BST 1200 / SST 1200 User Guide
Notice 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.
Introduction Dimension is designed with ultimate simplicity in mind. The system enables you to build parts quickly, even if you’ve never used a 3D printer before. Its display panel prompts you to press a few keys to get you modeling quickly. The system models with ABS plastic, so modeled parts are strong and durable. ABS also ensures you’ll be able to drill, tap, sand, and paint your creations.
How To Use This Manual This User’s Guide is laid out in easy to follow sections which cover Set-up, Operation, Maintenance, and Troubleshooting of your Dimension printer. Be sure to read each section carefully so that you will get the best performance from your system. Highlighted Information The manual is written in a step-by-step format so as to guide you through a variety of operational tasks.
Sections Of The Manual Overview... Provides a quick reference for the layout of the printer and its operating components. Overview also provides a quick reference for sources of additional information and printer supplies. Setup... Guides you through the initial printer installation and setup. Topics include unpacking, connecting power, installing software, and connecting to a computer network. Generally, topics in setup are only accomplished during installation or relocation of the printer. Operation...
Dimension BST 1200 / SST 1200 User Guide
Table of Contents Introduction................................................................................ 3 How To Use This Manual......................................................... 4 Highlighted Information .................................................................. 4 Sections Of The Manual................................................................. 5 Overview................................................................................... 11 Finding More Information ..........
Building a Test Part ................................................................37 Sending Your CAD File to the System ...................................37 Building a Part from Your File ...................................................... 39 Chamber Lights ......................................................................39 Pausing Build .........................................................................40 Resuming Build from Pause Mode.........................................
Troubleshooting ...................................................................... 59 Troubleshooting Checklist...................................................... 59 Fault Determination Codes .................................................... 61 Loss of Extrusion.................................................................... 61 Diagnosing Loss of Extrusion....................................................... 61 Recovering From Loss of Extrusion ............................................
Dimension BST 1200 / SST 1200 User Guide
Overview Dimension builds models, including internal features, directly from CAD STL files. The system builds three-dimensional parts by extruding a bead of ABS plastic through a computer-controlled extrusion head, producing high quality parts that are ready to use immediately after completion. With two layer resolution settings, you can choose to build a part quickly for design verification, or you can choose a finer setting for higher quality surface detail.
Overview 3 2 4 1 5 6 Figure 2: Dimension Rear View Item Nomenclature 1 2 3 Fan Cover Main Circuit Breaker Power Cord Adapter Item Nomenclature 4 5 6 Dimension BST 1200 / SST 1200 User Guide UPS Connection Diagnostic Hookup Network Cable Connection
Overview 13 The Dimension system consists of two primary components — the Dimension 3D printer and CatalystEX. CatalystEX is the preprocessing software that runs on a Windows 2000 or Windows XP Pro platform. Dimension’s build envelope measures 254 x 254 x 305 mm (10 x 10 x 12 in). Each material cartridge contains 922 cc (56.3 cu. in.) of usable material — enough to build continuously for about four days without reloading. Finding More Information Several references are available for use with Dimension.
Overview Supplies This section lists all replaceable supplies used by the Dimension modeling system. The parts mentioned in this list can be obtained by contacting the sales representative through whom you purchased your system.
Setup Workspace Observe the following when placing Dimension in its operating location: • Dimension has an approximate weight of 148 kg (326 lbs) and requires a table capable of safely supporting 181kg (400 lbs). • System Dimensions: 838 x 737 x 1143 mm (33 x 29 x 45 in) Four-inch minimum space behind unit for air circulation • Dedicated outlet requirements: 110-120 VAC, 60 Hz, 15 A min. (20 amp recommended) –or– 220-240 VAC, 50/60 Hz, 7 A min.
Setup Unpacking This section describes the recommended procedures for unpacking and preparing Dimension for its first use. Unpack the printer: WARNING The Dimension printer weighs approximately 148 kg (326 lbs). Use proper moving and lifting techniques when positioning the unit. For your convenience, there are forklift pads built into the bottom of the unit. They are accessible from the side of the unit. 1. Before unpacking the printer, move it near to its operating location. 2.
Setup 17 CAUTION Remove the foam tubes that isolate the extrusion head from the frame (see Figure 3). The printer will be damaged if powered on with the foam tubes in place. CAUTION Be careful not to damage the rod sensors when removing the foam tubes (see Figure 3). 8. Remove the foam tubes that isolate the extrusion head from the frame (see Figure 3). Extrusion Head Circles indicate Rod Sensor locations. There is also one sensor on each side of the Extrusion Head.
Setup Installing Forklift Access Covers The forklift access covers can be placed over the forklift channels after the printer is placed in its final location (see Figure 4). The covers are press-fit in the front and held in place with one screw in the rear. Attachment Screw on Back of Printer Insert Tab in Slot Push Cover Toward Front of Printer Figure 4: Installing the forklift access covers Power Connections This section discusses the procedure for preparing all power connections for the printer.
Setup 19 Figure 5: Connecting to a grounded electrical outlet CAUTION Do not use an extension cord or power strip with the Dimension system. Connect the cord directly into the receptacle or UPS. 2. Connect the female end of the power cord directly into the rear of the cabinet. 3. Switch the Dimension circuit breaker to the on (up) position. The Dimension system is now ready to have power applied.
Setup Powering On Dimension WARNING Dimension’s build chamber and extrusion-head tip get very hot! The chamber and head tip reach temperatures of approximately 75° C (167° F) and 300° C (572° F) respectively. Personal injury can occur if proper techniques and safety materials are not used. Use the leather safety gloves provided in the Startup Kit when working inside the printer. CAUTION Remove the foam tubes that isolate the extrusion head from the frame (see Figure 3 on page 17).
Setup 21 NOTE If the printer was off and is at room temperature, it requires approximately 40 minutes to warm up before you can perform any functions. Temperatures are factory-preset and not adjustable. The panel displays the head and envelope temperatures while Dimension is warming up and cooling down. NOTE For safety, the head and Z Platform do not move while the chamber door is open. During warm-up and operation the door is locked.
Setup Installing Software There are two software programs that work with Dimension. • CatalystEX is the preprocessing software that controls Dimension. If you have not already done so, you will need to install the CatalystEX software on your PC. You will find the CatalystEX software on the CD-ROM included in your Startup Kit (See “Install CatalystEX:” on page 22.). • There is also ‘controller’ software loaded directly onto your Dimension system from the factory.
Setup 23 2. Compare the version number to the controller software CD provided in the Startup Kit. 3. If the version on the controller software CD is newer than the system version, follow the Controller Software Upgrade Notice instructions provided in the Startup Kit. Networking Your Printer You will need to establish communication between your PC and printer before you can send files to print. How you establish this communication is dependent upon how your computer network is configured.
Setup B. Click the ‘Add from Network...’ button in the lower right corner of the pop-up. C. A new pop-up, ‘Add 3D Printer’, should list your printer in the main window (identified by its UDN). Click on the printer in this window and enter a Name and Location (your choice) in the lower portion of the pop-up. D. Click ‘Add Printer’ - and you are ready to go. Close the 3D Printer pop-up. NOTE If your printer is not displayed in the ‘Add 3D Printer’ pop-up, you are not using a Dynamic network.
Setup 25 6. Use the three functions above to set your IP address. 7. After setting the final digit of the IP address, move the cursor one more place to the right. The cursor moves to the NM (or Netmask) address. Follow the same steps for setting the NM and GW addresses. 8. When you have finished setting the addresses, press Done. The panel displays Change IP, Netmask, Gateway? 9. Press Yes. The panel then displays Resetting Network and after a moment returns to Idle or starts warming up. 10.
Setup D. Enter the IP Address for your printer in the appropriate field. It will be the same address as the one entered in Step 4. E. Select the appropriate printer type from the drop down list. F. Click ‘Add Printer’ and close the 3D Printer pop-up. 13. If you are unable to connect the printer to your PC, contact your Network Administrator. Connecting Directly To Your PC You can connect the Dimension printer directly to your PC without the use of a network.
Setup 27 C. A new pop-up, ‘Add 3D Printer’, should list your printer in the main window (identified by its UDN). Click on the printer in this window and enter a Name and Location (your choice) in the lower portion of the pop-up. NOTE It may take up to 1 minute for your printer to appear in the pop-up window. D. Click ‘Add Printer’ - and you are ready to go. Close the 3D Printer pop-up. 4. If your printer does not appear in the pop-up window: A.
Setup vi. After allowing your PC a minute or so to adjust to the new setting, your PC should connect to your printer. vii. If you are still unable to connect to your printer, recheck your connections and settings. Contact your local reseller for additional customer service.
Operation Display Panel and Keypad The main User Interface to Dimension is the Display Panel and Keypad (see Figure 8). Display Panel Keypad buttons Contextsensitive displays Figure 8: Dimension display panel and keypad The Dimension display panel and keypad are very easy to use, consisting of a larger multiple-line LCD display on top, and four single-line context-sensitive displays, each with one button (or key). The top line in the large display always reveals the printer status.
Operation Inserting a Modeling Base Prior to inserting a modeling base into the tray, remove any material buildup on and behind the Z Platform and around the lead screw. Failure to do so could cause the modeling base to be unlevel or, if the amount of buildup is large enough, the Z Platform could jam at its upper limit. Install the modeling base (See “Insert Modeling Base” on page 21. - "Setup"). Reusing a modeling base: The square outlines on the modeling base represent modeling areas.
Operation 31 Powering Off Dimension To power-off Dimension, move the power switch to the OFF position (see Figure 6 on page 20). You can do this at any time without harming the printer. No other steps are necessary. If this is done while the printer is building a part, the current build will be lost. System cooling fans will continue to operate for several minutes. This ensures a safe, systematic power down. NOTE For extended non-use periods, unload the material cartridges and then power off the system.
Operation Loading Material Material cartridges are factory packaged in a box and an anti-static, moisture-proof bag to preserve shelf life. Material will stay humidity free inside the cartridge for at least 30 days after opening. Shelf life is more than one year if the cartridge package remains sealed. Load material cartridges: 1. Remove packaging. 2. If present, remove the red sealing plug from the cartridge: (see Figure 9) NOTE Plug must be removed before cartridge can be installed. A.
Operation 33 CAUTION Be careful when touching the pinch roller on the side of the cartridge. If you roll it backwards, you could draw the material into the cartridge (see Figure 10 for the correct direction to move the cartridge roller). If this occurs, there is no way to retrieve the filament without opening the cartridge and exposing the material to humidity, which reduces shelf life to a few days. Figure 10: Direction to move cartridge roller 4.
Operation Figure 11: Snipping the material filament 6. If the printer is in Idle, press the Material Load button, which will be blinking. 7. Display will prompt with Load Model - Replace Both Cartridges (flashing) 8. Insert material cartridges into their appropriate slot from the front of the printer (Model material cartridge goes in the Top slot; Support material goes in the Bottom slot). NOTE You might get the message, Cartridge Not Replaced Or Invalid.
Operation 35 10. Next you are prompted with Load Support - Ready to Load Support Material (if not previously loaded). Press Load to load support material. • Watch the support extrusion tip (see Figure 12) to see if material extrudes (purges) after loading. The panel will then display Did Support Material Purge? • Press Yes (to return the printer to the Ready to Build state) or No (to return to Load Material) as appropriate — or press Purge Again if you’re unsure which to choose.
Operation Unload material cartridges: 1. From Idle (or Ready To Build), Press Material Load. A. The panel displays Load Material and prompts with, Replace model? • Press Yes. to unload the Model Material. The panel displays Replacing model, • Press No if you do not wish to unload the model material. B. The panel then prompts with, Replace support? • Press Yes. to unload the Support Material. The panel displays Replacing support, • Press No if you do not wish to unload the support material. C.
Operation 37 Building a Test Part Factory test parts have been preloaded into your Dimension. To familiarize yourself with the system, it is recommended that you build one of the test parts before attempting to build one of your own files . Once the printer has warmed up, material has been loaded, and a modeling base is in place, you can send a test part to the printer. Build a test part: 1. Press Maintenance. 2. Press Test Parts, and select one of the available sample parts.
Operation Figure 13: Catalyst main window 3. From the File menu, click Open. 4. Select and Open an STL file produced with your CAD software. 5. Choose one of several options for printing your part. From the General Tab: NOTE For detailed information about the many file processing options available in CatalystEX, refer to the CatalystEX Help files. • Click ‘Print’ to have CatalystEX process your part and immediately send it to your Dimension for printing.
Operation 39 Building a Part from Your File After CatalystEX sends the CMB file to the printer, the panel displays Ready to Build along with your file’s name. Build a part: Press Start Model. The system will warm up to correct build temperatures. After warm-up, the panel displays Finding Home, (the extrusion head is currently finding the top of the modeling base on which the part is to be built). After finding its starting point, Dimension begins building the part.
Operation Pausing Build While building a part, you may want to pause the operation - e.g, to allow for replacement of a material cartridge. To pause the build operation at any time, press Pause. NOTE When the build process is paused, Dimension completes the current tool path before pausing. Resuming Build from Pause Mode If you have pressed Pause, and are ready to resume building the part, press Resume. Dimension resumes modeling.
Operation 41 Canceling a Job You can cancel a job at any time while the part is building. Cancel a job: 1. Press Pause. 2. Once Dimension stops building, press Cancel Build. The panel displays Are you Sure? 3. Press Yes. The panel displays Build Stopped followed by the part name. • The panel prompts you to remove the part and replace the modeling base (See “Inserting a Modeling Base” on page 30.). Once the chamber door has been opened and closed, the panel asks: Part Removed? 4.
Operation 5. After you have opened and closed the door, the panel displays Part Removed? only after removing the part, press Yes. CAUTION The system can be damaged if you answer Yes and the part has not been removed! • After you press Yes, the panel displays the status as Ready to Build for the next part in the queue. Remove a completed part from the modeling base: 1. After removing the base from the printer, firmly flex the modeling base back and forth with your hands to loosen the part.
Operation 43 Soluble Supports WARNING Wear safety goggles and safety gloves (provided in Startup Kit) when removing soluble supports. When removing soluble supports by hand, wear LEATHER gloves. When removing soluble supports with the soluble concentrate, wear RUBBER gloves. Dimension SST uses soluble supports - a water-based solution designed to allow you to simply wash away the support material. Your part is left smooth and clean with the fine details intact.
Operation Dimension BST 1200 / SST 1200 User Guide
Maintenance Follow the simple procedures within this chapter to ensure continued proper operation of Dimension. Startup Kit Tools The Dimension Startup Kit contains replacement parts and a set of tools used to help you maintain the system.The following is a list of the tools contained in the Startup Kit.
Maintenance After Each Build Empty Purge Container The black, plastic purge container is attached to the right side of the modeling envelope rear wall (see Figure 1 on page 11). NOTE A full purge container may impact part quality. 1. Remove the purge container by grasping it and pushing it upward to release it from its three mounts. 2. Pull the container towards you and out of the chamber.
Maintenance 47 Tip Cleaning Assembly (Brush/Flicker Assembly) (Refer to Figure 17 on page 48). NOTE The flicker should be replaced after 500 hours. It is only necessary to replace the brush after 2000 hours. 1. Completely power down Dimension. See "Powering Off Dimension" on page 21. 2. Remove the purge container. See “Dimension Front View” on page 11. 3. Remove plastic head cover by squeezing raised pads on sides of cover (Figure 15). Squeeze Tabs (one on each side) to Remove Cover.
Maintenance 9. Push the Tip Toggle Bar to the left. This makes the Model (Right Tip) the ‘active’ tip (Figure 16). Position Tip Toggle Bar to Left Figure 16: Position Tip Toggle Bar for Adjustment of Cleaning Brush 10. Adjust the tip cleaning assembly until the brush lightly touches the bottom of the Model Tip Shroud. Tighten the brush mounting screws - but not to final torque. 11. Push the Tip Toggle Bar to the right - making the Support (Left Tip) the active tip. 12.
Maintenance 49 2000 Hour Maintenance NOTE For printer hours, refer to the CatalystEX ‘Printer Services’ tab - ‘Printer Info’ button. Axis Maintenance 1. Clean and lubricate the Z-axis lead screw (drive screw), X-axis guide rods (2), Y-axis guide rods (2), and Z-axis guide rods (2). See Figure 18 for locations. • Clean with isopropyl alcohol. WARNING Krytox grease can cause skin irritation. When it is being handled, use impervious gloves and avoid contact with skin and clothing.
Maintenance As Needed Maintenance The following maintenance items have no routine schedule but should be tended to as needed. Remove Debris Buildup Remove all material buildup on the Z Platform and around the lead screw (See “Lead Screw and Guide Rod Identification” on page 49.). Failure to do so could cause the base to become unlevel or the Z Platform to jam at its upper limit. Vacuum Build Chamber Vacuum the build chamber to remove all foreign particles and purged material.
Maintenance 51 4. Remove the light bar by removing the 3 attachment screws (top, middle, bottom) - use the 1/8 T-handle wrench supplied in the Startup Kit. 5. Install a replacement light bar with the 3 attachment screws do not overtighten the screws. 6. Re-attach the wiring harness lead. Tip Area Clean-up Material can build up on the metal strip behind the extrusion tips (Figure 19). Build up can be caused by an overflowing Purge Bucket or an improperly adjusted Tip Cleaning Assembly. 1.
Maintenance Tip Shroud Replacement Tip shrouds can become torn or damaged over time. This can have a negative impact on the surface finish and detail of models. Damaged Shroud Figure 20: Tip Shroud Damage 1. Enter Head Maintenance. A. From Idle, press Maintenance. B. Press Next. The head will come to rest in the center of the chamber and the Z Platform will change position. Choose Head Maintenance. WARNING The head area is very hot!! Use leather gloves when working in this area of printer! 2.
Maintenance 53 4. Clean the tip using the wire brush supplied with the Start Up Kit to remove any debris. 5. Install a new Tip Shroud by pushing it, by hand, over the exposed tip. Make sure it is fully seated against the Tip Shield. 6. Exit Maintenance. Tip Replacement Tips will need to be replaced at approximately 2000 hours depending upon operating conditions. Tips can also be damaged by improper care while performing maintenance in the area around the tips.
Maintenance C. Pull the tip shield toward you, then pull down to remove the tip. Discard the used tip. Figure 22: Tip Removal 4. Install Tip A. For a Dimension BST, the SUPPORT tip and MODEL tip are interchangeable. Both tips are the same as the MODEL tip shown in Figure 23 on page 55. (The tips come in a Red capped container). B. For a Dimension SST, you must identify the correct replacement tip. The SST uses two tip types.
Maintenance 55 CAUTION For a Dimension SST: Model and SOLUBLE support tips are different. The correct tip must be installed in the correct side. Figure 23: Identifying Tips C. With gloved hand, insert the new tip into the heater block. D. Use needle nose pliers to grasp the stainless steel shield of the tip. E. Pull the tip shield toward you, then lift up to install the tip. F. Push the tip toward the back of the printer once it is all the way up against the heater block. G.
Maintenance H. Use 7/64 T-Handle Allen wrench to firmly tighten the heater block clamp screws. NOTE Make sure Tip remains all the way up against the heater block as you tighten the screws. Figure 24: Installation Examples 5. Repeat steps 3 & 4 for second tip if necessary. 6. Replace Plastic Head Cover and close the printer door. 7. The printer will display Tip Maintenance - Tips Replaced? - select Yes to begin material load. A. The printer will display Load Model - Replace Both Cartridges (flashing).
Maintenance 57 B. The printer will now begin to load material. See "Loading Material", paragraphs 9 and 10 on page 35 for procedure C. After Material Loading is complete the printer will display Tip Calibration - Install Modeling Base And Build Calibration Part. CAUTION Make sure a NEW, UNUSED modeling base is installed before starting calibration. Calibration results will be incorrect if a NEW, UNUSED modeling base is not used. D. Select Start Part (flashing).
Maintenance C. Read the number closest to this location. This is the required X Tip Offset adjustment, in mils. If the number is on the -X side, a negative offset is required. D. Select Increment or Decrement to input the X offset adjustment - the value will change in the upper display window (by default, the printer will be ready to accept the X value). E. When you are satisfied with your X offset value, Select Y and repeat the procedure to identify and input the required Y Tip Offset adjustment. 4.
Troubleshooting Troubleshooting Checklist Problem or error message Solution No power Verify power cord is securely plugged in. Verify that the circuit breaker (at rear of system) and the power switch (on front panel of system) are both in the ON position. Verify AC power is present at wall outlet. System fails to reach operating temperatures Verify the system is not connected to an extension cord or power strip.
Troubleshooting Problem or error message Solution Re-configure settings per (see “Networking Your Printer” on page 23). If using a Static network address, verify that the IP address entered in CatalystEX has the same value as the address entered for the printer. Your system configuration may have changed. Contact your Network Administator. Error Code displayed on Display Panel Call your local reseller for customer service. For more information, refer to “Fault Determination Codes” on page 61.
Troubleshooting 61 Fault Determination Codes If a fault occurs, which would prevent Dimension from executing an operator request, the system will begin to shut down and cool. The panel will display one or two error codes. An error-code list (with the filename “error.txt”) can be found on the CD-ROM for the controller software. (Because this list may change with each new software version, make sure to use your most recent version of the controller software on CD-ROM).
Troubleshooting 2. Insert a new modeling base. 3. From Idle, enter Head Maintenance A. Using the keypad, press Maintenance. B. Press Next. The head will come to rest in the center of the chamber and the Z Platform will change position. Choose Head Maintenance. 4. The display will read: Model Drive Motor Stopped 5. Determine if there is a model material extrusion problem by pressing Forward (command will be available after Head reaches operating temperature).
Troubleshooting 63 14. If material did not extrude from both tips follow the procedure in the following section, "Recovering From Loss of Extrusion". Recovering From Loss of Extrusion NOTE It is recommended that you read and understand this entire procedure before performing any of the work. 1. Enter Head Maintenance mode. • From Idle, press Maintenance > then Next > then Head Maintenance. WARNING The head area is very hot!! Use leather gloves when working in this area of printer! 2.
Troubleshooting CAUTION The end of the extrusion tip where the material enters is called the Liquefier Tube. Liquefier Tubes are fragile. Use care when working in this area so as to avoid damage to the tubes. 4. Remove excess material found around the head area. NOTE Filament feed to the tip can sometimes jam causing a buildup of material under the head cover. A. Clean out as much of the material as possible using needle nose pliers, a probe, or equivalent tool. B.
Troubleshooting 65 NOTE Move only one idler wheel assembly at a time. Finish cleaning around the moved wheel and restore it to its normal position before moving the other idler wheel. Having both wheels out of position simultaneously could stretch the spring. i. Using a 7/64 T-handled hex driver (from Start-Up Kit) to leverage against the lower idler wheel shaft, push the idler assembly away from the filament drive gear by pushing against the spring tension.
Troubleshooting 6. Snip the filament line from the cartridge close to the drive wheel. 7. Make sure that all loose filament is removed from the affected liquefier inlet area. 8. Check for loose material in the other liquefier inlet area. Clean the area as necessary. 9. Install plastic head cover. 10. Exit Maintenance - press Next > then Done. 11. Unload the material. Make sure that the cartridges are entirely removed so that all of the filament loaded into the printer can be withdrawn.
Troubleshooting 67 Dimension BST 1200 / SST 1200 User Guide
Troubleshooting 14950 Martin Drive Eden Prairie, MN 55344 USA Telephone: (952) 937-3000 Fax: (952) 937-0070 Web Site: www.dimensionprinting.
