Stratasys Fortus 360mc User manual

www.stratasys.com | c-suppo[email protected]
FORTUS 360mc/400mc™
3D Production System
Service Manual
Part No. 109156-0003, Rev. A

ii
Liability Statement
The information in this document is subject to change without notice.
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. 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 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, FORTUS, and FDM are registered trademarks of Stratasys Inc.
FORTUS 360mc/400mc is a trademark of Stratasys Inc. in the United States and other
countries.
Windows NT, Windows 2000, and Windows XP are registered trademarks of
Microsoft Corporation.
Unix is a registered trademark of AT&T Bell Laboratories.
SGI is a registered trademark of Silicon Graphics Incorporated.
Ultem* 9085 is a trademark of SABIC Innovative Plastics IP BV.
Krytox and Teflon are registered trademarks of DuPont.
TriGel is a registered trademark of Danaher Motion.
TiltWatch and ShockWatch are registered trademarks of Shockwatch, Inc.
NILOS-Ring is a registered trademark of Ziller GmbH & Co. KG.
All other product names are the property of their respective owners.
Stratasys Inc.
7665 Commerce Way
Eden Prairie, MN 55344 USA
952.937.3000
Fax: [phone]
www.stratasys.com
© Copyright 2014 Stratasys Inc. All rights reserved.
Printed in the United States of America

iii
Table of Contents
Safety ____________________________________________________________ 1-1
Safety ________________________________________________________________ 1-2
Safe Environment _________________________________________________ 1-2
Safe Human Interface _____________________________________________ 1-2
Hazard Classifications _____________________________________________ 1-3
Potential Safety Hazard Areas______________________________________ 1-4
Guard Door Interlocks _____________________________________________ 1-4
General Safety Practices __________________________________________ 1-4
Removing Electrical Power ____________________________________________ 1-5
System Overview__________________________________________________ 2-1
Specifications ________________________________________________________ 2-2
System Specifications______________________________________________ 2-2
Liquefier Tip Specifications _________________________________________ 2-4
Theory of Operation __________________________________________________ 2-12
General _________________________________________________________ 2-12
FDM Technology______________________________________________ 2-12
Extrusion _____________________________________________________ 2-12
First Layer Adhesion ___________________________________________ 2-14
Thermal Expansion ____________________________________________ 2-16
Systems __________________________________________________________ 2-17
AC Board ____________________________________________________ 2-17
Computer____________________________________________________ 2-19
Z Stage ______________________________________________________ 2-19
MIO Board ___________________________________________________ 2-20
Head ________________________________________________________ 2-22
Head Cooling Fan ____________________________________________ 2-25
Gantry (XY Table)_____________________________________________ 2-27
Canister______________________________________________________ 2-30
Canister Drive Block___________________________________________ 2-32
Loading/Unloading Filament to the Head ______________________ 2-36
Door Interlock ________________________________________________ 2-40
Air Dryer System ______________________________________________ 2-41
Operation____________________________________________________ 2-42
Vacuum System ______________________________________________ 2-43
Oven Temperature Control____________________________________ 2-46
Thermal Safety Circuit_________________________________________ 2-48
Calibration and Sensors___________________________________________ 2-50
Homing ______________________________________________________ 2-50
Z Stage Homing ______________________________________________ 2-51
Gantry Homing _______________________________________________ 2-52
Auto Z Zero ___________________________________________________ 2-53
Measure Flatness _____________________________________________ 2-54

iv
Tip Sensor ____________________________________________________ 2-54
Linear Compensation _________________________________________ 2-56
Setup and Installation _____________________________________________ 3-1
General Information __________________________________________________ 3-2
Installation Checklist _______________________________________________ 3-2
Installation ________________________________________________________ 3-2
Un-Crate the System ___________________________________________ 3-2
Stabilize System________________________________________________ 3-2
Pre-Power Up Checks __________________________________________ 3-3
AC Power Verification ________________________________________ 3-12
Initial Power Up, Network Configuration and System Activation__ 3-14
Upgrade Controller Software __________________________________ 3-20
System Verification and Calibration____________________________ 3-21
Final Test _____________________________________________________ 3-22
Software __________________________________________________________ 4-1
Insight________________________________________________________________ 4-2
Building a Part ____________________________________________________ 4-2
Start Insight____________________________________________________ 4-2
Open an STL File _______________________________________________ 4-2
Modeler Set-Up________________________________________________ 4-3
Prepare the Part _______________________________________________ 4-6
User Interface (UI) Menu Structure_____________________________________ 4-11
Main Menu __________________________________________________________ 4-11
Build Job_________________________________________________________ 4-11
Show Job Queue _____________________________________________ 4-11
Show Sample Job Queue _____________________________________ 4-11
Main Menu __________________________________________________________ 4-12
Operator Control_________________________________________________ 4-12
Load/Unload Material ________________________________________ 4-12
s/Material ____________________________________________________ 4-13
Calibrate_____________________________________________________ 4-14
Temp Control_________________________________________________ 4-15
Move Head/Stage____________________________________________ 4-15
Main Menu __________________________________________________________ 4-16
Modeler Status ___________________________________________________ 4-16
Temperatures ________________________________________________ 4-16
Material Status _______________________________________________ 4-16
Tip Status _____________________________________________________ 4-16
Machine State _______________________________________________ 4-17
Main Menu __________________________________________________________ 4-19
Maintenance ____________________________________________________ 4-19
Modeler Default ______________________________________________ 4-19
Administration ________________________________________________ 4-19
Reboot Machine _____________________________________________ 4-24

v
Procedures ___________________________________________________ 4-24
Service Procedures________________________________________________ 5-1
General ______________________________________________________________ 5-5
Panels ____________________________________________________________ 5-5
Panel Removal ________________________________________________ 5-6
Panel Installation ______________________________________________ 5-7
System Power Down/Power Up_____________________________________ 5-8
System Power Down ___________________________________________ 5-8
System Power Up ______________________________________________ 5-9
Operator Power Down/Power Up _________________________________ 5-10
Operator Power Down ________________________________________ 5-10
Operator Power Up ___________________________________________ 5-10
Oven Door Window ______________________________________________ 5-11
Oven Door Window Removal _________________________________ 5-11
Oven Door Window Installation ________________________________ 5-12
Head________________________________________________________________ 5-13
Head Maintenance Position ______________________________________ 5-13
Place Head in the Maintenance Position_______________________ 5-13
Place Head in the Operating Position __________________________ 5-14
Head Cable _____________________________________________________ 5-15
Head Cable Removal_________________________________________ 5-15
Head Cable Installation _______________________________________ 5-16
Liquefier Tip ______________________________________________________ 5-17
Liquefier Tip Removal _________________________________________ 5-17
Liquefier Tip Installation________________________________________ 5-18
Head ____________________________________________________________ 5-19
Head Removal _______________________________________________ 5-19
Head Installation _____________________________________________ 5-20
XY Gantry ___________________________________________________________ 5-21
XY Gantry Cooling Fans___________________________________________ 5-21
Gantry Cooling Fans Removal _________________________________ 5-21
Gantry Cooling Fans Installation _______________________________ 5-22
Y Carriage Kapton Barrier_________________________________________ 5-23
Y Carriage Kapton Barrier Replacement _______________________ 5-23
X and Y Belt ______________________________________________________ 5-24
X and Y Belt Removal _________________________________________ 5-24
X and Y Belt Installation _______________________________________ 5-26
X and Y Pulley____________________________________________________ 5-28
X and Y Pulley Removal _______________________________________ 5-28
X and Y Pulley Installation _____________________________________ 5-29
X and Y Motor____________________________________________________ 5-31
X and Y Motor Removal _______________________________________ 5-31
X and Y Motor Installation _____________________________________ 5-32
X and Y Bellows __________________________________________________ 5-34
X and Y Bellows Removal______________________________________ 5-34

vi
X and Y Bellow Installation_____________________________________ 5-35
Y Bridge _________________________________________________________ 5-36
Y Bridge Removal_____________________________________________ 5-36
Y Bridge Installation ___________________________________________ 5-40
X-Axis Guide Rod/Pillow Block _____________________________________ 5-44
X-Axis Guide Rod/Pillow Block Bearing Removal ________________ 5-44
X-Axis Guide Rod/Pillow Block Bearing Installation ______________ 5-48
Z Stage ______________________________________________________________ 5-53
Z Drive Motor_____________________________________________________ 5-53
Z Drive Motor Removal ________________________________________ 5-53
Z Drive Motor Installation ______________________________________ 5-55
Lead Screw Assembly ____________________________________________ 5-56
Z Lead Screw Removal________________________________________ 5-57
Z Lead Screw Installation ______________________________________ 5-58
Z Guide Rod/Pillow Block _________________________________________ 5-63
Z Guide Rod/Pillow Block Removal_____________________________ 5-64
Z Guide Rod/Pillow Block Installation ___________________________ 5-65
Z Stage Drive Belt_________________________________________________ 5-67
Z Stage Drive Belt Removal ____________________________________ 5-67
Z Stage Drive Belt Installation __________________________________ 5-68
Z Stage Idler Pulley _______________________________________________ 5-69
Z Stage Idler Pulley Removal___________________________________ 5-69
Z Stage Idler Pulley Installation _________________________________ 5-70
Platen Vacuum Screen ___________________________________________ 5-71
Vacuum Screen Removal _____________________________________ 5-71
Vacuum Screen Installation ___________________________________ 5-71
Platen ___________________________________________________________ 5-72
Platen Removal ______________________________________________ 5-72
Platen Installation_____________________________________________ 5-73
Electronic Components ______________________________________________ 5-74
Display Panel ____________________________________________________ 5-74
Display Panel Removal________________________________________ 5-74
Display Panel Installation ______________________________________ 5-75
AC Board ________________________________________________________ 5-75
AC Board Removal ___________________________________________ 5-75
AC Board Installation _________________________________________ 5-77
MIO Board _______________________________________________________ 5-78
MIO Board Removal __________________________________________ 5-78
MIO Board Installation ________________________________________ 5-79
24/48 Volt Power Supply __________________________________________ 5-81
24/48 Volt Power Supply Removal _____________________________ 5-81
24/48 Volt Power Supply Installation____________________________ 5-82
UPS ______________________________________________________________ 5-84
UPS Removal _________________________________________________ 5-84
UPS Installation _______________________________________________ 5-84

vii
Computer _______________________________________________________ 5-85
Computer Removal___________________________________________ 5-85
Computer Installation _________________________________________ 5-86
Oven Components___________________________________________________ 5-87
Upper Waste Chute Funnel Kapton Barrier _________________________ 5-87
Upper Waste Chute Funnel Kapton Barrier Replacement________ 5-87
Oven Blower _____________________________________________________ 5-88
Oven Blower Removal ________________________________________ 5-88
Oven Blower Installation_______________________________________ 5-91
Oven Thermocouple _____________________________________________ 5-93
Oven Thermocouple Removal_________________________________ 5-93
Oven Thermocouple Installation _______________________________ 5-94
Oven Thermal Circuit Breaker _____________________________________ 5-96
Oven Thermal Circuit Breaker Removal ________________________ 5-96
Oven Thermal Circuit Breaker Installation_______________________ 5-97
Oven Heaters ____________________________________________________ 5-98
Oven Heaters Removal _______________________________________ 5-98
Oven Heaters Installation_____________________________________ 5-103
Oven Blanket (right side)_________________________________________ 5-104
Oven Blanket (right side) Removal ____________________________ 5-104
Oven Blanket (right side) Installation __________________________ 5-107
Oven Blanket (left side) __________________________________________ 5-107
Oven Blanket (left side) Removal _____________________________ 5-107
Oven Blanket (left side) Installation ___________________________ 5-108
Tip Sensor/Tip Sensor Cable ______________________________________ 5-109
Tip Sensor/Cable Removal ___________________________________ 5-109
Tip Sensor/Cable Installation__________________________________ 5-110
Filament Path ______________________________________________________ 5-112
Filament Drive___________________________________________________ 5-112
Filament Drive Removal ______________________________________ 5-112
Filament Drive Installation ____________________________________ 5-114
Y Block _________________________________________________________ 5-116
Y Block Removal_____________________________________________ 5-116
Y Bock Installation ___________________________________________ 5-117
Internal Air Components ___________________________________________ 5-118
Internal Vacuum Pump __________________________________________ 5-118
Internal Vacuum Pump Removal _____________________________ 5-118
Internal Vacuum Pump Installation____________________________ 5-119
Internal Air Compressor __________________________________________ 5-120
Internal Air Compressor Removal _____________________________ 5-120
Internal Air Compressor Installation ___________________________ 5-121
Adjustments and Calibrations ______________________________________ 6-1
Calibrations __________________________________________________________ 6-2
Autohome XYZ ____________________________________________________ 6-2
Z Zero Calibrations_________________________________________________ 6-3

viii
Manual Z Zero Calibration ______________________________________ 6-3
Auto Z Zero Calibration ________________________________________ 6-4
Tip Offset Calibrations _____________________________________________ 6-5
AutoCal Tips___________________________________________________ 6-5
XYZ Tip Offset __________________________________________________ 6-6
PPU/Scaling Calibration __________________________________________ 6-10
Adjustment __________________________________________________________ 6-12
Platen Level Adjustment __________________________________________ 6-12
Upper Z Stage Hard Stop Adjustment ______________________________ 6-16
Head Filament Alignment_________________________________________ 6-19
Head Filament Presence Detect Switch Adjustment ________________ 6-21
Belt Tension Gauge Setup ________________________________________ 6-23
XY Gantry Belt Tension ____________________________________________ 6-24
Z Stage Belt Tension ______________________________________________ 6-28
Tip Wipe Height Adjustment_______________________________________ 6-30
Standard Tip Wipe Assembly __________________________________ 6-30
Quick Adjust Tip Wipe Assembly _______________________________ 6-33
Air Pressure and Air Flow Adjustment ______________________________ 6-34
Z Homing Switch Adjustment ______________________________________ 6-35
Tip Air Deflector Adjustment_______________________________________ 6-37
Interlock Switch and Sensor Adjustments___________________________ 6-38
Tip Sensor Location/Setting Position________________________________ 6-39
Purge Location/Setting Position ___________________________________ 6-40
Troubleshooting ___________________________________________________ 7-1
How to Use this Guide _________________________________________________ 7-2
General Information_______________________________________________ 7-2
Who Should Use This Guide?____________________________________ 7-2
Systems Covered By This Guide. ________________________________ 7-2
Alternate Troubleshooting References. __________________________ 7-2
How to Troubleshoot the System____________________________________ 7-2
Definition of Terms _________________________________________________ 7-3
System Problems______________________________________________________ 7-4
Power ____________________________________________________________ 7-4
System will not power up _______________________________________ 7-4
System will not power down ____________________________________ 7-5
System powers down unexpectedly ____________________________ 7-6
Computer ________________________________________________________ 7-7
User interface is blank __________________________________________ 7-7
User interface is unresponsive (system locked up)________________ 7-7
Computer unable to restart properly____________________________ 7-7
Vacuum __________________________________________________________ 7-8
Calibration________________________________________________________ 7-8
Autohome XYZ failed __________________________________________ 7-8
AutoCal tip failed______________________________________________ 7-9
Build Failures _____________________________________________________ 7-12

ix
Part build won’t start __________________________________________ 7-12
Part build stopped ___________________________________________ 7-15
Part quality ___________________________________________________ 7-17
Operation: Failure ________________________________________________ 7-22
Part download failed _________________________________________ 7-22
Material load failed___________________________________________ 7-23
Loss of extrusion (LOE)_________________________________________ 7-26
Operation: Condition_____________________________________________ 7-29
Odor/Burning_________________________________________________ 7-29
Error Messages ______________________________________________________ 7-30
UI Messages _____________________________________________________ 7-30
UI HELP Messages ________________________________________________ 7-31
CFG File ERROR Messages ________________________________________ 7-32
Preventive Maintenance __________________________________________ 8-1
PM Procedure Checklist _______________________________________________ 8-2
Preventive Maintenance Procedures ___________________________________ 8-2
Lubricate the X Y Gantry Guide Rods _______________________________ 8-2
Lubricate Z Stage _________________________________________________ 8-3
Head Cable Inspection____________________________________________ 8-5
Filament Drive Inspection __________________________________________ 8-7
Filament Drive Load Time Test ______________________________________ 8-8
Internal Air Compressor Filters ______________________________________ 8-9
Internal Vacuum Pump Filters Replacement _______________________ 8-10
Cleaning Oven Door Glass________________________________________ 8-12
Drive Belt Inspection ______________________________________________ 8-12
Platen Inspection_________________________________________________ 8-12
Schematics _______________________________________________________ 9-1
Schematics___________________________________________________________ 9-3
Block Diagram ____________________________________________________ 9-3
Cable Wiring Diagrams ____________________________________________ 9-4
Left/Right Fan Bay Cables 101266_______________________________ 9-4
Light Blower Cable 101325 _____________________________________ 9-5
RS485 Cable PIC Bus 101342 ____________________________________ 9-6
Oven Heater Cable 101428 ____________________________________ 9-7
Cassette Interface Cable 101470 Sheet 1 of 2 ___________________ 9-8
Z Limit Switch Cable 101471 ___________________________________ 9-10
Cassette LED Cable 101472 ___________________________________ 9-11
Display Internal Cable 101473 _________________________________ 9-12
Display Switch Interface Cable 101474 _________________________ 9-13
RJ45 Communication Cable 101515 ___________________________ 9-14
Door Switch Solenoid Cable 101543 ___________________________ 9-15
Display Interface Cable 101786________________________________ 9-16
X Motor Cable 102349 ________________________________________ 9-17
Y Motor Cable 102350 ________________________________________ 9-18

x
Z Motor Cable 102351_________________________________________ 9-19
Head Umbilical Cable 102628 _________________________________ 9-20
Signal Motor Driver Board Cable 102630 _______________________ 9-21
Power Motor Drive Board Cable 102631________________________ 9-22
Filament Sensor Cable 102997 _________________________________ 9-23
MIO AC Board Interface Cable 103027 ________________________ 9-24
Top Hood Switch Solenoid Cable 103029 _______________________ 9-25
Thermal Fuse Cable 103031 ___________________________________ 9-26
Twin Tower Tip Wipe Comp Cable 103033 ______________________ 9-27
Computer UPS Power Cable 103046 ___________________________ 9-28
PCI Communication Cable 103047 ____________________________ 9-29
24/48V to IO Cable 103049 ____________________________________ 9-30
Power Switch/UPS Vacuum Pump Cable 103050________________ 9-31
24/48V Power Supply Cable 103054____________________________ 9-32
Contactor Control Cable 103610-0002 _________________________ 9-33
Door/Hood Vane Switch 104466 _______________________________ 9-34
Door Cover Solenoid 105569 __________________________________ 9-35
Bay Communication Jumper 105570___________________________ 9-36
Vacuum Switch 105571 _______________________________________ 9-37
Door Switch 105572 ___________________________________________ 9-38
External Air Diagram______________________________________________ 9-39
Supplemental Information ________________________________________ 10-1
Specifications _______________________________________________________ 10-3
System Specifications_____________________________________________ 10-3
Liquefier Tip Specifications ________________________________________ 10-4
General Information __________________________________________ 10-4
Tip Compatibility and Selection________________________________ 10-4
Tip Identification and Slice Height _________________________________ 10-8
Material Build Temperatures ______________________________________ 10-9
Removal and Replacement ________________________________________ 10-10
Oven Door Window _____________________________________________ 10-10
Oven Door Window Removal ________________________________ 10-10
Oven Door Window Installation _______________________________ 10-13
Y Bridge ________________________________________________________ 10-15
Y Bridge Removal____________________________________________ 10-15
Y Bridge ________________________________________________________ 10-16
Y Bridge Installation __________________________________________ 10-16
X-Axis Guide Rod / Pillow Block___________________________________ 10-19
X-Axis Guide Rod / Pillow Block Removal ______________________ 10-19
X-Axis Guide Rod / Pillow Block___________________________________ 10-20
X-Axis Guide Rod / Pillow Block Installation ____________________ 10-20
Y-Axis Guide Rod Assembly ______________________________________ 10-22
Y-Axis Guide Rod Assembly Removal _________________________ 10-22
Y-Axis Guide Rod Installation _________________________________ 10-25
Electronic Components ____________________________________________ 10-27

xi
Display Panel ___________________________________________________ 10-27
Display Panel Removal_______________________________________ 10-27
Display Panel Installation _____________________________________ 10-29
Computer ______________________________________________________ 10-30
Computer Removal__________________________________________ 10-30
Computer Installation ________________________________________ 10-31
Calibration and Adjustment ________________________________________ 10-33
Linear Compensation ___________________________________________ 10-33
X and Y Belt Tension Settings _____________________________________ 10-36
Component Adjustment _________________________________________ 10-37
Tip Wipe Height Adjustment __________________________________ 10-37
Tip Clean Position / Purge Location ___________________________ 10-41
Filament Dryer Air Pressure and Air Flow _______________________ 10-44
Interlock Switch and Sensor Adjustments ______________________ 10-46
XY Gantry PPU/Scaling Calibration (alternate method) ____________ 10-51
Air Conversion Procedures _________________________________________ 10-58
External Air______________________________________________________ 10-58
Internal Air ______________________________________________________ 10-70

xii
Revision Log
FORTUS 360mc/400mc Service ManualfA
Date Description of Changes
December 2012 New release of this manual.
April 2014 Added Nylon 12 material information throughout.
Incorporated Head Filament Presence Detect Switch
Adjustment procedure instructions.
Added 3mm belt upgrade information to Chapter 6.
September 2014 Added ASA material information throughout.

xiii
Safety
The following basic safety tips are given to ensure safe installation,
operation, and maintenance of Stratasys equipment and are not to be
considered as comprehensive on matters of safety. The Fortus 360mc/
400mc system is designed to be safe and reliable rapid prototyping
system. Access to areas of the system are potentially dangerous.
Safe Environment
• Connect equipment to a grounded facility power source. Do not defeat
or bypass the ground lead.
• Know the location of equipment branch circuit interrupters or circuit
breakers and how to turn them on and off in case of emergency.
• Know the location of fire extinguishers and how to use them. Use only
ABC type extinguishers on electrical fires.
• Know local procedures for first aid and emergency assistance at the
customer facility.
• Use adequate lighting at the equipment.
• Maintain the recommended range of temperature and humidity in
equipment area.
• Do not use this product in an environment containing volatile or
flammable compounds.
Safe Human Interface
• Use proper lifting techniques when moving or installing the
equipment.
• Use standard electrostatic discharge (ESD) precautions when working
on or near electrical circuits.
Hazard Classifications
Be aware of the following hazard classification used in this manual.
Caution: Indicates a potentially hazardous situation that may result in
minor or moderate injury.
Warning: Indicates a potentially hazardous situation that may result in
death or serious injury.
Note: Always read and adhere to safety statements, and be aware of the
following safety signs located on the system.

xiv
Potential Safety Hazard Areas
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.
High Voltage Sign. 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 Sign. 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.
Gloves and Sleeves–Required Sign. The gloves sign indicates that safety
gloves and sleeves approved for high temperatures must be used. These
are provided in the Startup Kit.
Crushed–Hand Sign. The crushed hand sign indicates that a crushing
hazard exists between two objects.
Oven Always wear safety gloves and long sleeves when working inside the
oven. Components are hot! The oven temperature is extremely hot. The
oven heater is controlled by a safety thermal breaker that shuts the
system off the temperature reaches 260° C (500° F). Opening the oven
door shuts the oven heaters off.
XY Gantry Never wear a tie, loose clothing or dangling jewelry when working
around moving components of the system. Beneath the top cover 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 is extremely
powerful so care must be taken. The servo motors are disabled when
the oven door or top covers are 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 Never wear a tie, loose clothing or dangling jewelry when working
around moving components of the system. The Z stage and Z stage
servo motor can cause severe injury. The Z stage crushing hazard is
minimized by locking the door during Z stage movement and disables
the Z-Motor when the door is open. If the side covers are removed, the
Z stage components are exposed.

xv
Guard Door Interlocks
Interlock switches are used to communicate the status of the oven door
and the top covers to the system. For safety reasons, the oven door and top
covers must be closed before the X, Y, and Z motors will operate.
General Safety Practices
Use the following safety practices when working with this system.
Warning: High voltage is present in the system when powered off and
unplugged due to the UPS (Uninterruptible Power Supply).
Warning: Only use an OSHA or CE approved step stool when accessing
the gantry area under the top covers (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 can get very hot.

FORTUS 360mc/400mc Service Manual 1-1
Chapter 1: Safety
This chapter describes the Stratasys Fortus 360mc/400mc system
and its safety information.
Safety _______________________________________________________________ 1-2
Safe Environment__________________________________________________ 1-2
Safe Human Interface _____________________________________________ 1-2
Hazard Classifications______________________________________________ 1-3
Potential Safety Hazard Areas ______________________________________ 1-4
Guard Door Interlocks _____________________________________________ 1-4
General Safety Practices___________________________________________ 1-4
Removing Electrical Power ___________________________________________ 1-5

FORTUS 360mc/400mc Service Manual 1-2
Safety
The following basic safety tips are given to ensure safe installation, operation, and
maintenance of Stratasys equipment and are not to be considered as comprehensive on
matters of safety. The Fortus360mc/400mc system is designed to be safe and reliable rapid
prototyping system. Access to areas of the system are potentially dangerous.
Safe Environment
• Connect equipment to a grounded facility power source. Do not defeat or bypass the
ground lead.
• Know the location of equipment branch circuit interrupters or circuit breakers and
how to turn them on and off in case of emergency.
• Know the location of fire extinguishers and how to use them. Use only ABC type
extinguishers on electrical fires.
• Know local procedures for first aid and emergency assistance at the customer facility.
• Use adequate lighting at the equipment.
• Maintain the recommended range of temperature and humidity in equipment area.
• Do not use this product in an environment containing volatile or flammable
compounds.
Safe Human Interface
• Use proper lifting techniques when moving or installing the equipment.
• Use standard electrostatic discharge (ESD) precautions when working on or near
electrical circuits.
• Do not defeat or disconnect safety interlocks.

FORTUS 360mc/400mc Service Manual 1-3
Hazard Classifications
Be aware of the following hazard classification used in this manual.
Caution: Indicates a potentially hazardous situation that may result in
minor or moderate injury.
Warning: Indicates a potentially hazardous situation that may result in
death or serious injury.
Note: Always read and adhere to safety statements, and be aware of the
following safety signs located on the system.
Personal Injury Sign. The personal injury sign indicates 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 Sign. 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 Sign. 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 the360mc/400mc Startup Kit.
Gloves and Sleeves–Required Sign. The gloves sign indicates that safety
gloves and sleeves approved for high temperatures must be used. These
are provided in the Startup Kit.
Sharp–Object Sign. 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 Sign. The crushed hand sign indicates that a crushing
hazard exists between two objects.
Use standard electrostatic discharge (ESD) precautions when
working on or near electrical circuits.

FORTUS 360mc/400mc Service Manual 1-4
Potential Safety Hazard Areas
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 status of the oven door and the top covers to
the system. For safety reasons, the oven door and top covers must be closed before the X, Y,
and Z motors will operate.
General Safety Practices
Use the following safety practices when working with this system.
Oven Always wear safety gloves and long sleeves when working inside the
oven. Components are hot! The oven temperature is extremely hot. The
oven heater is controlled by a safety thermal breaker that shuts the
system off the temperature reaches 300° C (572° F). Opening the oven
door shuts the oven heaters off.
XY Gantry Never wear a tie, loose clothing or dangling jewelry when working
around moving components of the system. Beneath the top cover 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 is extremely
powerful so care must be taken. The servo motors are disabled when
the oven door or top covers are 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 Never wear a tie, loose clothing or dangling jewelry when working
around moving components of the system. The Z Stage and Z Stage
servo motor can cause severe injury. The Z Stage crushing hazard is
minimized by locking the door during Z Stage movement and disables
the Z-Motor when the door is open.
Warning: High voltage is present in the system when powered off
and unplugged due to the UPS (Uninterruptible Power Supply).
Warning: Only use an OSHA or CE approved step stool when
accessing the gantry area under the top covers (located at the top of
the system).

FORTUS 360mc/400mc Service Manual 1-5
Removing Electrical Power
Any time service is being performed on the Fortus360mc/400mc, AC power must be
removed to the system. Perform the system shutdown sequence on the system before
removing power to the system.
Make sure the main breakers at the facility site are in their OFF position before preceding to
remove any electrical panels.
Any time service is being performed on the Fortus360mc/400mc system, especially the
electrical panel where high voltage power is present, the incoming power should be locked
out to prevent someone else from inadvertently energizing the electrical system.
When line voltage is removed from the system, a UPS (Uninterruptible Power Supply) is
designed to provide power to some components in the of the system. Make sure to manually
turn off the UPS when servicing the system.
Procedure
• Power down the system and turn Off the power. (See “System Power Down” on page5-
8.)
Warning: Always wear safety gloves and long sleeves when working in the
oven, with the head, or liquefier tips. these components can get very hot.
Warning: Make sure AC power is removed from the system. Voltage
of 230V AC is present and can be lethal.
Warning: Make sure the UPS is manually turned off and not
powering components in the system.