PVA Emergence PRO User manual

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

Emergence PRO™3D Printer Manual
Revision F /July 2023
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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 © 2021
Precision Valve and Automation, Inc.
All Rights Reserved.

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Table of Contents
1. Introduction...........................................................................................................6
1.1 PVA Contact Information ........................................................................................................6
1.2 Document History.....................................................................................................................6
1.3 Safety ..........................................................................................................................................7
1.4 Best Practices............................................................................................................................9
2. Getting Started ................................................................................................... 10
2.1 Unboxing...................................................................................................................................10
2.2 Local Ventilation Disclaimer .................................................................................................12
2.2.1 Exhaust Flange Installation ..........................................................................................12
2.3 Initial Setup ..............................................................................................................................14
2.3.1 Printer Tool Kit.................................................................................................................14
2.3.2 Setting Up the Printer....................................................................................................16
2.4 Emergence PRO™Setup........................................................................................................19
2.4.1 Printer Control Screen ...................................................................................................19
2.4.2 Level Print Surface Relative to Gantry.......................................................................21
2.4.3 Install and Gap Hot End ................................................................................................ 22
2.4.4 Load Filament ................................................................................................................. 24
2.4.5 Load Filament Mid-Print............................................................................................... 29
2.4.6 Unload Filament ............................................................................................................. 29
2.4.7 Remove Hot End............................................................................................................. 30
2.4.8 Setting Up the Emergence PRO™Network Connection ........................................ 32
3. Print...................................................................................................................... 34
3.1 Print Screen ............................................................................................................................ 34
3.2 Starting the Print ................................................................................................................... 35
3.2.1 Pre-Print Checklist ........................................................................................................ 35
3.2.2 MicroSD ............................................................................................................................ 36
3.2.3 Internet Upload............................................................................................................... 39
3.2.4 G-code Files ....................................................................................................................40
3.2.5 Run Test Prints................................................................................................................41
3.2.6 Run G-Codes................................................................................................................... 43

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3.3 Monitoring the Print Process............................................................................................... 44
3.3.1 First Layer........................................................................................................................ 44
3.3.2 Next Layers ..................................................................................................................... 44
3.3.3 Opening the Door and Pausing the Print.................................................................. 44
3.3.4 Filament Break Detection System ............................................................................. 44
4. Helpful Recommendations ............................................................................... 45
4.1 Best Practices......................................................................................................................... 45
4.1.1 Filament Storage and Drying........................................................................................... 45
4.1.2 Tracking Filament .......................................................................................................... 45
4.1.3 Hot End............................................................................................................................. 46
4.1.4 Touch Probe.................................................................................................................... 46
4.1.5 Print Bed .......................................................................................................................... 46
4.1.6 Printer............................................................................................................................... 46
4.1.7 Spare Parts Kit................................................................................................................ 46
4.1.8 Standby Temperature Tool.......................................................................................... 47
4.1.9 Installing Nozzle and Melt Zone Extender ................................................................ 49
4.1.10 Removing Nozzle and Melt Zone Extender............................................................... 49
4.2 Cleaning and Maintenance .................................................................................................. 50
4.2.1 Hot End Cleaning and Maintenance........................................................................... 50
4.2.2 Bed Maintenance ........................................................................................................... 50
4.2.3 Dehumidifier Charging.................................................................................................. 50
4.2.4 Rail Maintenance.............................................................................................................51
4.2.5 Belt Maintenance ........................................................................................................... 53
4.3 Check for Quality.................................................................................................................... 54
4.3.1 Quality Checklist ............................................................................................................ 54
4.4 Quick Tips................................................................................................................................. 56
4.4.1 Changing Print Speed................................................................................................... 56
4.4.2 Changing Flow Rate ...................................................................................................... 56
4.5 Frequently Asked Questions ................................................................................................57
4.5.1 Under Extrusion ..............................................................................................................57
4.5.2 Over Extrusion .................................................................................................................57
4.5.3 First Layer Not Sticking to Bed/Print Lifting from Bed..........................................57

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4.5.4 Print Sagging or Drooping............................................................................................ 58
4.5.5 Print Appears Cloudy .................................................................................................... 58
4.5.6 Layer Shift ....................................................................................................................... 58
4.5.7 Clogged Nozzle............................................................................................................... 59
4.5.8 Materials Errors .............................................................................................................. 60
4.5.9 Printer Warning Messages and Remedies ................................................................ 60
5. APPENDIX A.......................................................................................................... 61
5.1 Printing Terminology..............................................................................................................61
6. APPENDIX B..........................................................................................................62
6.1 Printer Dimensions and Parts ............................................................................................. 62
6.1.1 X-/Y-Assembly................................................................................................................... 63
6.1.2 Z Assembly ...................................................................................................................... 64
6.1.3 Print Head........................................................................................................................ 65
6.2 Technical Specifications and Warnings ............................................................................ 66
6.2.1 Warnings .......................................................................................................................... 66
7. APPENDIX C..........................................................................................................67
7.1 Recommended Maintenance Schedule .............................................................................67
8. Table of Figures .................................................................................................. 68
9. Warranty ...............................................................................................................70
9.1 PVA Warranty Policy.............................................................................................................. 70

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1. 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.
1.1 PVA Contact Information
Main Office PVA
6 Corporate Drive
Halfmoon, NY 12065
Tel [phone]
Fax [phone]
Website: rapidplaster.pva.net
Email: [email protected]
Technical Support
Tel [phone]
Email: [e-mail]
1.2 Document History
Revision
Revision Date
Reason for Changes
REV F
July 2023
Emergence PRO™V3 Updates
REV E
August 2021
WalkStrong Updates
REV D
April 2021
Printer Tool Kit Note
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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1.3 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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1.4 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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2. Getting Started
2.1 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.
Figure 4: Raise and Lower Feet

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2.2 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.
2.2.1 Exhaust Flange Installation
If local ventilation is required, follow the steps below to install the exhaust flange.
1. Remove cover from exhaust flange mount in the top rear corner of the machine.
Figure 5: Remove Exhaust Flange Cover
2. Locate the 4-inch exhaust flange provided with the machine.
Figure 6: Exhaust Flange

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3. Install exhaust flange through top hole and secure with four (4) M6X1 hex nuts.
Figure 7: Secure Exhaust Flange

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2.3 Initial Setup
2.3.1 Printer Tool Kit
Note: The printer tool kit is specific to orthotics and prosthetics and available for
printer sales through PVA Med.
Before starting the setup process, locate the Tool Kit included with your printer. The
following items are included.
Figure 8: Tool Kit

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Item
Description
1
Grease cartridge
2
Lubricant
3
7 mm nut driver
4
10 mm nut driver
5
Bubble level
6
Tweezers
7
Wire brush
8
Spade/Putty knife
9
Side cutters
10
SD card and converter
11
Hex keys
12
Toolbox
13
Storage container
14
Renewable mini dehumidifier
15
1.1 mm drill bit
16
Grease gun
Figure 9: Tool Kit Contents

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2.3.2 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 brackets securing the print head for shipment
using a 4 mm hex key.
Figure 10: Remove Bracket from Print Head
4. Remove the brackets attached to the front rail and print bed using a 4 mm hex key.
Figure 11: Remove Brackets from Print Bed

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5. Install the nozzle brush in the hole on the front right of the print bed.
Figure 12: Install Nozzle Brush
6. Insert the dehumidifier into the dehumidifier holding brackets.
Figure 13: Insert Dehumidifier

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7. Plug the power cord located in the back of the printer in the appropriate 120/220V*
outlet. *Refer to the machine serial tag.
8. Plug the provided ethernet cable into the ethernet port located in the back of the
printer and connect to the facility’s network.
Figure 14: Connect Power Cord

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2.4 Emergence PRO™Setup
2.4.1 Printer Control Screen
The printer control screen is a touch screen controller consisting of four screens: Control,
Print, Console, and Setup. See image on next page.
1
Stop Button
Stops and reboots printer.
2
Bed Button
Sets bed to active state or standby.
3
Hot End Button
Sets hot end to active state or standby.
4
Current Temperature
Displays current tool temperature.
5
Active Temperature
Set point for active tool temperature.
6
Standby Temperature
Set point for standby tool temperature.
7
Print Head Position
Displays position of print head.
8
Axes Homing Buttons
Homes the print head in all axes or in an individual axis.
•Auto homing -- button on the far left
•X-axis -- button in the middle left
•Y-axis -- button in the middle right
•Z-axis -- button on the far right
9
Bed Level
Probes bed and level print surface.
10
File Selection
Displays available prints.
11
Move Selection
Allows movement of print head
•X-axis -- negative moves left, positive moves right
•Y-axis -- negative moves towards front of the
machine, positive moves towards rear of the machine
•Z-axis -- negative moves up, positive moves down
12
Extrusion Selection
Allows for extrusion of filament when hot end is at
temperature.
13
Macro Selection
Allows for selection of macros. Three macros are found
on the right side of the Control Screen. Additional macros
can be accessed by selecting Macro button.
14
Control Screen
Main menu for the control screen.
15
Print Screen
Similar to the control screen and only used when
printing. Allows for pause, resume, and cancel
commands.
16
Console Screen
Displays codes and commands recently entered in the
printer.
17
Setup Screen
Options for adjusting the touchscreen display settings.
18
Status
Displays the status of the printer.

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Figure 15: Printer Control Screen