. Navigate to Macros to via web interface or printer’s HMI.
2. Select the Set Wi-Fi Client Mode macro.
3. The printer will temporarily switch to client mode and attempt to connect to the
assigned network until there is a power cycle or emergency stop.
4. If printer does not connect to the network, confirm network credentials, network
strength, and frequency.
•To revert the printer back to host mode, select the Set Wi-Fi Host Mode
macro to return the unit to host mode.
•To view printers current network status, the M552 command can be entered
in the console tab of the HMI.
Set Printer Wi-Fi to Start in Client Mode
5. To switch the web interface network from host mode to client mode, select
Settings.
6. Select System Editor.
7. Navigate to the config.g file and right click. Select Edit. The file will open.
Figure 17: Access System Editor