Stratasys Dimension BST 1200 User manual

BST 1200 / SST 1200
User Guide

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DimensionBST1200/SST1200UserGuide
Notice
The information in this document is subject to change without notice.
STRATASYS, INC. MAKES NO WARRANTY OF ANY KIND WITH REGARD TO THIS MATE-
RIAL, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANT-
ABILITY AND FITNESS FOR A PARTICULAR PURPOSE. Stratasys, Inc. shall not be liable
for errors contained herein or for incidental or consequential damages in connection with
the furnishing, performance, or use of this material.
This equipment has been tested and found to comply with the limits for a Class A digital
device, pursuant to part 15 of the FCC Rules. These limits are designed to provide rea-
sonable protection against harmful interference when the equipment is operated in a
commercial environment. This equipment generates, uses and can radiate radio fre-
quency energy and, if not installed and used in accordance with the instruction manual,
may cause harmful interference to radio communications. Operation of this equipment in
a residential area is likely to cause harmful interference in which case the user will be
required to correct the interference at his own expense.
Changes or modifications to the Dimension system not expressly approved by Stratasys,
the party responsible for compliance, could void the user’s authority for use.
This document is protected by copyright. All rights reserved. Its use, disclosure, and
possession are restricted by an agreement with Stratasys per software copyright. No part
of this document may be photocopied, reproduced or translated into another language
without the prior written consent of Stratasys, Inc. Printed in the USA.
Stratasys, Dimension, and Catalyst are registered trademarks of Stratasys, Inc.
Krytox, Windows 2000, and Windows XP are registered trademarks of their respective
companies.
© Copyright 2006 Stratasys, Incorporated.
April 2006
The Dimension system conforms with the following standards, in
accordance with the EU Machinery, Low Voltage and Electromagnetic
Compatibility Directives: EU 89/392/EEC, EU 98/37/EEC, EU 73/23/EEC
amended by 93/68/EEC, EU 89/336/EEC

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Dimension BST 1200 / SST 1200 User Guide
Introduction
Dimension is designed with ultimate simplicity in mind. The system
enables you to build parts quickly, even if you’ve never used a 3D
printer before. Its display panel prompts you to press a few keys to
get you modeling quickly.
The system models with ABS plastic, so modeled parts are strong
and durable. ABS also ensures you’ll be able to drill, tap, sand, and
paint your creations. With the speed and convenience of
Breakaway Support Technology (BST) or Soluble Support
Technology (SST), your completed parts are quickly available for
review and test.
Dimension is an innovative combination of proprietary hardware,
software, and material technology.
Congratulations…
you’ve made a smart choice!

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DimensionBST1200/SST1200UserGuide
How To Use This Manual
This User’s Guide is laid out in easy to follow sections which cover
Set-up, Operation, Maintenance, and Troubleshooting of your
Dimension printer. Be sure to read each section carefully so that
you will get the best performance from your system.
Highlighted Information
The manual is written in a step-by-step format so as to guide you
through a variety of operational tasks. Information of particular
importance is presented in one of three formats
NOTE
A NOTE is used to highlight a specific point or to provide an
operational tip. While useful, a NOTE does not indicate a
procedure that can cause injury or damage if it is not
followed. A NOTE will follow the paragraph of instruction to
which it relates.
The Dimension printer guides you through operational tasks from a
User Interface (UI) on the front panel of the printer. Throughout the
User Guide, text representing messages that appear on the UI are
presented in a specific format. Interface Messages appear as
a bold, serif, fixed-pitch (mono-space) font.
WARNING
A WARNING indicates a procedure that
may cause Injury to an operator if the
procedure is not followed. A WARNING
will precede the paragraph of instruction
to which it relates.
CAUTION
A CAUTION indicates a procedure that
may cause Damage To Equipment if the
procedure is not followed. A CAUTION
will precede the paragraph of instruction
to which it relates.

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Dimension BST 1200 / SST 1200 User Guide
Sections Of The Manual
Overview...
Provides a quick reference for the layout of the printer and its
operating components. Overview also provides a quick reference
for sources of additional information and printer supplies.
Setup...
Guides you through the initial printer installation and setup. Topics
include unpacking, connecting power, installing software, and
connecting to a computer network. Generally, topics in setup are
only accomplished during installation or relocation of the printer.
Operation...
Further develops your understanding of the printer by presenting
the User Interface, Loading and Unloading of Material, Building
Parts, Removing Completed Parts, and Removing Support
Material. The tasks presented are common procedures
accomplished during the normal operation of the printer.
Maintenance...
Lists several tasks that you will need to perform to keep your
printer performing at its best. Some tasks are ‘As Needed’ while
others are determined by a set number of printer hours (CatalystEX
includes an odometer of printer hours). ‘House Cleaning’, Axis
Maintenance, Tip Cleaning Assembly Replacement, Chamber
Light Bar Replacement, Tip Area Clean-up, and Tip Replacement
are procedures that you can perform with the help of the User
Guide.
Troubleshooting..
Allows you to perform some problem diagnosis and correction
procedures in the event that your printer has a problem. A
Troubleshooting Checklist, Fault Determination Codes, and a
procedure to recover from a Loss of Extrusion are provided.

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DimensionBST1200/SST1200UserGuide

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Dimension BST 1200 / SST 1200 User Guide
Table of Contents
Introduction................................................................................3
How To Use This Manual.........................................................4
Highlighted Information .................................................................. 4
Sections Of The Manual................................................................. 5
Overview...................................................................................11
Finding More Information.......................................................13
Setting up Dimension................................................................... 13
Using Dimension.......................................................................... 13
Supplies .................................................................................14
Setup.........................................................................................15
Workspace.............................................................................15
Unpacking..............................................................................16
Installing Forklift Access Covers............................................18
Power Connections................................................................18
Powering On Dimension ........................................................20
Insert Modeling Base .............................................................21
Installing Software..................................................................22
Networking Your Printer.........................................................23
Connecting Directly To Your PC............................................26
Operation..................................................................................29
Display Panel and Keypad.....................................................29
Inserting a Modeling Base......................................................30
Powering On Dimension ........................................................30
Powering Off Dimension ........................................................31
Cycling Power........................................................................31
Loading Material.....................................................................32
Unloading Material.................................................................35

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DimensionBST1200/SST1200UserGuide
Building a Test Part................................................................37
Sending Your CAD File to the System...................................37
Building a Part from Your File...................................................... 39
Chamber Lights......................................................................39
Pausing Build .........................................................................40
Resuming Build from Pause Mode.........................................40
Resuming Operations from Standby Mode............................40
Canceling a Job......................................................................41
Removing a Completed Part..................................................41
Removing Support Material....................................................42
Breakaway Supports.................................................................... 42
Soluble Supports.......................................................................... 43
Maintenance.............................................................................45
Startup Kit Tools.....................................................................45
After Each Build......................................................................46
Empty Purge Container................................................................ 46
500 Hour Maintenance...........................................................46
Clean Fan Filter............................................................................ 46
Tip Cleaning Assembly (Brush/Flicker Assembly) ....................... 47
2000 Hour Maintenance.........................................................49
Axis Maintenance......................................................................... 49
As Needed Maintenance........................................................50
Remove Debris Buildup ............................................................... 50
Vacuum Build Chamber............................................................... 50
Clean Door Glass......................................................................... 50
Chamber Light Bar....................................................................... 50
Tip Area Clean-up........................................................................ 51
Tip Shroud Replacement ............................................................. 52
Tip Replacement.......................................................................... 53

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Dimension BST 1200 / SST 1200 User Guide
Troubleshooting ......................................................................59
Troubleshooting Checklist......................................................59
Fault Determination Codes ....................................................61
Loss of Extrusion....................................................................61
Diagnosing Loss of Extrusion....................................................... 61
Recovering From Loss of Extrusion............................................. 63

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DimensionBST1200/SST1200UserGuide

Dimension BST 1200 / SST 1200 User Guide
Overview
Dimension builds models, including internal features, directly from
CAD STL files. The system builds three-dimensional parts by
extruding a bead of ABS plastic through a computer-controlled
extrusion head, producing high quality parts that are ready to use
immediately after completion. With two layer resolution settings,
you can choose to build a part quickly for design verification, or you
can choose a finer setting for higher quality surface detail.
Figure 1: Dimension Front View
Item Nomenclature Item Nomenclature
1 Extrusion Head 8 Tip Cleaning Assembly
2 Extrusion Tips 9 Purge Container
3 Guide Rods 10 Modeling Base
4 Lead Screw 11 Z Platform
5 Model Material Cartridge 12 Platform Retainers (2)
6 Support Material Cartridge 13 Power Switch
7 Display Panel
1
2
3
4
5
6
8
9
11
13
10
7
12

12 Overview
DimensionBST1200/SST1200UserGuide
Figure 2: Dimension Rear View
Item Nomenclature Item Nomenclature
1 Fan Cover 4 UPS Connection
2 Main Circuit Breaker 5 Diagnostic Hookup
3 Power Cord Adapter 6 Network Cable
Connection
1
23
4
5
6

Dimension BST 1200 / SST 1200 User Guide
Overview 13
The Dimension system consists of two primary components — the
Dimension 3D printer and CatalystEX. CatalystEX is the
preprocessing software that runs on a Windows 2000 or Windows
XP Pro platform.
Dimension’s build envelope measures 254 x 254 x 305 mm (10 x
10 x 12 in). Each material cartridge contains 922 cc (56.3 cu. in.) of
usable material — enough to build continuously for about four days
without reloading.
Finding More Information
Several references are available for use with Dimension.
Setting up Dimension
Dimension User Guide
Step-by-step instructions for
installing, setting up and operating
the Dimension system.
Using Dimension
CatalystEX Online Help
Simple operating instructions for
CatalystEX are available through the
application. Help is displayed in the
Dynamic Help window ...or... you
can access them at from the Menu
Bar - Help>Contents.
World Wide Web
Additional information is available at:
http://www.dimensionprinting.com

14 Overview
DimensionBST1200/SST1200UserGuide
Supplies
This section lists all replaceable supplies used by the Dimension
modeling system. The parts mentioned in this list can be obtained
by contacting the sales representative through whom you
purchased your system.
Part Number Description
Modeling Material
340-20000 White ABS Filament Cartridge
340-20200 Black ABS Filament Cartridge
340-20300 Red ABS Filament Cartridge
340-20400 Blue ABS Filament Cartridge
340-20500 Green ABS Filament Cartridge
340-20600 Yellow ABS Filament Cartridge
340-20800 Steel Gray ABS Filament Cartridge
Breakaway Support Material (BST Only)
340-30000 Breakaway Support Cartridge
Soluble Support Material/Concentrate (SST Only)
340-30200 Soluble Support Cartridge
300-00600 Soluble Soluble Concentrate (12 bottles)
Modeling Base
340-00300 Modeling Base (qty. 24)
Tip Replacement Kits
540.10100 BST 1200 Tip Replacement Kit
540.10500 SST 1200 Tip Replacement Kit
Miscellaneous
540.00101 Tip Cleaning Kit (1 brush, 5 flickers)
300-00100 Z-Stage (Krytox) Grease
300-01100 ABS Glue (case of 12)
To order supplies for your Dimension system, contact your local Dimension reseller.

Dimension BST 1200 / SST 1200 User Guide
Setup
Workspace
Observe the following when placing Dimension in its operating
location:
• Dimension has an approximate weight of 148 kg (326 lbs)
and requires a table capable of safely supporting 181kg
(400 lbs).
• System Dimensions:
838 x 737 x 1143 mm (33 x 29 x 45 in)
Four-inch minimum space behind unit for air circulation
• Dedicated outlet requirements:
110-120 VAC, 60 Hz, 15 A min. (20 amp recommended)
–or–
220-240 VAC, 50/60 Hz, 7 A min. (10 amp recommended)
• Temperature: 18–30°C (65-86°F)
• Relative Humidity: 30-70%, Non-condensing
• Ethernet 10/100 Base T network
• Optional UPS for power interruptions (brown-out
conditions):
Rated Power – 2200 VA
Output Power – 1600 watts

16 Setup
DimensionBST1200/SST1200UserGuide
Unpacking
This section describes the recommended procedures for
unpacking and preparing Dimension for its first use.
Unpack the printer:
1. Before unpacking the printer, move it near to its operating
location.
2. Remove the plastic banding from around the cardboard.
3. Remove the top cover. Set aside the fork access covers (2)
and bag of screws (2).
4. Remove screws (4) that attach cardboard to pallet and remove
the cardboard side panels.
5. Remove the top foam.
6. Remove outer plastic wrap - use care if using a knife so as to
not scratch the printer.
7. Remove the foam door channels (2) and tape.
WARNING
The Dimension printer weighs
approximately 148 kg (326 lbs). Use
proper moving and lifting techniques
when positioning the unit. For your
convenience, there are forklift pads built
into the bottom of the unit. They are
accessible from the side of the unit.
WARNING
The Lead Screw and Guide Rods are
lubricated with a thin coat of Krytox
grease. Krytox grease can cause skin
irritation. Be careful not to get the grease
on your hands or clothing.

Dimension BST 1200 / SST 1200 User Guide
Setup 17
8. Remove the foam tubes that isolate the extrusion head from
the frame (see Figure 3).
Figure 3: Foam tubes isolating the extrusion head from the Z-axis frame
9. After unpacking, inspect the printer and report any shipping
damage to the carrier.
CAUTION
Remove the foam tubes that isolate the
extrusion head from the frame (see
Figure 3). The printer will be damaged if
powered on with the foam tubes in place.
CAUTION
Be careful not to damage the rod sensors
when removing the foam tubes (see
Figure 3).
Extrusion Head
Circles indicate
Rod Sensor loca-
tions. There is
also one sensor
on each side of
the Extrusion
Head.
Foam Tubes (4)

18 Setup
DimensionBST1200/SST1200UserGuide
Installing Forklift Access Covers
The forklift access covers can be placed over the forklift channels
after the printer is placed in its final location (see Figure 4). The
covers are press-fit in the front and held in place with one screw in
the rear.
Figure 4: Installing the forklift access covers
Power Connections
This section discusses the procedure for preparing all power
connections for the printer.
Dimension is provided with two power cords: one for 110 V and one
for 220 V.
Prepare all power connections:
1. Connect the male end of the supplied power cord directly into a
grounded electrical outlet, as shown in Figure 5 on page 19. (If
using a Uninterrupted Power Supply (UPS), connect the cord
directly into the UPS).
CAUTION
Before connecting power to the printer,
make sure that the Dimension circuit
breaker is in the off (down) position. It is
located in the rear of the printer next to
the power cord attachment point.
Insert Tab in Slot
Push Cover Toward Front
of Printer
Attachment Screw
on Back of Printer

Dimension BST 1200 / SST 1200 User Guide
Setup 19
Figure 5: Connecting to a grounded electrical outlet
2. Connect the female end of the power cord directly into the rear
of the cabinet.
3. Switch the Dimension circuit breaker to the on (up) position.
The Dimension system is now ready to have power applied.
CAUTION
Do not use an extension cord or power
strip with the Dimension system. Connect
the cord directly into the receptacle or
UPS.

20 Setup
DimensionBST1200/SST1200UserGuide
Powering On Dimension
Dimension’s power switch is located on the front of the cabinet,
near the bottom right corner (see Figure 6). After the switch is
pushed, Dimension boots up in three to seven minutes.
Figure 6: Location of Power Switch
(View From Front of Printer)
WARNING
Dimension’s build chamber and
extrusion-head tip get very hot! The
chamber and head tip reach
temperatures of approximately 75° C
(167° F) and 300° C (572° F) respectively.
Personal injury can occur if proper
techniques and safety materials are not
used. Use the leather safety gloves
provided in the Startup Kit when working
inside the printer.
CAUTION
Remove the foam tubes that isolate the
extrusion head from the frame (see
Figure 3 on page 17). The printer will be
damaged if powered on with the foam
tubes in place.