Stratasys Fortus 360mc User manual

www.stratasys.com | [email protected]
Fortus®360mc/400mc
3D Production System
User Guide
Part No. 107166-0012, Rev. A

ii
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 2014 Stratasys, Inc.
Publication Date: July, 2014
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

iii
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.

iv
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
ASA Material Option/Upgrade X X
Nylon 12 Material Option/Upgrade X 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

v
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

vi
Table of Contents
Chapter 1: Service and Support __________________________________ 1-1
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 _____________________________________________ 1-5
General Safety Practices __________________________________________ 1-5
Chapter 2: Setup and Installation _________________________________ 2-1
General Information _________________________________________________ 2-1
Prepare Your Facility for Installation_________________________________ 2-1
Identifying Your System ____________________________________________ 2-1
Basic Setup __________________________________________________________ 2-2
Making the Network Connection___________________________________ 2-2
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 _____________________________________________ 2-4
Moving the System___________________________________________________ 2-5
Chapter 3: System Components __________________________________ 3-1
System Protection____________________________________________________ 3-1
Main Circuit Breaker _______________________________________________ 3-1
Thermal Cut-Out Fuses _____________________________________________ 3-1
UPS _______________________________________________________________ 3-1
If power is lost to the modeler __________________________________ 3-2
During normal system power-down _____________________________ 3-2
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 ____________________________________________ 3-4
Right Side Door - Lower ____________________________________________ 3-4
Left Side Door - Upper _____________________________________________ 3-4
Left Side Door - Lower _____________________________________________ 3-4
Gantry Area (XY Table)_______________________________________________ 3-5
Opening the Top Door and Top Hood ______________________________ 3-5
XY Gantry Assembly _______________________________________________ 3-5
Head Assembly______________________________________________________ 3-6
Head Maintenance Bracket _______________________________________ 3-6

vii
Modeling Materials and Tips __________________________________________ 3-8
Materials__________________________________________________________ 3-8
Materials Used_________________________________________________ 3-8
Materials Compatibility ________________________________________ 3-8
Liquefier Tips ______________________________________________________ 3-9
Liquefier Tips and Slice Heights__________________________________ 3-9
Tip Compatibility & Selection ___________________________________ 3-9
Tip Identification ______________________________________________ 3-12
Oven Bay __________________________________________________________ 3-13
Oven Door_______________________________________________________ 3-13
Oven Components_______________________________________________ 3-13
Oven Lamps _________________________________________________ 3-13
The Platen____________________________________________________ 3-14
Tip Cleaning Assembly ________________________________________ 3-14
Z Stage ______________________________________________________ 3-15
Canister Bay________________________________________________________ 3-16
Accessing the Bays _______________________________________________ 3-16
Canister Bay Components ________________________________________ 3-16
SmartSpool System _______________________________________________ 3-18
Vacuum and Air Dryer Systems ______________________________________ 3-20
On Board Vacuum System ________________________________________ 3-20
On Board Air Dryer System ________________________________________ 3-20
Chapter 4: 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 _________________________________________________ 4-4
Before a Job Build _________________________________________________ 4-4
Select a Job to Build_______________________________________________ 4-6
Build Job Warnings ________________________________________________ 4-7
Information Available During a Build________________________________ 4-9
Pausing or Aborting a Job _________________________________________ 4-9
After a Job Build _________________________________________________ 4-10
Removing Supports _________________________________________________ 4-11
Breakaway Support Material ______________________________________ 4-11
Soluble Release Support Material _________________________________ 4-11
Support Material for PPSF Parts ____________________________________ 4-11
Material, Canisters, and Liquefier Tips ________________________________ 4-13
Unloading Material from the Liquefier Tips _________________________ 4-13
Removing Canisters ______________________________________________ 4-14
Canister Installation ______________________________________________ 4-15
Loading Material to the Liquefier Tips ______________________________ 4-18
Canister Auto Change-over ______________________________________ 4-20

viii
Handling/Storing Canisters ________________________________________ 4-21
Changing Tips or Material Type ___________________________________ 4-22
Working with the Job Queues ________________________________________ 4-29
Change Modeler Default Values _____________________________________ 4-30
Display Units _____________________________________________________ 4-30
Part Build Location _______________________________________________ 4-31
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
Chapter 5: 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
Chapter 6: 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
XY and Z Tip Offset - Manual Start _________________________________ 6-10
Chapter 7: System Maintenance _________________________________ 7-1
Updating Controller Software _________________________________________ 7-1

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Web Method (preferred method) __________________________________ 7-1
CD Method (alternate method)____________________________________ 7-2
Placing System in Receive Software Upgrade Mode ___________________ 7-3
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 ____________________________________________ 7-9
Upgrading Software or Entering a System Code_____________________ 7-9
Platen Flatness Diagnostic ________________________________________ 7-11
Clean Exterior Surface of System __________________________________ 7-11
Clean the Liquefier Tips ___________________________________________ 7-11
Replace an Interior Lamp_________________________________________ 7-11
Chapter 8: Troubleshooting_______________________________________ 8-1
Getting Help_________________________________________________________ 8-1
Finding a Remedy ___________________________________________________ 8-2
Appendix A: UI Menu Structure____________________________________ A-1
Main Menu __________________________________________________________ A-1

1-1
Chapter 1: Service and
Support
This chapter provides the user with information on service and
support for the Fortus 360mc/400mc system.
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 4-34), and hardware serial number available
(see“Identifying Your System” on page 2-1). 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.

1-2
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.

1-3
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.

1-4
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.
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).

1-5
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.
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.

2-1
Chapter 2: Setup and
Installation
This chapter describes basic setup and installation of the Fortus
360mc/400mc system.
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.
Model Tag
Serial Tag

2-2
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)
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)
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

2-3
Figure 2-4: Power Cable Connection
Network Setup
Your system is configured for your network as a part of its initial installation and
setup. This section is provided in case you have need to change your network
settings.
Configuring the Network
1. The network address can be Dynamic or Static.
• Dynamic address - a network server or PC will generate an IP address for
the system. A different IP address may be generated from time to time by
the server or PC.
• Static address - you must enter an IP address, subnet mask, and gateway
address for the system (provided by the system administrator). Once
entered, the address will not change.
2. In addition to configuring the IP address, you can set the UPnP configuration
for the system.
• UPnP ON - the system will broadcast its (Unique Device Name) UDN
address across the network. This allows the Insight workstation software
to automatically detect the IP address of the modeler for communication.
• UPnP OFF - the system will NOT broadcast its IP address across the
network. The Insight workstation software will need to be manually
configured to communicate with the modeler.
High Voltage Power Cable Connection
High Voltage Power Cable Connection Main Circuit Breaker UPS Switch

2-4
Setting the IP Address
1. Power up the system, see “Powering Up the System” on page 4-3.
2. From the Ready screen, select Maintenance and press ENTER.
3. Select Administration and press ENTER.
4. Select Network Configuration and press ENTER.
5. Choose YES or NO for the Dynamic IP
6. If the Dynamic IP is set to NO, select Configure Static Network Address,
then:
• Select IP and enter the address using the keypad. Press ENTER. You can
use the DEL key to erase incorrect entries.
• Select MASK (Netmask) and enter the address. Press ENTER.
• Select GW (Gateway) and enter the address. Press ENTER.
7. Choose YES or NO for the UPnP
Build Job..
Operator Control..
Modeler Status..
>Maintenance..
| *Tips: Model T16
| * Support T16
Modeler Default..
>Administration..
Reboot system..
>Network Configuration..
Receive Software Upgrade or Code..<E>
Field Service.. password:
Dynamic IP: YES <E>
UpnP: ON <E>
*Configure Static Network Address
Dynamic IP: NO <E>
UpnP: ON <E>
>Configure Static Network Address
>IP : [172.16.70.10]
MASK: (.none found)
GW : [172.16.100.1]
Note: See your system administrator if you do not know the
IP, Netmask, or Gateway address.

2-5
Moving the System
If you need to move the system to a different location, a specific sequence of steps
must be followed.
1. Unload material filament from the liquefiers. See“Unloading Material from
the Liquefier Tips” on page 4-13.
2. Remove the material canisters. See “Removing Canisters” on page 4-14.
3. Lower the Z stage to the bottom of its travel. See “Moving the Z Stage to
Bottom of Travel.” on page 4-36.
4. Shut down power to the system. See “Powering Down the System” on page 4-
4.
5. Unplug the power cable from the power source.
6. Secure the Z stage:
A. Remove all side panels on the system.
B. Grasp the Z stage drive belt and the lower Z stage until the end plates rest
on the lower hard stops.
C. On the left and right side of the system, wrap a large wire tie around the
end plate and the lower bearing mount plate, see Figure 2-5.
• Make sure the wire tie is tight.
Figure 2-5: Securing the Z Stage
Warning: Due to the UPS, High voltage is present in the
system with the power cord unplugged.
Caution: Before unplugging the system always make sure the
oven is cool to avoid blowing the oven thermal cut-out fuses.
End Plate
Tie Wrap
Bearing Mount
Plate

2-6
7. Secure the XY Gantry: (Figure 2-6)
A. Open the hood door and hood lid.
B. Manually position the gantry in the left front corner of the XY table.
C. Using several wire ties, secure the head to the frame.
Figure 2-6: Securing the XY Gantry
8. Reinstall and secure all panels.
9. Raise the support feet located near each caster by loosening the locknut on
each foot (Figure 2-7).
Figure 2-7: System Casters
Warning: Use an approved safety ladder to access the hood.
Caution: Do not use the head service handle to secure the XY
Gantry. Damage to the head could occur.
Caution: If the system will be rolled over floor seams or
bumps, do not roll the system on the casters. Use an
appropriate lifting device.
Tie Wraps
Locknut