Stratasys V650 Flex User manual

Part No. 407388-0001_REV_A
V650 Flex
3D Printing System
USER GUIDE

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LIABILITY STATEMENT
Stratasys 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 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 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
© Copyright 2020 Stratasys. All rights reserved.
No part of this document may be photocopied, reproduced, or translated into any
human or computer language in any form, nor stored in a database or retrieval
system, without prior permission in writing from Stratasys. This document may be
printed for internal use only. All copies, shall contain a full copy of this copyright
notice.
TRADEMARK ACKNOWLEDGMENTS
© 2020 Stratasys. All rights reserved. Stratasys, the Stratasys Signet logo, V650
Flex, are registered trademarks of Stratasys Inc. All other trademarks are the
property of their respective owners, and Stratasys assumes no responsibility with
regard to the selection, performance, or use of these non-Stratasys products.
Product specifications subject to change without notice. Printed in the USA
DISCLAIMER
Customer acknowledges the contents of this document and that Stratasys parts,
materials, and supplies are subject to its standard terms and conditions, available
on http://www.stratasys.com/legal/terms-and-conditions-of-sale, which are incorporated
herein by reference.
The specifications and/or information on which this document is based are subject
to change without notice.

iii
ABOUT THIS GUIDE
This guide is your introduction to building prototypes and end-use
parts using a Stratasys 3D production, 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. You can read
this guide chapter by chapter or use the Table of Contents when
you need to quickly find specific information. Keeping this guide
close to your printer will efficiently allow you to troubleshoot and
maintain the printer.
CONVENTIONS USED IN THIS GUIDE
The following conventions are used in this guide:
• When you see text in this font, it indicates a button being pressed via the
User Interface touchscreen. For example, press the Queue button within
the Navigation Menu.
• When you see text in blue, it indicates that the text is a linked reference to
a specific figure, table, heading, or page number.
• Standard bold text is used to emphasize items within instructional
sequences or indicate a navigational path you must follow to locate/start a
software application, open or save a file on your workstation PC, or
perform an operation when working with GrabCAD Print. The > character
is used to separate items within a navigational path. For example, navigate
to File > Open from the Main Menu.
REVISION LOG
0.
Revision Date Description of Changes
A June 2020 First release of this document

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TABLE OF CONTENTS
1 SERVICE AND SUPPORT ...................................................................1
Hazard Types ........................................................................................................................................... 1
Safety Warnings ....................................................................................................................................... 2
Hazard Classifications........................................................................................................................... 5
Product Safety Signs................................................................................................................................ 5
Product Safety Label Locations ............................................................................................................... 7
Potential Safety Hazard Areas ............................................................................................................... 11
Door Interlocks ....................................................................................................................................... 11
General Safety Practices ....................................................................................................................... 12
Lockout Tagout (LOTO).......................................................................................................................... 12
Environmental Requirements................................................................................................................. 13
2 SETUP AND INSTALLATION ............................................................ 14
Welcome Kit Contents............................................................................................................................ 14
AC Power Requirements........................................................................................................................ 15
3 SYSTEM COMPONENTS .................................................................. 17
Vat Lift Assembly.................................................................................................................................... 19
Elevator Assembly.................................................................................................................................. 23
Recoater Assembly ................................................................................................................................ 24
Gauges................................................................................................................................................... 26
Vacuum Enclosure ................................................................................................................................. 27
Upper Access Doors .............................................................................................................................. 27
Computer ............................................................................................................................................... 28
Uninterrupted Power Supply (UPS) ....................................................................................................... 28
EMI Filter (part number) ......................................................................................................................... 31
48VDC Power Supply (PWR-50003) ..................................................................................................... 31
Vat Stepper Driver (DRV-50001) ............................................................................................................ 31
Elevator Stepper Driver (DRV-50001) .................................................................................................... 32
Recoater Stepper Driver (DRV-50001)................................................................................................... 32

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PLC CPU (PLC-50001) 33
PLC 12-24 VDC Input (PLC-50002)....................................................................................................... 33
PLC 12-24 VDC Output (PLC-50003) .................................................................................................... 33
PLC Analog Input (PLC-50004).............................................................................................................. 33
PLC Analog Input (PLC-50005).............................................................................................................. 33
Counter IO (PLC-50006) Left ................................................................................................................. 33
24 VDC Power Supply ........................................................................................................................... 33
5 VDC Power Supply ............................................................................................................................. 33
Scanner Assembly ................................................................................................................................. 35
4 USER INTERFACE AND SOLIDVIEW PRO V650 OVERVIEW ........36
Emergency Stop..................................................................................................................................... 36
Control Panel ......................................................................................................................................... 38
Stacklights / Horn ................................................................................................................................... 38
Optowave Laser Control Panel .............................................................................................................. 39
5 OPERATING THE PRINTER .............................................................69
Powering ON the Printer ........................................................................................................................ 69
Powering ON the Printer (Models No Longer in Production) ................................................................. 72
Powering OFF the Printer ...................................................................................................................... 73
Loading a Job......................................................................................................................................... 77
Previewing a Job.................................................................................................................................... 79
Starting a Build....................................................................................................................................... 80
Monitoring the Print Job ......................................................................................................................... 82
Job Information ...................................................................................................................................... 82
Stacklight Signals and On-screen Status............................................................................................... 83
Unloading a Part .................................................................................................................................... 83
Clearing a Fault...................................................................................................................................... 84
Emergency Shutdown Procedures......................................................................................................... 84
Advanced Operations............................................................................................................................. 85

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6 CALIBRATION AND ADJUSTMENTS ............................................... 87
Line-Width Mapping “Roots” Parts ......................................................................................................... 98
Resin Shrinkage “Tree” Parts............................................................................................................... 103
7 MAINTENANCE ............................................................................... 107
Clean Fan Filter.................................................................................................................................... 108
Clean Power Meter Window and Replace Washer .............................................................................. 109
Clean Laser Window ............................................................................................................................ 112
Clean Recoater Blade .......................................................................................................................... 113
Clean Level Sensor Baffle.................................................................................................................... 117
Check Vacuum Level............................................................................................................................ 118
Recoater Blade Compression Spring Replacement............................................................................. 120
Power Meter Window Replacement Kit................................................................................................ 122
Recoater Blade Air Flow Control Valve, Breather Vent, and Cap......................................................... 126
Platform Locating Pin and Set Screw................................................................................................... 127
Screw Jack Support Shim .................................................................................................................... 128
Stacklight Elements and Horn.............................................................................................................. 129
UPS System......................................................................................................................................... 130
LED Light Fixture ................................................................................................................................. 131
8 TROUBLESHOOTING ..................................................................... 132

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9 SUPPLEMENTARY INFORMATION ................................................. 142
Recoat/Build Parameters Selection Screen ......................................................................................... 142
Edit Parameters Screens ..................................................................................................................... 143
EMC Class A Warning .......................................................................................................................... 144
FCC Statements (U.S.A.)..................................................................................................................... 144
Canada Electromagnetic compatibility (EMC)...................................................................................... 144
MSDS (Material Safety Data Sheet) .................................................................................................... 145
Disposal of Waste Equipment by Users in Private Households in the European Union ...................... 145

Service Hazard Types
Page 1
© Copyright 2020 Stratasys. All rights reserved.
1 SERVICE AND SUPPORT
This chapter provides information on service and support for the V650 Flex as well as safety
information and safety label locations.
Service
If you have a problem with your printer that is not covered in this guide, please contact
Stratasys Customer Support. Contact information is available from the Stratasys website at:
http://www.stratasys.com/customer-support/contact-customer-support.
When calling in for service, always have your printer’s software version and hardware serial
number available. You may need to provide a SVD file from SolidView PRO V650 to aid in
troubleshooting your system.
Software Support
If you have a software problem that is not covered in this guide, please contact Stratasys
Customer Support. Contact information is available from the Stratasys website at: http://
www.stratasys.com/customer-support/contact-customer-support.
When calling in for service, always have your printer’s software version and printer serial
number available. You may need to provide a SVD file from SolidView PRO V650 to aid in
troubleshooting your system.
Safety Instructions
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 V650 Flex printer is designed to be safe and reliable rapid prototyping
printers. Access to areas of the printer are potentially dangerous.
Hazard Types
Stratasys recommends that all services be performed by qualified personnel. All personnel
working on or around the printer should be knowledgeable of what the following hazard
classifications mean throughout this guide.

Safety Instructions Safety Warnings
Page 2
© Copyright 2020 Stratasys. All rights reserved.
Safety Warnings
Laser
Figure 1: Laser Warning Labels
Laser Safety
This Stratasys automated laser-based 3D printing system fully complies with Federal Laser
Product Performance Standards (FLPPS) 21CFR1040.10 and IEC-60825 as a Class 1 laser. A
Class 1 laser means any laser product that does not permit access to levels of laser radiation
in excess of Class 1 accessible emission limits (AEL) during operation.
A Class 1 laser system can contain a higher Class laser (i.e. embedded) however cannot emit
accessible laser radiation levels during operation in excess of Class 1 AEL. Definition per ANSI
Z136.1 standard for Safe Use of Lasers; a Class 1 laser system is considered to be incapable
of producing damaging radiation levels during operation and exempt from any user control
measures. Control measures are a means to mitigate potential hazards associated with the
use of lasers and can be divided into three groups; engineering, procedural (administrative)
and personal protective equipment (PPE).
This Class 1 laser-based 3D printing system utilizes an embedded Class 4 ultraviolet (UV)
laser within the interlocked and labeled protective housing. Protective housing means those
portions of a laser product that are designed to prevent human access to laser and/or collateral
radiation in excess of Class 1 accessible emission limits during operation.
A Class 4 laser product means any laser that does permit human access during operation to
levels of laser radiation in excess of the accessible emission limits. A Class 4 laser system is a
hazard to the eye or skin from the direct beam, may pose a fire hazard or diffuse reflection
hazard, and may also produce laser generated air contaminants (LGACs) and hazardous
plasma radiation.

Safety Instructions Safety Warnings
Page 3
© Copyright 2020 Stratasys. All rights reserved.
The V650 Flex utilizes a 355-nm laser with a maximum output of maximum output of 1.25 kW
@ 30khz at source. Typical usage is at 100khz. Repetition range is single shot to 300khz.
Pulse duration is <35ns. Laser duty cycle is dependent on repetition rate. When the build
chamber access doors are open and the interlocks defeated, Class IV-High Power Laser
visible and invisible radiation exposure is possible. Only authorized personnel should access
the Laser Enclosure, and must be equipped with necessary eye protection.
A Guarding System employs an electromechanical laser shutter that prevents the emission of
laser light. Opening any of the chamber doors, or engaging the E-Stop, blocks the output of the
beam. With the Guarding System enabled, the product qualifies as a Class 1 Laser Product.
This safety feature can be defeated by turning the "Guarding" key switch to the Bypass
position. In this position, all safety features are disabled and exposure to the laser beam is
possible. Anyone operating the machine in the bypassed state should be familiar with Class IV-
High Power Laser safe practices, and take the appropriate precautions.
The laser beam is a fire and safety hazard. Precautions must be taken to prevent accidental
exposure to direct or reflected laser beam. Both diffuse and specula reflections can cause
severe skin or immediate and permanent eye damage. Proper eyewear must be worn at all
times.
A Class 4 high-powered laser system:
• Is a hazard to the eye or skin from the direct beam
• May pose a diffuse reflection risk or fire hazard
• May also produce laser-generated air contaminants (LGAC) and hazardous plasma
radiation
A laser is also used to monitor resin level while building. It is a class II laser (FDA CDRH
21CFR PART1040.10) with a maximum output of 0.95mW. It has a wavelength of 650 nm
visible light.
Resin
Wear Nitrile gloves when handling any system component that has been contaminated with
resin. Prolonged or repeated contact with certain resins can result in allergic reactions.
Caution:
Use of controls or adjustments or performance of procedures other than those
specified herein may result in hazardous radiation exposure.
Note:
By engineering design no laser radiation exceeding Class 1 accessible emission
limits are present or accessible during operation of this laser-based 3D printing
system.

Safety Instructions Safety Warnings
Page 4
© Copyright 2020 Stratasys. All rights reserved.
Moving Parts
The V650 Flex employs moving mechanical parts which pose the risk of severe personal injury.
Always use extra care when working around the machine. Do not wear ties, loose clothing, or
dangling jewelry. Keep long hair tied up and away from any moving parts.
Moving parts are located inside both the Build Chamber and Vat Enclosure. These areas
should not be opened while any part of the machine is still moving. The Guarding System, if not
disabled, will immediately stop all moving parts when either area is opened. Operators are
prevented from using the system with the Guarding System disabled.
High Voltage
The "High Voltage" warning label indicates the presence of high voltages. Always stay away
from any exposed electrical circuitry. It is recommended that all jewelry be removed before
working around the machine.
High Voltage systems are located inside the Electrical Enclosure. The machine should be
completely powered down before replacing any electrical component.

Safety Instructions Hazard Classifications
Page 5
© Copyright 2020 Stratasys. All rights reserved.
Hazard Classifications
Stratasys recommends that all services be performed by qualified personnel. All personnel
working on or around this printer 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.
Product Safety Signs
Stratasys makes every effort to ensure that our printers are safe and reliable at all times.
However, there will be times when you must access areas of the printer where potentially high
voltages, hot temperatures, and/or moving mechanical components could cause severe injury.
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.
Indicates additional information relative to the current topic.
Always read and adhere to safety statements, and be aware of the following safety
signs when you see them on the printer.
Warning Symbols Meaning Location Comments
Class 1 laser
product
Next to the emergency stop
buttons, front and left side
top panels. Also on the rear
top panel.
Class 1 laser present.
Avoid long-term viewing of
the laser.
Class 4 laser
exposure
Beneath the bypass switch
on the front panel and on
the top cover.
Class 4 visible and
invisible laser radiation
exists within the system.
Risk of eye or skin
exposure to direct or
scattered radiation when
open.

Safety Instructions Product Safety Signs
Page 6
© Copyright 2020 Stratasys. All rights reserved.
High voltage
On the electrical panel
door, above and below the
main disconnect switch.
Risk of electric shock.
Gloves Vat and resin bottles
Risk of chemical exposure.
Wear approved safety
gloves and sleeves.
Moving parts Beneath the build area
door, front and left side.
Risk of injury from moving
parts.
Warning Symbols Meaning Location Comments

Safety Instructions Product Safety Label Locations
Page 7
© Copyright 2020 Stratasys. All rights reserved.
Product Safety Label Locations
Figure 2: Front safety label locations

Safety Instructions Product Safety Label Locations
Page 8
© Copyright 2020 Stratasys. All rights reserved.
Figure 3: Left side safety label locations

Safety Instructions Product Safety Label Locations
Page 9
© Copyright 2020 Stratasys. All rights reserved.
Figure 4: Right side safety label locations

Safety Instructions Product Safety Label Locations
Page 10
© Copyright 2020 Stratasys. All rights reserved.
Figure 5: Rear and Top safety label locations

Safety Instructions Potential Safety Hazard Areas
Page 11
© Copyright 2020 Stratasys. All rights reserved.
Potential Safety Hazard Areas
The build chamber, recoater, elevator, and vat lift are highlighted as potential safety hazards
that may cause printer failure or reliability problems if proper safety procedures are not
followed.
Door Interlocks
Interlock switches are used to communicate the status of the five upper and lower doors
located on the back, side, and front of the printer. For safety reasons, all doors and their
corresponding interlock switches must be closed before the vat, elevator and recoater motors
will operate. Additionally, the laser enters a shuttered state when any of the doors and
interlocks are open.
The printer’s servo motors are disabled by interlock switches when any door is open.
Use caution.
Warning: Chemical Exposure.
Always wear safety gloves and long sleeves when working in the build area and vat
enclosures.
Warning: Moving Parts.
Never wear a tie, loose clothing or dangling jewelry when working around moving
components of the printer. The build chamber, recoater, elevator, and vat lift contain
mechanical drive components that can cause severe injury. The Vat drive assembly
and weight of the Vat can cause severe injury. Hazards are minimized by interlock
switches but caution should be used around any moving part. Use extreme caution
whenever accessing these areas of the printer.

Safety Instructions General Safety Practices
Page 12
© Copyright 2020 Stratasys. All rights reserved.
General Safety Practices
Abide by these general safety practices when working with this printer.
Lockout Tagout (LOTO)
Warning: High Voltage.
High voltage is present in the printer.
Warning: Falling Hazard.
Only use an OSHA or CE approved step stool when accessing the area under the
top cover.
Warning: Chemical Exposure.
Always wear safety gloves and long sleeves when working in the build area.
Warning: Chemical Exposure Eyewear.
Always wear safety glasses when working in the build area.
Warning: LASER Exposure Eyewear.
Always wear 200nm-540nm LASER protective safety glasses when working on the
LASER. Glasses must meet ANSI 136.1 standards. A minimum optical density of 4
is required at 355nm. (+OD4 @355nm).
Warning: LASER Exposure Clothing.
Always wear safety gloves and long sleeves when working on the LASER.
Customer site procedures regarding lockout tagout always take precedence over the
Stratasys service procedure.

Safety Instructions Environmental Requirements
Page 13
© Copyright 2020 Stratasys. All rights reserved.
Environmental Requirements
• The V650 Flex printer is for indoor use only.
• Air quality conditions with excessive solid particulates (conductive or non-conductive) may
result in system damage.
• Air quality conditions in which airborne oils are allowed to accumulate on or within the
printer can damage the plastic components.
• System operating temperature shall be in the range of 59°F to 72°F (15°C to 22°C), with
relative humidity range of 10% to 50% non-condensing.
• System storage temperature shall be in the range of 32°F to 95°F (0°C to 35°C), with
relative humidity range of 20% to 90% non-condensing.
• Altitude shall not exceed 6561.68 feet (2000 m).
•Material storage shall be in the range of 55°F to 86°F (13°C to 30°C), with relative humidity
less than 70%.
• Typical Heat output: 210W or 716 BTU per hour
Typical heat output is calculated at 50% of typical power consumption:
3.5Amps @ 120V. 120 * 3.5 * 50% = 210W; 210 * 3.41 = 716BTU/hr
• Maximum Heat output: 1000W or ~3410 BTU per hour with resin heaters on.
Some resins will require lower humidity ranges to operate correctly.