Stratasys Fortus 360mc User manual

www.stratasys.com | c-suppo[email protected]
360mc/400mc
User Guide
Part No. 107166-0010, Rev. J

FORTUS 360mc/400mc and FDM 360mc/400mc User Guide
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Liability Statement
The information in this document is subject to change without notice.
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.
Stratasys, Inc. makes no warranty of any kind with regard to this material,
including, but not limited to, the implied warranties of merchantability and
fitness for a particular purpose. It is the responsibility of the system owner/
material buyer to determine that the Stratasys material is safe, lawful, and
technically suitable for the intended application as well as identify the proper
disposal (or recycling) method consistent with local environmental
regulations. Except as provided in Stratasys' standard conditions of sale,
Stratasys shall not be responsible for any loss resulting from any use of its
products described herein.
Copyright Statement
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.
All drawings and information herein are the property of Stratasys Inc. All
unauthorized use and reproduction is prohibited.
Trademark Acknowledgments
Stratasys, Insight, WaterWorks, and FORTUS are registered trademarks of
Stratasys, Inc.
FORTUS 360mc, FORTUS 400mc, and FORTUS 900mc are trademarks and
service marks of Stratasys Inc. in the United States and other countries.
FDM 360mc and FDM 400mc are registered trademarks and service marks of
Stratasys Inc. in the United States and other countries.
Windows NT, Windows 2000, and Windows XP are registered trademarks of
Microsoft Corporation.
Ultem* 9085 is a trademark of SABIC Innovative Plastics IP BV.
© Copyright 2013 Stratasys, Inc.
Publication Date: July, 2013
The FORTUS 360mc/400mc and FDM 360mc/400mc systems conform with the following standards, in
accordance with the EU Machinery, Low Voltage and Electromagnetic Compatibility Directives: EU 2006/42/EC
EU 2006/95/EC
EU 2004/108/EC

FORTUS 360mc/400mc and FDM 360mc/400mc User Guide
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About the FORTUS 360mc/400mc and FDM
360mc/400mc
Welcome to the Fortus 360mc/400mc™ and FDM 360mc/400mc™ 3D
Production Systems which are referred to throughout this User Guide as the
360mc/400mc. These systems incorporate the latest in innovative technologies
to provide you with precise prototypes from a CAD design. Stratasys’ Fused
Deposition Modeling (FDM) technology provides prototype parts, including
internal features, that can be used to field-test form, fit, and function. The
360mc/400mc systems feature a servo/belt driven XY gantry with multiple
high temperature modeling material capability.
Components of the 360mc/400mc Modeling System
• Insight Software Package
• A Computer Workstation (not sold by Stratasys)
• The 360mc/400mc Modeling Machine
• Modeling Material
• Support Material
System Highlights
• Envelope Size: 14 x 10 x 10 inch (355 x 254 x 254 mm)
• Material Bays: 1 model, 1 support
• Tips/Slice Heights:
Tip Type Slice Height
ABSi Material Option/Upgrade 0.005 in. (0.127 mm)
ABS-M30 Material Option/Upgrade 0.007 in. (0.178 mm)
ABS-M30i Material Option/Upgrade 0.010 in. (0.254 mm)
ABS-ESD7 0.013 in. (0.330 mm)
Note: Material choice affects available tip size/slice height.

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Available Options
About This Guide
This guide is your introduction to building prototypes using a Stratasys rapid
prototype system. It is designed as a learning and reference tool that explains
system operation in an easy to understand, step-by-step, process.
How to Use This Guide
This guide is divided into easy-to-follow chapters. The tabs allow you to
quickly and easily find the information you want. You can read this user
guide chapter by chapter or use the tabs, Table of Contents when you need to
quickly find specific information. Keeping this user guide close to your
system will efficiently allow you to troubleshoot and maintain the system.
Available Options 360mc 400mc
ABSi Material Option/Upgrade X
ABS-M30 Material Option/Upgrade X X
ABS-M30i Material Option/Upgrade X
ABS-ESD7 X
PC-ABS Material Option/Upgrade X X
PC Material Option/Upgrade X X
PC-ISO Material Option/Upgrade X
Ultem* 9085 Material Option/Upgrade X
PPSF Material Option/Upgrade X
Large Envelope Option/Upgrade:
Envelope upgrade to 16x14x16 inch (406x355x406 mm)
Adds one (1) additional model material bay
Adds one (1) additional support material bay
Adds Material Auto-Changeover
XX

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Conventions Used in This Guide
The following conventions are used in this guide.
• When you see text in this font, it indicates a menu item
that can be selected from the Operator Panel Screen. For
example, select Build Last Job.
• If you see text in BOLD CAPS it indicates that this is a key
located on the Operator Panel keypad. For example, From
the Main Menu select Build Job and press ENTER.
• If you see boxed blue text, it indicates that this information
is being shown on the Operator Panel Screen. For example:
Build Job..
>Operator Control..
Modeler Status..
Maintenance..
|*Tips: Model T16
|* Support T16

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Table of Contents
Table of Contents ......................................................................... 1-vii
Service and Support .......................................................................1-1
360mc/400mc Service .................................................................................. 1-1
Software Support ...................................................................................... 1-1
Safety Instructions.......................................................................................... 1-2
Hazard Types............................................................................................. 1-2
Product Safety Signs................................................................................. 1-3
Specific Safety Practices ......................................................................... 1-4
Guard Door Interlocks.............................................................................. 1-4
General Safety Practices......................................................................... 1-5
Setup and Installation ....................................................................2-1
General Information ...................................................................................... 2-1
Prepare Your Facility for Installation ....................................................... 2-1
Identifying Your System ............................................................................ 2-1
Basic Setup..................................................................................................... 2-1
Making the Network Connection........................................................... 2-1
Making the External Air Connection ...................................................... 2-2
Making the Power Cable Connection................................................... 2-2
Network Setup................................................................................................ 2-3
Configuring the Network ......................................................................... 2-3
Setting the IP Address .............................................................................. 2-3
Moving the System ........................................................................................ 2-5
System Components ......................................................................3-1
System Protection .......................................................................................... 3-1
Main Circuit Breaker................................................................................. 3-1
Thermal Cut-Out Fuses ............................................................................. 3-1
UPS.............................................................................................................. 3-1
Access Doors and Panels ............................................................................. 3-2
Top Door and Top Hood .......................................................................... 3-3
Oven Door................................................................................................. 3-3
Canister Bay Doors ................................................................................... 3-3
Right Side Door - Upper ........................................................................... 3-3
Right Side Door - Lower............................................................................ 3-3
Left Side Door - Upper.............................................................................. 3-4
Left Side Door - Lower .............................................................................. 3-4
Gantry Area (XY Table)................................................................................. 3-4

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Opening the Top Door and Top Hood ................................................... 3-4
XY Gantry Assembly.................................................................................. 3-4
Head Assembly .............................................................................................. 3-5
Head Maintenance Bracket.................................................................... 3-6
Modeling Materials and Tips ......................................................................... 3-7
Materials..................................................................................................... 3-7
Liquefier Tips............................................................................................... 3-8
Oven Bay ...................................................................................................... 3-11
Oven Door ............................................................................................... 3-11
Oven Components ................................................................................. 3-12
Canister Bay ................................................................................................. 3-15
Accessing the Bays ................................................................................. 3-15
Canister Bay Components..................................................................... 3-15
SmartSpool System.................................................................................. 3-17
Vacuum and Air Dryer Systems .................................................................. 3-19
On Board Vacuum System .................................................................... 3-19
On Board Air Dryer System ..................................................................... 3-19
Operating the System ................................................................... 4-1
Basic User Interface and Operations ........................................................... 4-1
Using the Keypad...................................................................................... 4-2
Screen Symbols ......................................................................................... 4-3
Powering Up the System........................................................................... 4-3
Powering Down the System ..................................................................... 4-4
Basic Job Build Tasks ..................................................................................... 4-5
Before a Job Build ..................................................................................... 4-5
Select a Job to Build ................................................................................. 4-7
Build Job Warnings.................................................................................... 4-8
Information Available During a Build ...................................................... 4-9
Pausing or Aborting a Job ..................................................................... 4-10
After a Job Build...................................................................................... 4-11
Removing Supports ...................................................................................... 4-12
Breakaway Support Material ................................................................. 4-12
Soluble Release Support Material ......................................................... 4-12
Support Material for PPSF Parts.............................................................. 4-12
Material, Canisters, and Liquefier Tips........................................................ 4-12
Unloading Material from the Liquefier Tips........................................... 4-12
Removing Canisters ................................................................................ 4-13
Canister Installation................................................................................. 4-15
Loading Material to the Liquefier Tips................................................... 4-18
Canister Auto Change-over .................................................................. 4-19

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Handling/Storing Canisters .................................................................... 4-20
Changing Tips or Material Type ........................................................... 4-21
Working with the Job Queues .................................................................... 4-29
Change Modeler Default Values ............................................................... 4-30
Display Units............................................................................................. 4-30
Part Build Location.................................................................................. 4-30
System Status ............................................................................................... 4-32
Temperature Status ................................................................................ 4-32
Odometer Status .................................................................................... 4-32
Material Status ........................................................................................ 4-33
System Software Version........................................................................ 4-34
Sensor, System, or UPS Status................................................................. 4-34
Miscellaneous Operating Tasks ................................................................. 4-35
Oven Temperature Control ................................................................... 4-35
Operator Control of Head and Z Stage Movement .......................... 4-36
Operating Insight ............................................................................5-1
Getting Started with Insight........................................................................... 5-1
Starting Insight........................................................................................... 5-1
Opening an STL File .................................................................................. 5-1
Modeler Setup - Insight ................................................................................. 5-2
Configure Your Modeler .......................................................................... 5-2
Part Build Parameters ............................................................................... 5-3
Preparing the Model - Insight ....................................................................... 5-4
Orienting the Part in the Build Envelope ................................................ 5-4
Slicing the Part .......................................................................................... 5-5
Building Supports and a Base for the Part ............................................. 5-5
Saving the Job File ................................................................................... 5-5
Creating Toolpaths................................................................................... 5-5
Saving the Toolpath (CMB file) ............................................................... 5-6
Flag Button Shortcut................................................................................. 5-6
Sending a Part to the Modeler ............................................................... 5-7
Calibration ......................................................................................6-1
Automatic Calibration................................................................................... 6-1
Auto Z Stage Zero Calibration................................................................. 6-1
Auto Tip-to-Tip Calibration (AutoCal Tip Offset) ................................... 6-2
XY and Z Tip Offset Calibration ............................................................... 6-2
Manual Calibration........................................................................................ 6-6
Manual Z Stage Zero ................................................................................ 6-6
Auto Z Stage Zero Calibration - Manual Start ....................................... 6-8
Auto Tip-Tip Calibration (AutoCal Tip Offset) - Manual Start............... 6-9

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XY and Z Tip Offset - Manual Start......................................................... 6-10
System Maintenance .................................................................... 7-1
Updating Controller Software........................................................................ 7-1
Web Method (preferred method) .......................................................... 7-1
CD Method (alternate method) ............................................................. 7-2
Placing System in Receive Software Upgrade Mode................................. 7-2
Maintenance Schedule................................................................................. 7-3
Daily Maintenance ........................................................................................ 7-4
Clean the Platen ....................................................................................... 7-4
Empty the Purge Waste Bucket............................................................... 7-4
Weekly Maintenance .................................................................................... 7-5
Vacuum the Build Envelope .................................................................... 7-5
Clean/Inspect Tip Wipe Assembly .......................................................... 7-5
Quarterly Maintenance ................................................................................. 7-8
Inspect the Platen O-Ring ........................................................................ 7-8
Clean the Vacuum System In-Line Filter and Jar .................................. 7-8
Clean the Tip Sensor Plunger ................................................................... 7-9
As Needed Maintenance............................................................................ 7-10
Upgrading Software or Entering a System Code ................................ 7-10
Platen Flatness Diagnostic ..................................................................... 7-11
Clean Exterior Surface of System .......................................................... 7-12
Clean the Liquefier Tips .......................................................................... 7-12
Replace an Interior Lamp ...................................................................... 7-12
Troubleshooting ............................................................................. 8-1
Getting Help ................................................................................................... 8-1
Finding a Remedy .......................................................................................... 8-2
PPSF Materials User Guide .............................................................A-1
Introduction to PPSF ...................................................................................... A-1
Terminology ................................................................................................... A-1
Hazard Classifications .................................................................................. A-2
Pre-Processing............................................................................................... A-2
Setting up PPSF in Insight (Version 6.0 or Later)..................................... A-2
Modeler Operation with PPSF....................................................................... A-3
Switching to PPSF From Another Material ................................................... A-3
Replacing the Tip ..................................................................................... A-3
Replacing the Purge Ledge ................................................................... A-3
General Operation with PPSF ....................................................................... A-4
Removing PPSF_S Supports........................................................................... A-4
Using the Support Removal Toolkit Items.................................................... A-6

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Tool Maintenance .................................................................................... A-6
Support Removal Tool Kit ......................................................................... A-7
Reheating a PPSF Part.................................................................................. A-10
Reheating with the Modeler Oven....................................................... A-10
Reheating with a Convection or Consumer Oven ............................ A-10
Reheating with Laboratory Ovens........................................................ A-11
Reheating with a Hot Air Gun ............................................................... A-11
Material Safety Data Sheets (MSDS) .......................................................... A-11
Material Abbreviations........................................................................... A-11
Finishing ........................................................................................................ A-11
Sealing/Adhesive.................................................................................... A-11
Sealing/Adhesive Data.......................................................................... A-12
Drilling and Sanding ............................................................................... A-12
UI Menu Structure ...........................................................................B-1
Main Menu ..................................................................................................... B-1
WaterWorks ....................................................................................C-1
About WaterWorks Soluble Concentrate .................................................... C-1
Service and Support ...................................................................................... C-1
System, Material, and Liquefier Tip Compatibility ...................................... C-2
ABS (P400)................................................................................................. C-2
ABS-ESD7................................................................................................... C-2
ABS-M30 (P430), ABS-M30i*..................................................................... C-2
ABSi (P500) ................................................................................................ C-3
PC .............................................................................................................. C-4
PC-ABS ...................................................................................................... C-4
Tip Identification ............................................................................................ C-5
Vantage and Titan System Tip Identification ....................................... C-5
Fortus System Tip Identification .............................................................. C-5
Choosing a Support Removal Tank ............................................................. C-6
Circulation Tanks...................................................................................... C-6
Ultrasonic Tanks........................................................................................ C-6
Safety Guidelines........................................................................................... C-7
Support Removal Items ................................................................................. C-7
Removing Support Material .......................................................................... C-8
Manually Removing Support Material .................................................. C-8
Removing SR-100 Support Material ....................................................... C-8
Adding Solution to the Tank.......................................................................... C-8
Tank Temperature.......................................................................................... C-9
Placing Parts in the Tank ............................................................................... C-9
Inspecting Parts and Solution ..................................................................... C-10

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Removing Parts from the Tank ................................................................... C-11
Changing Solution in the Tank ................................................................... C-12
Disposing of Soluble Concentrate............................................................. C-13
Soluble Solution Drain Effluent .............................................................. C-13
Neutralization.......................................................................................... C-13
SR-100 Support Removal Quick Reference .................................D-1
Minimize Cleaning Time in Support Removal Tank Solution ..................... D-1
Sustain Proper Temperature of Support Removal Tank Solution............... D-1
Maintain Clean Support Removal Tank Solution........................................ D-2
Minimize Support Material on Thin-Walled or Fine Feature Geometries.. D-2

FORTUS 360mc/400mc and FDM 360mc/400mc User Guide
Chapter 1
Service and Support
360mc/400mc Service
If you have a problem with your 360mc/400mc that is not covered in this User
Guide, please contact Stratasys Customer Support:
• Call [phone] (7:00 a.m. to 5:00 p.m. C.T.)
• E-mail us at [email protected]
When calling in for service, always have your system’s software version (see
“System Software Version” on page34), and hardware serial number
available (see“Identifying Your System” on page1). You may also need access
to your Insight workstation to provide a diagnostic file from your hardware.
Software Support
If you have a software problem that is not covered in this user guide, please
contact Stratasys Customer Support:
• Call [phone] (7:00 a.m. to 5:00 p.m. C.T.)
• E-mail us at [email protected]
When calling for support, please have your system’s serial number and
software version available.

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Safety Instructions
Hazard Types
Stratasys recommends that all services be performed by qualified personnel.
All personnel working on or around this system should be knowledgeable of
what the following hazard classifications mean throughout this guide.
WARNINGS and CAUTIONS precede the paragraph to which they pertain.
Notes follow the relative paragraph.
Warning: Indicates a potentially hazardous situation which, if
not avoided, may result in injury or death.
Caution: Indicates a situation which, if not avoided, could
result in damage to equipment.
Note: Indicates additional information relative to the current
topic.

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Product Safety Signs
We make every effort to ensure that our systems are safe and reliable at all
times. However, there will be times when you must access areas of the system
where potentially high voltages, hot temperatures, and/or moving
mechanical components could cause severe injury.
Note: Always read and adhere to safety statements, and be
aware of the following safety signs when you see them on the
system.
Personal Injury: The personal injury sign indicates that you
are near moving mechanical parts, and severe personal injury
is possible. Always use extra care. Do not wear ties, loose
clothing, or dangling jewelry. Keep long hair tied up and
away from any moving parts.
High Voltage: The high voltage sign indicates the presence of
high voltages. Always stay away from any exposed electrical
circuitry. It is recommended that all jewelry be removed.
Hot Surface: The hot surface sign indicates the presence of
devices with high temperatures. Always use extra care when
working around heated components. Always wear the safety
gloves and safety sleeves provided in the 360mc/400mc
Startup Kit.
Head temperatures in the system can exceed 350° C (662° F).
Gloves: The gloves sign indicates that if you enter the area
specified by the symbol you must wear safety gloves and
sleeves approved for high temperatures provided in the
Startup Kit.
Sharp Object: The sharp object sign indicates the presence of
sharp objects. Do not touch sharp objects as they may cause a
loss of body parts.
Crushed Hand: The crushed hand sign indicates that a hazard
exists where you could get your hand crushed between two
objects. One or more objects move in the area that you are
working.

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Specific Safety Practices
The following components and areas of the system are highlighted as
potential safety hazards that may cause system failure or reliability problems
if proper safety procedures are not followed.
Guard Door Interlocks
Interlock switches are used to communicate the oven door, gantry door, and
top hatch states to the system. For safety reasons, the doors and hatch must be
closed before the X, Y and Z motors will operate.
Oven.............. Warning: Always wear safety gloves and long sleeves when
working inside the oven. Components are hot!
The oven temperature is extremely hot. The oven temperature
is controlled by a safety thermal breaker that shuts the system
off when temperatures reach 260° C (500° F)
Note: Opening the oven door shuts the oven heaters off.
XY Gantry...... Warning: Never wear a tie, loose clothing or dangling jewelry
when working around moving components of the system.
Beneath the top lid of the system is the XY Gantry. This area
houses the mechanical drive components of the X and Y axes.
Use extreme caution whenever accessing this area of the
system. The servo drive system, including the motors, pulleys
and belts are extremely powerful, and care must be taken.
Note: The servo motors are disabled when the oven door or
top hood is opened. The XY pinch hazard between the timing
belts and pulleys is minimized by locking the hood while
building and disabling the motors when the top hood is open.
Z Stage.......... Warning: Never wear a tie, loose clothing or dangling jewelry
when working around moving components of the system.
The drive belt, pulleys and Z stage servo motor can cause
severe injury. The Z stage crushing hazard is minimized by
locking the door during Z stage moves and disabling the Z
motor when the door is open.
Head temperatures in the system can exceed 450° C (800° F).

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1-5
General Safety Practices
Abide by these general safety practices when working with this system.
High Voltage: High voltage is present in the system when
powered off and unplugged due to the Uninterruptible Power
supply (UPS).
Warning: only use an osha or ce approved step stool when
accessing the area under the hood (located at the top of the
system).
Warning: always wear safety gloves and long sleeves when
working in the oven, with the head, or liquefier tips. these
components are very hot.
Warning: always level the system prior to operation. improper
leveling could cause the door to swing closed while you are
working in the oven.

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FORTUS 360mc/400mc and FDM 360mc/400mc User Guide
2-1
Chapter 2
Setup and Installation
General Information
Prepare Your Facility for Installation
Follow the 360mc/400mc Site Preparation Guide to ensure that your facility is
effectively and safely prepared for system installation.
Identifying Your System
Use the following two tags to identify your system: (Figure 2-1)
• Serial Number Tag - Refer to this number when requesting service.
• Model Tag - The model number, the power requirements, and the
company’s address and phone number are given on the tag. All
patent numbers associated with the system are listed on the lower
left part of the tag.
Figure 2-1: ID Tag Location
Both tags are located on the back side of the system near the bottom. They are
typically placed near the system’s power connection. Use the information on
these tags when identifying your system.
Basic Setup
Making the Network Connection
Processed job files are transferred to the 360mc/400mc modeler through your
facility’s Ethernet network. An RJ45 network connector is located in the lower
left corner of the back panel for the network connection. (Figure 2-2)
Model Tag
Serial Tag

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2-2
Figure 2-2: Network Connection
Making the External Air Connection
The external air connector is located in the lower left corner of the back panel.
(Figure 2-3)
Figure 2-3: External Air Connection
Making the Power Cable Connection
This system requires a high voltage connection, which is made at the right,
rear corner of the system (as viewed from the rear). High voltage is applied to
the system via a Delta connection. The main breaker must be off until a
Stratasys Service Technician has verified the connection. This system is only
provided with a Delta connection. (Figure 2-4)
Figure 2-4: Power Cable Connection
Warning: A licensed electrician must perform all wiring from
service connect to the transformer, and from the transformer
to the system - including all connectors, cables and proper
strain relief.
RJ45 Connector
External Air Connector
High Voltage Power Cable Connection
High Voltage Power Cable Connection Main Circuit Breaker UPS Switch