Stratasys 360mc, 400mc Service Manual

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FORTUS 360mc/400mc™

3D Production System

Service Manual

Part No. 109156-0003, Rev. A

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

ii

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

iii

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

iv

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

v

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

vi

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

vii

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

viii

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

ix

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

x

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

xi

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.

xii

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.

xiii

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.

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.

Oven

XY Gantry

Z Stage

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.

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.

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.

xiv

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.

xv

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 1-1

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 1-2

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 1-3

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.

Oven

XY Gantry

Z Stage

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.

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.

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.

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).

FORTUS 360mc/400mc Service Manual 1-4

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.

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.

Warning: Make sure AC power is removed from the system. Voltage
of 230V AC is present and can be lethal.

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.

Warning: Make sure the UPS is manually turned off and not
powering components in the system.

Procedure

• Power down the system and turn Off the power. (See “System Power Down” on page5-

8.)

FORTUS 360mc/400mc Service Manual 1-5

Chapter 2: System Overview

This chapter provides system specifications and a theory of
operation for the Fortus 360mc/400mc systems.

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
Tip Sensor_____________________________________________________ 2-54

FORTUS 360mc/400mc Service Manual 2-1

Linear Compensation _________________________________________ 2-56

Specifications

System Specifications

Fortus 360mc/400mc

Envelope Size 14 x 10 x 10 in

355 x 254 x 254 mm
Upgradeable to
16 x 14 x 16 in
406 x 355 x 406 mm

Material Bays 1 model

1 support
Upgradeable to: 2 model, 2 support

Model Materials Fortus 360mc:

ABS-M30, ASA, PC-ABS, PC, and Nylon 12
Fortus 400mc:
ABS-M30, ASA, Nylon 12, PC-ABS, PC, ABSi, ABS-M30i, PC-ISO, PPSF, and
Ultem* 9085
(Available individually or in any combination)

Support Structures Water soluble release supports for ABS-M30, ABS-M30i, ABSi, ASA, Nylon 12,

and PC-ABS.

TM

BASS

Accuracy Models are produced within an accuracy of ± 0.005 inch (± 0.127 mm) up

to 5 inches (127 mm). Accuracy on models greater than 5 inches (127
mm) is ± 0.0015 inch per inch (± 0.0381 mm) per each inch over 5 inches.

Compatibility Windows NT 4.0, Windows 2000, Windows XP, Windows 7

Network
Communication

Power Requirements 230V AC 50/60 Hz, 3 phase, 20A/phase ±5% fluctuation (dedicated circuit

Size 50.25 inches (1277 mm) wide x 35.25 inches (896 mm) deep x 77.25 inches

10/100 base T connection. Ethernet protocol.

required).

(2197 mm) high

breakaway support for PC-ISO, PPSF, PC and Ultem* 9085.

Weight 1600 pounds (726 kg) shipping weight

Environmental
Requirements

FORTUS 360mc/400mc Service Manual 2-2

Maximum Environmental Temperature: 85°F (29°C)
Maximum Dew Point: 78°F (25°C)

Fortus 360mc/400mc

Clearance
Requirements

Compressed Air
Requirements

Air Source
Connection

Minimum vertical clearance: 28 inches (71.12 cm)
Minimum side clearance: 30 inches (76.29 cm) (required on each side)
Minimum front clearance: 36 inches (91.44 cm)
Minimum back clearance: 12 inches (30.48 cm)

Supply pressure at the system: 55 psi with a minimum flow of 2.5CFM
Non-lubricated
Non-condensing
DIN ISO 8573-1 Quality Class 5 or better is recommended to improve
onboard filter life.

The air source connector must meet dimensional standard (A-A-59439) for
the quick disconnect female ¼-inch coupler. The system is equipped with
a standard ¼-inch quick disconnect male plug (A-A-59439).

FORTUS 360mc/400mc Service Manual 2-3

Liquefier Tip Specifications

1. General Information

A. The head assembly uses a support liquefier tip and a model

liquefier tip.

B. There are four tip sizes available - T10, T12, T16, and T20.

C. For soluble support material:

• For Fortus using SR20: Use the T12 SR20 tip for support when
using modeling tips T10, T12, T16, and T20.

• For Fortus using SR30 with ABS-M30: Use the T12 SR30 tip for
support when using modeling tips T10, T12, T16, and T20 with
SR30.

• For Fortus using SR-110 with Nylon 12: Use the T12 SR100 tip
for support when using modeling tips T12, T16, and T20 with
SR-110.

D. For breakaway support material use standard tips of matching size

for model and support, except for T20 model which uses T16
support.

E. For Fortus 360mc systems - Table 2-1 shows the available material

and tips. Table 2-2 shows the tip life.

Table 2-1: Fortus 360mc Available Tips

Model Material Model Tip Support Material Support Tip

ABS-M30 T10, T12,T16, T20 SR20

SR30

ASA T10, T12,T16, T20 SR30 T12SR30

PC-ABS T10, T12,T16, T20 SR20 T12SR20

PC T10 SR-100 T12SR100

T12 PC_S

SR-100

T16 PC_S

SR-100

T12SR20
T12SR30

T12

T12SR100

T16

T12SR100

T20 PC_S T16

Nylon 12 T12, T16, T20 SR-110 T12SR100

FORTUS 360mc/400mc Service Manual 2-4

Table 2-2: Fortus 360mc Tip Life

Model Tip Life

Model
Material

ABS-M30 T10 620 10160 6.5 T12SR20

ABS-M30 T12 770 12620 8.5 T12SR20

ABS-M30 T16 920 15080 10.0 T12SR20

ABS-M30 T20 920 15080 10.0 T12SR20

ASA T10 620 10160 6.5 T12SR30 270 4420 3.0

ASA T12 770 12620 8.5 T12SR30 550 9010 6.0

ASA T16 920 15080 10.0 T12SR30 640 10550 7.0

ASA T20 920 15080 10.0 T12SR30 640 10550 7.0

a

Model

Tip

cu.

cu.

in.

cm. Canisters

b

Support Tip

T12SR30

T12SR30

T12SR30

T12SR30

Support Tip Life

cu.

in.

270 4420 3.0

550 9010 6.0

640 10550 7.0

640 10550 7.0

cu.

cm. Canisters

b

Nylon 12 T12 491 8050 5.3 T12SR100 550 9010 6.0

Nylon 12 T16 552 9010 6.0 T12SR100 664 10880 7.1

Nylon 12 T20 552 9010 6.0 T12SR100 664 10880 7.1

PC T10 620 10160 6.67 T12SR100 270 4420 3.0

PC T12 740 12060 8.0 T12

T12SR100

PC T16 830 13570 9.0 T16

T12SR100

PC T20 830 13570 9.0 T16 460 7540 5.0

PC-ABS T10 270 4420 3.0 T12SR20 270 4420 3.0

PC-ABS T12 550 9010 6.0 T12SR20 550 9010 6.0

PC-ABS T16 828 13570 9.0 T12SR20 640 10550 7.0

PC-ABS T20 828 13570 9.0 T12SR20 640 10550 7.0

370
550

460
644

6030
9010

7540

10553

4.0

6.0

5.0

7.0

FORTUS 360mc/400mc Service Manual 2-5

Model

a

Material

Model

Tip

Model Tip Life

cu.

cu.

in.

cm. Canisters

b

Support Tip

Support Tip Life

cu.

in.

cu.

cm. Canisters

b

a. ABS-M30 model material can use SR20 or SR30 support materials. Use the T12SR20 tip

for SR20 material (regardless of model tip size) and use the T12SR30 tip for SR30
material (regardless of model tip size).
ASA model material uses SR30 support material. A T12SR30 support tip should be
used regardless of model material tip size.
PC model material can use PC_S or SR-100 support materials. A T12SR100 tip should
be used for SR-100 material (regardless of model tip size). For PC_S, support tip
matches model tip size for T16 and T12; PC T20 uses a T16 support tip.
PC-ABS model material requires the use of SR20 support material and the T12SR20
support tip (regardless of model tip size).
Nylon 12 model material uses SR-110 support material. A T12SR100 support tip should
be used regardless of model material tip size.

b. Tip Life is directly related to the amount of material that passes through the tip. The

amounts listed above are approximates of how much material will pass through a tip
before the tip will need to be replaced. Because other factors can affect tip life, the
material amounts are only approximates.

FORTUS 360mc/400mc Service Manual 2-6

F. For Fortus 400mc systems - Table 2-3 shows the available material

and tips. Table shows the tip life.

Table 2-3: Fortus 400mc Available Tips

Model
Material Model Tip

Support

Material

Support

Tip

ABSi T10, T12, T16, T20 SR20 T12SR20

ABS-M30
ABS-M30i

T10, T12, T16, T20 SR20

SR30

T12SR20
T12SR30

ABS-ESD7 T12, T16 SR30 T12SR30

ASA T10, T12,T16, T20 SR30 T12SR30

Nylon 12 T12, T16, T20 SR-110 T12SR100

PC-ABS T10, T12, T16, T20 SR20 T12SR20

PC T10, T12, T16 SR-100 T12SR100

PC/PC-IS0 T12 PC_S T12

PC/PC-IS0 T16, T20 PC_S T16

Ultem* 9085 T16 ULT_S T16

PPSF T16, T20 PPSF_S T16

Table 2-4: Fortus 400mc Tip Life

a

Support Tip

Support Tip Life

cu.

in.

cu.

cm. Canisters

Model

a

Material

Model

Tip

Model Tip Life

cu.

in.

cu.

cm. Canisters

ABSi T10 620 10160 6.5 T12SR20 270 4420 3.0

ABSi T12 770 12620 8.5 T12SR20 550 9010 6.0

ABSi T16 920 15080 10.0 T12SR20 640 10550 7.0

ABSi T20 920 15080 10.0 T12SR20 640 10550 7.0

ABS-M30
ABS-M30i

T10 620 10160 6.5 T12SR20

T12SR30

270 4420 3.0

FORTUS 360mc/400mc Service Manual 2-7

b

a

Support Tip

Support Tip Life

cu.

in.

cu.

cm. Canisters

550 9010 6.0

T12SR30

640 10550 7.0

T12SR30

640 10550 7.0

T12SR30

Model

a

Material

ABS-M30
ABS-M30i

ABS-M30
ABS-M30i

ABS-M30
ABS-M30i

Model Tip Life

Model

Tip

cu.

in.

cu.

cm. Canisters

T12 770 12620 8.5 T12SR20

T16 920 15080 10.0 T12SR20

T20 920 15080 10.0 T12SR20

ABS-ESD7 T12 770 12620 8.5 T12SR30 550 9010 6.0

ABS-ESD7 T16 920 15080 10.0 T12SR30 640 10550 7.0

ASA T10 620 10160 6.5

ASA T12 770 12620 8.5

ASA T16 920 15080 10.0

T12SR30 270 4420 3.0

T12SR30 550 9010 6.0

T12SR30 640 10550 7.0

b

ASA T20 920 15080 10.0

T12SR30 640 10550 7.0

Nylon 12 T12 491 8050 5.3 T12SR100 550 9010 6.0

Nylon 12 T16 552 9010 6.0 T12SR100 664 10880 7.1

Nylon 12 T20 552 9010 6.0 T12SR100 664 10880 7.1

PC T10 620 10160 6.67 T12SR100 270 4420 3.0

PC T12 740 12060 8.0 T12

T12SR100

PC T16 830 13570 9.0 T16

T12SR100

PC T20 830 13570 9.0 T16 460 7540 5.0

370
550

460
644

6030
9010

7540

10553

4.0

6.0

5.0

7.0

PC-ABS T10 270 4420 3.0 T12SR20 270 4420 3.0

PC-ABS T12 550 9010 6.0 T12SR20 550 9010 6.0

PC-ABS T16 828 13570 9.0 T12SR20 640 10550 7.0

PC-ABS T20 828 13570 9.0 T12SR20 640 10550 7.0

PC-ISO T12 740 12060 8.0 T12 370 6030 4.0

FORTUS 360mc/400mc Service Manual 2-8

a

Support Tip

Support Tip Life

cu.

in.

cu.

cm. Canisters

Model

a

Material

Model

Tip

Model Tip Life

cu.

in.

cu.

cm. Canisters

PC-ISO T16 830 13570 9.0 T16 460 7540 5.0

PC-ISO T20 830 13570 9.0 T16 460 7540 5.0

Ultem* 9085 T16 550 9010 6.0 T16 460 7540 5.0

PPSF T16 180 3010 2.0 T16 180 3010 2.0

PPSF T20 180 3010 2.0 T16 180 3010 2.0

a. ABS-M30/M30i model materials can use SR20 or SR30 support materials. Use the

T12SR20 tip for SR20 material (regardless of model tip size) and use the T12SR30 tip for
SR30 material (regardless of model tip size).
ASA model material uses SR30 support material. A T12SR30 support tip should be
used regardless of model material tip size.
PC model material can use PC_S or SR-100 support materials. A T12SR100 tip should
be used for SR-100 material (regardless of model tip size). For PC_S, support tip
matches model tip size for T16 and T12; PC T20 uses a T16 support tip.
PC-ABS and ABSi model material requires the use of SR20 support material and the
T12SR20 support tip (regardless of model tip size).
Ultem* 9085 model material uses ULT_S support material. Support tip size matches
model tip size.
PPSF model material uses PPSF_S support material. Support tip size matches model
tip size.
Nylon 12 model material uses SR-110 support material. A T12SR100 support tip should
be used regardless of model material tip size.

b

b. Tip Life is directly related to the amount of material that passes through the tip. The

amounts listed above are approximates of how much material will pass through a
tip before the tip will need to be replaced. Because other factors can affect tip life,
the material amounts are only approximates.

FORTUS 360mc/400mc Service Manual 2-9

All unused model and
support tips are
interchangeable - EXCEPT
for the Soluble Release
support tips.

Tip Size is imprinted on
top-side of plate

The T12SR20 tip is shorter
than the T12SR30 tip and
the T12SR30 tip is shorter
than the standard T12 tip.

Soluble Release support tip
is imprinted with T12SR20
or T12SR30 on the top-side
of plate.

2. Tip Identification and Slice Height

A. Figure 2-1 provides tip identification information. When using

SR20 Soluble Support material, you must use a T12SR20 support
tip for all model tips. When using SR30 Soluble Support material,
you must use a T12SR30 support tip for all model tips. The
T12SR30 tip is only available when using ABS-M30 or ABS-M30i
material. The T12SR20 tip or T12SR30 is clearly marked on the top
side of the plate. When using SR-110 Soluble Support material, you
must use a T12SR100 support tip for all model tips.

Figure 2-1: Fortus 360mc/400mc Tip Identification

FORTUS 360mc/400mc Service Manual 2-10

B. Tip Slice Height information is provided in Table 2-5.

Table 2-5: Slice Height

Model Tip Slice Height

T10 0.005 inch (0.127 mm)

T12 0.007 inch (0.178 mm)

T16 0.010 inch (0.254 mm)

T20 0.013 inch (0.330 mm)

3. Material Build Temperatures

A. Table 2-6 provides Material Build Temperatures. Temperatures are

automatically set by the modeler.

Material Maximum Extrusion Temp Maximum Oven Temp

ABSi 330° C (626° F) 85° C (185° F)

Table 2-6: Material Build Temperatures

ABS-M30
ABS-M30i

ABS-ESD7 320° C (609° F) 95° C (203° F)

ASA 330° C (626° F) 100° C (212° F)

Nylon 12 355° C (671° F) 120° C (248° F)

PC-ABS 330° C (626° F) 110° C (230° F)

PC/PC-ISO 365° C (689° F) 145° C (293° F)

Ultem* 9085 400° C (752° F) 190° C (374° F)

PPSF 415° C (779° F) 225° C (437° F)

320° C (609° F) 95° C (203° F)

FORTUS 360mc/400mc Service Manual 2-11

Theory of Operation

General

FDM Technology

FDM works on an “additive” principle - laying down material in layers. A plastic filament is
unwound from a coil and supplies material to an extrusion nozzle which can turn on and off
the flow. The nozzle is heated to melt the material and can be moved in both horizontal and
vertical directions by an internal computer. The model is built up from layers as the plastic
hardens immediately after extrusion from the nozzle.

Several materials are available with different trade-offs between strength and temperature.
Some materials use a “water-soluble” material for making temporary supports. This soluble
support material is actually dissolved in a heated sodium hydroxide solution with the
assistance of agitation.

Extrusion

Purpose

Extrusion is the process used to deliver material to a part being created.

Heat is used to turn solid plastic material into a liquid. The liquid plastic is then pushed
through a calibrated tip creating a path of controlled width and height.

Components

1. Filament

• Fuel required for modeling - key factors of the filament: purity, diameter,
dry environment. Filament manufacturing processes and modeler
systems focus on these factors.

• A dry environment is essential to maintaining the basic properties of the
filament to ensure proper liquefying and extrusion.

2. Tips

• One-piece, disposable item - tips have precision extrusion holes with
different diameters. The diameter of the hole is used to define the size of
the tip.

• Material compatibility - once a tip is used for a material type, it cannot be
used for another material type. This is due to the different extrusion
temperatures and the chemical make-up of the various materials.

• Tip Life - normal operation will result in side wall deposits within the tip.
Over time, the tip will not extrude material correctly, and will need to be
replaced. Each material type has a different tip life associated with it.

FORTUS 360mc/400mc Service Manual 2-12

3. Head

• Controls the temperature and extrusion rate of the material. (See “Head”

on page2-22.)

4. Oven

• Controls the cooling rate of the extruded material. (See “Oven

Temperature Control” on page 2-46.)

5. Build sheet

• Disposable base for modeling parts. (See “First Layer Adhesion” on

page 2-14.)

Operation

1. ‘Prepump’ is a parameter applied at the beginning of a toolpath.

• This valve is programmed into the machine software and is not
adjustable.

• When head filament drive motors are started, there is a short delay before
extrusion begins as pressure builds in the tip to push material depending
on the parameters from Insight.

• If head/tip motion were to begin simultaneously with the start of the
filament drive motors, there is an air gap at the beginning of a toolpath.

• Prepump delays the movement of the head - matching it to the beginning
of extrusion, not to the initialization of the filament drive motors.

2. ‘Suckback’ (Rollback) is a parameter applied at the end of a toolpath.

• This valve is programmed into the machine software and is not
adjustable.

• When head filament drive motors are stopped, there is a residual amount
of pressure in the liquefier tube which will continue to push material from
the tip.

• This additional extrusion creates ‘blobs’ at the end of toolpaths.

• Suckback causes the filament drive motor to reverse direction before
stopping at the end of the toolpath - relieving pressure and eliminating
blobs.

3. There is a Liquefier Time Constant required for the filament to heat to its extrusion

temperature inside the liquefier tube. The speed at which the filament is pushed through
the tube is determined by the time constant.

• If extrusion is too slow, material can burn and crystallize. If extrusion is
too fast, material will not have enough time to liquefy for proper
extrusion.

FORTUS 360mc/400mc Service Manual 2-13

• Extrusion speed can vary, but must strike a balance between ‘too slow’
and ‘too fast’.

First Layer Adhesion

Purpose

The platen and build sheet are not perfectly level - therefore a slight variation exists in the
gap between the Model tip and the top surface of the build sheet as the tip travels across the
platen.

Oven temperature, due to thermal expansion within the build envelope, is also a key
consideration when modeling the first layer.

The first layers of a part lay the “foundation” on which the part will build.

The unique requirements of the first layers demand special parameters be applied to them.

Operation

1. Insight creates a ‘base’ when the part is processed for modeling.

• The base consists of four layers of model material, followed by either 1 or
2 layers of support material (depending on parameters from Insight).

• The support layer is ‘solid’ fill.

• The completed base establishes a stable, level surface for building a
model.

2. The part build begins with the Model tip moving into position to start the first toolpath of

the layer with the Z stage at the Z Zero position.

• The gap between the Model tip and the build sheet is greater than that of
‘normal’ layer thickness.

• The extra gap compensates for slight out-of-level platen conditions - as
long as the platen is level to within specifications.

• The extra gap also compensates for minor build sheet surface
imperfections.

3. For the first layer, the extrusion rate is greater (approximately 3 times) than normal and

the head moves at a slower speed than normal

• The extra volume of material fills the extra gap and levels the path.

• The slower speed allows for better material adhesion to the build sheet.

It is also important that the build sheet be heated to the correct build temperature to improve
adhesion of the first layer.

Z Zero position is another critical factor. Thermal expansion or contraction that occurs after
the last Z Zero calibration affects first layer extrusion results. (See “Thermal Expansion” on

FORTUS 360mc/400mc Service Manual 2-14

First Layer - Over extrusion insures
consistent adhesion despite varying gap.

Model Tip

Build Sheet

Top V ie w of F ir st L ay er

Layer is thicker when there is less gap.

Layer is thinner when there is more gap.

page 2-16.)

FORTUS 360mc/400mc Service Manual 2-15

Thermal Expansion

General Information

1. Thermal expansion is the change in a components physical dimensions due to a change

in temperature.

2. Thermal expansion does not occur instantly when the temperature surrounding a

component changes. It takes time for the component to reach its thermal dimensions.
This rate of change is affected by:

• Component size - the larger the physical mass of a component, the longer
it will take to expand (or contract) - relative to another component made
of the same material.

• The rate of thermal expansion is different for each material type.

Table 2-7: Oven Stabilization Times (in hours)

Current Oven

Temp.

ABSi ABS-M30 ABS-

Material Type Being Installed

ASA Nylon 12 PC-

ESD7

ABS

PC/

PC-ISO

Ultem*

9085

PPSF

Room temp. 4 4 4 4 4 4 4 8 8

ABS-M30, ABSi

Auto Cool-Down

ABS-ESD7 -- -- -- -- -- 4 4 6 6

ASA -- -- -- -- -- 4 4 6 6

Nylon 12 -- -- -- -- -- 4 4 6 6

PC-ABS 4 4 4 4 4 -- 4 6 6

PC 4 4 4 4 4 4 -- 4 4

Ultem* 9085 6 6 6 6 6 6 4 -- --

PPSF 6 6 6 6 6 6 4 -- --

-- -- -- -- -- 4 4 6 6

Affect on Operation

1. The oven is heated to a set-point temperature based upon the type of modeling material

that is chosen. (See “Oven Temperature Control” on page 2-46.)

2. The oven temperature reaches the set-point in a minimum of 15 to 20 minutes.

3. Thermal expansion (or contraction) of oven components continues for several hours.

• The relationships between the platen, the oven compartment, the head,
etc. are constantly changing. This results in a significant impact on the
accuracy of the Z Zero position. (See “Auto Z Zero” on page 2-53.)

• Gantry belt tensions will change due to different expansion rates of the
frame, pulleys, axle bolts, and belts.

FORTUS 360mc/400mc Service Manual 2-16

4. Adjustments - such as Z Zero and setting belt tension - should be accomplished after

thermal expansion has completed. Oven temperatures should be allowed to stabilize for
four hours.

Systems

AC Board

Purpose

Distributes AC power

Components, Circuits, and Operation

1. AC Board/MIO Interface.

• HVDC 1 and 2 for head heaters.

• Safety circuit connections.

• Communication connections.

• Oven heat control.

2. Safety circuit

• AC board generates 24 volts DC for the safety circuit.

• 24 volts is fused at F6 on the AC board.

• The safety circuit leaves and returns on connection JP18.

3. Oven Heaters Circuit

• Three Solid State relays control the duty cycle of the heaters.

• Powered by 230 volts.

• Each phase of incoming power powers one set of heaters.

• The MIO PIC commands the duty cycle to the SSRs.

• The computer relays the duty cycle to the AC PIC.

4. Head heaters Circuit

A. The AC board distributes 230 volts AC to the transformer.

B. The transformer provides 120 volts AC. (This voltage depends on

how high or low the incoming AC voltage is at the transformer.)

C. The AC board then rectifies the 120 volts AC to 120 volts DC.

D. This is then distributed to the head through the MIO board.

E. Power goes to the transformer and returns on connection JP4.

F. Power goes to the head on connection JP23.

FORTUS 360mc/400mc Service Manual 2-17

G. Fused at F4 and F5 on the AC board.

5. Communication to Computer

• All communications go through the AC board.

6. 230V AC interface to system

7. AC Fuses

• F1, F2, and F3 are main power line fuses.

• F4 and F5 are head heater fuses.

• F6 is the 24V DC for safety circuit fuses.

8. LEDs

• D21 – HVDC2 (LED is prior to fuse)

• D22 – HVDC1 (LED is prior to fuse)

• D23 – 230 volts AC present

• D24 – Air Compressor/Air Solenoid

• D25 – Oven Blower

• D26 – Contactor

• D27 – Dryer

• D28 – Tip N/A

• D29 – UPS

• D30 – Head Blower

• D31 – Light

• D32 – Sys

• D33 – Cooling Fan for Air Compressor

• D34 – RX

• D35 – TX

FORTUS 360mc/400mc Service Manual 2-18

Computer

Purpose

Controls motion, temperatures, the display and receives CMB data.

Components, Circuits, and Operation

• SOK computer.

• PMD Motion Control boards (2X).

• Controls the display.

• Controls communication to all PICs.

• Creates and stores the CFG file.

Z Stage

Purpose

The Z stage converts rotational motion into linear motion which is necessary to position and
move the platen in the build chamber.

Components

• Guide rods and pillow blocks (4X).

• lead screws.

• Bearings, Nilos-Ring, and transtorques.

• Drive belt.

• Idler pulleys and drive pulleys.

• End plates.

• Servomotor.

Operation

1. The computer PMD board distributes motor speed and direction through the MIO Board.

The motor encoder provides position information feedback to the computer through the
MIO board.

2. Motor rotational motion is translated to the platen linear motion through the motor drive

pulleys and drive belt.

FORTUS 360mc/400mc Service Manual 2-19

MIO Board

Purpose

Receives and distributes motion, temperature, and filament information/messages. The MIO
board also distributes 24/48V DC to the system.

Components, Circuits, and Operation

1. AC board/MIO interface provides:

• Pass though of HVDC 1 and 2 for head heaters.

• Safety circuit connections.

• Communication connections.

• Oven heat control signal.

2. 24/48V DC interface to system:

• 48V DC supply for 3 servomotors.

• 24V DC supply for head board, drive blocks, oven thermocouple, etc. ­with the exception that the 24V DC Thermal Safety Circuit is supplied by
the AC board.

• Creates -24V DC and 5V DC.

3. Motion Control interface:

• Uses two PMD boards located in the computer to control motion that are
located in the computer.

• All axis motion and extrusion is controlled by the motion control board(s).

4. XYZ axis servo amplifiers:

• There are 3 self-contained servo amplifiers mounted on the MIO board.
Each amplifier controls one of the axis servomotors.

• The PMD board(s) in the computer sends reference signals to each
amplifier.

• The amplifier applies power to the motor and monitors the motor encoder
feedback.

• The amplifier makes speed and current changes as required to keep each
axis in position.

• The amplifiers are also equipped with an Enable input - used to remove
motor power when any system door or top cover is opened.

5. Head filament drive motor servo amplifiers

• Part of the MIO board circuitry - P1 (Model), P2 (Support).

• The motion control board(s) sends signals to each amplifier.

• The amplifier applies power to the motor.

FORTUS 360mc/400mc Service Manual 2-20

• A head motor disable function is not available.

• A -24V DC signal is used for reversing the head motors.

6. Cassette (canister drive) input.

• Wiring interface to all cassette boards in the system.

• Provides PIC communications and 24V DC power to each of the drive
blocks.

7. Low Vacuum, Cone Sensor, and Z Home monitoring.

• VAC - monitors Low Vacuum switch.

• CONE - monitors the Cone Sensor Switch.

• Z - monitors the Z homing switch.

• OFF - not used.

8. Oven thermocouple input.

• IC U4 monitors the oven thermocouple.

9. Door safety/interlock system.

• Controlled and monitored from the MIO board.

10. MIO fuses:

• 48V DC

• 24V DC

11. LEDs

• D4 24V DC

• D3 48V DC

• D13 Oven heater signal

• D6 PIC

• D8 CPLD

• D9 Door locked

• D11 Hood locked

FORTUS 360mc/400mc Service Manual 2-21

Head

Purpose

Extrudes model and support material for modeling as directed by the system. Functions
include:

Components

1. Head Board:

• Provides direct control of heater blocks and support liquefier switching.

• Onboard processor communicates (PIC) with system.

• Monitors thermocouple temperatures - model and support.

• Provides encoder feedback from the filament drive motors through the
MIO board to the computer PMD1.

2. Filament Present Sensors:

• Detect when filament has been loaded to the head.

• Electrically connected to the head board.

3. Heater blocks:

• Responsible for heating the filament in the tip.

• There are two heater block assemblies - one for model, one for support.

• The liquefier block is a two-part assembly with a center channel for the tip
(solid surface contact between the two block halves and the tip is critical to
successful heat transfer).

4. Heater and temperature control:

• The heaters are controlled by Pulse Width Modulation on the head board
using 120 volts DC supplied by the AC board.

• There are two heater packs - one installed in each half of the liquefier
block.

• The heaters are electrically connected to the head board.

• Heat control is provided through a thermocouple installed in the back half
of each heater block and electrically connected to the head board.

FORTUS 360mc/400mc Service Manual 2-22

5. DC motor:

• Actuates to lower support tip for extrusion.

• When model tip is active, the motor retracts the support tip.

6. Head Cooling Fan:

• Controlled (ON and OFF) by AC board.

Operation

1. The system commands the head board to raise the temperature of a tip to Modeling

temperature. The inactive tip is set to Standby temperature.

• There are three heater set-point temperatures:

Idle - Lowest temperature setting. Used when the system is not building,
purging, or loading/unloading material.

Modeling - Highest temperature setting. Used when a tip is the active tip
during build, purge, or load/unload material. Only one tip will be at
modeling temperature. The other tip will be set to Standby temperature. If
material remains at Modeling temperature while not being extruded,
uncontrolled material may ooze from the tip, or burn and crystallize.

Standby - Temperature setting used for the inactive tip during build,
purge, or load/unload material. This temperature is higher than Idle, but
lower than Modeling. It allows for the tip to quickly reach Modeling
temperature when it becomes the active tip.

• Each material type has its own unique set of set-point temperatures.

2. The head board applies heat to each tip, monitoring temperature through the

thermocouple.

• If the active tip is the support tip, the support tip motor will engage ­lowering the support tip into modeling position.

• If the active tip is the model tip, the support tip motor will retract the
support tip - raising the support tip away from the build platen.

3. The head board informs the system when the set temperatures are reached.

4. The system turns the head blower off for a short time - this allows the filament to load

into the tip.

5. A purge of the tip and a tip wipe is performed.

6. The head is moved to the build area and modeling begins.

7. As the active tip nears completion of its layering cycle, a preheat command is sent to the

inactive tip (“look ahead”).

FORTUS 360mc/400mc Service Manual 2-23

8. The active tip completes its cycle and the head moves to the purge position.

9. The active tip is lowered to Standby temperature - the inactive tip is raised to Modeling

temperature and becomes the active tip.

10. Steps 4 through step 9 are repeated until modeling is complete.

The system will build two layers of model and then two layers of
support. This process is repeated as long as there is support
structure to build.

11. At the end of build, the head will move to the park position and the tip temperatures will

be lowered to Idle.

FORTUS 360mc/400mc Service Manual 2-24

Drive Wheels

Filament must
remain solid in
this area.

Tip
Flange Area

Liquefier

Heater Block

Heater Block

Head Cooling Fan

Purpose

1. Prevents filament from softening before entering the tip (Figure 2-2).

Figure 2-2: Filament Path from Drive Wheels to Liquefier

• Filament serves two purposes within the system: in a liquefied state, it is
extruded to build models; in a solid state, it is used to push softened
filament through the modeling tip.

• Filament must remain solid from the point at which it leaves the drive
wheels until it is inside the tip. If the filament softens too early, filament

FORTUS 360mc/400mc Service Manual 2-25

mis-feed will occur.

• The Head Cooling Fan directs cooling air to the drive wheel and tip flange
area. This allows the tip to reach extruding temperature while filament
entering flange remains solid.

Components

• Cooling fan

• Cooling hose

• AC board

Operation

1. The cooling fan runs constantly while material is being extruded.

2. When the temperature of a liquefier is being raised from Standby to Modeling the cooling

fan will turn off for a short period of time.

• The tip flange area is not in direct contact with the liquefier heater block.
Material within the flange must be softened for extrusion. If the fan is
running, the time necessary to heat the filament within the flange is
excessive.

3. The cooling fan is turned on again after the extrusion begins.

FORTUS 360mc/400mc Service Manual 2-26

X

Y

Gantry (XY Table)

Purpose

The gantry converts rotational motion to linear motion - necessary to position and move the
extruding tip along the toolpath.

Simultaneously creates motion along two axes - X (left to right) and Y (front to back).

Figure 2-3: Gantry XY Table

Components

1. Y-Axis:

• Made up of one servo motor, two guide rods, four linear bearings, and the

2. X-Axis:

• Made up of one servo motor, two guide rods, four linear bearings, and the

• Y-Axis components attach to the Y-Bridge.

• Back bearing mounts attach to the carriage with spring washers to allow

3. Drive belts and pulleys

A. Belts:

Y carriage.

Y-Bridge.

for limited movement due to slight rod mis-aligned.

• Two belts are used - one for each axis.

• The X-axis belt is the top belt and is 236 inches (599.44 mm) in

length.

• The Y-axis belt is the bottom belt and is 144.5 inches (3670.3

mm) in length (367 mm).

• Correct belt tension is critical to proper system operation. (See

“XY Gantry Belt Tension” on page 6-24.)

FORTUS 360mc/400mc Service Manual 2-27

4. Energy Chain:

5. Heat shields:

• Belt clamps are used to attach the ends of the belts to the XY

table. (See “Belt Tensioner Assembly” on page 5-26.)

B. Pulleys:

• Two different types of pulleys are used in the XY table -

toothed (Powergrip) pulleys and flat (Idler) pulleys.

• All pulleys are equipped with sealed bearings - lubrication is

not required.

• A flexible chain that routes the head cable, filament tubes, and head
cooling hose to the head.

• Links can be opened to access cable, tubes, and hose.

• There are two metal heat shield assemblies - one for each axis.

• Used in conjunction with the bellows assemblies to prevent oven heat

6. Bellows:

• There are four bellows assemblies - two for each axis (these are accordion

• Used in conjunction with the metal heat shields to prevent oven heat from

7. Air deflector:

• Deflects heated airflow around the tips during the extrusion process.

• Attached to the Y-Axis heat shield.

8. Axis Motors:

• There is a separate servomotor for each axis.

• Motors are equipped with optical encoders.

from escaping into the gantry area.

styled blankets).

escaping into the gantry area.

FORTUS 360mc/400mc Service Manual 2-28

Operation

1. The computer through the MIO board amplifier commands motor speed and direction.

The motor encoder provides position information back through the MIO board to the
computer PMD.

2. Motor Rotational motion is translated to head linear motion through the motor drive

pulley and the drive belt.

3. The ability of the servomotors to operate simultaneously and in conjunction with the

infinite positions available to the head. The movement must be within the limits of axis
travel and account for the application of extruded material at the exact location and time
required.

FORTUS 360mc/400mc Service Manual 2-29

5

1

2

3

3A

4C

4D

4B

4A

4

Canister

Purpose

Provides storage and supply of material in a moisture-free environment. The canister
contains a canister EEPROM to record canister material type and material remaining
information.

Components

Figure 2-4: Canister Assembly

Table 2-8: Key to Figure 2-4

Item Nomenclature Item Nomenclature

1Canister Base 4AFilament Spool

2 Canister Cover 4B Desiccant Bags (Drying Agent)

3 Snout 4C Bobber

FORTUS 360mc/400mc Service Manual 2-30

3A Canister EEPROM 4D Filament

4Filament Spool Assembly 5Anti-Rotation Plug

Operation

1. Canister:

A. During the manufacturing process, filament is wound onto the

spool in even layers to make sure filament does not bind.

B. Filament is routed through a bobber to straighten the filament as it

exits the canister.

C. Filament is wound onto the spool with a specific tension.

D. An anti-rotation plug helps to prevent the spool from rotating

during shipment.

E. When the canister is stored, the thumb wheel, thumb wheel insert,

and thumb wheel door (items not illustrated) combine to apply
pressure to the filament to maintain tension.

F. Desiccant material and sealing tape maintain the moisture-free

environment.

2. Canister EEPROM:

A. Consists of an EEPROM for storage of canister material type and

material quantity information.

B. The drive block cassette board connects to the canister EEPROM

through the drive block pogo pins.

C. The cassette board reads stored information and updates the

remaining quantity of the canister as filament is used by the
system.

D. Material use is calculated by monitoring the head motor encoders.

FORTUS 360mc/400mc Service Manual 2-31

Canister Drive Block

Purpose

Automates much of the process for loading/unloading material canisters. Monitors canister
filament use and quantity of canister material remaining. A system will have two or four
drive blocks - one model and one support or two model and two support (depending on the
option purchased by the customer).

Components

1. Canister Drive Block Housing:

• Weight of block helps create positive seal with canister to prevent filament
contamination.

• Spring loaded to maintain canister EEPROM (pogo pins to canister
electronics).

• Detent lever locks housing in raised position to allow ease of loading/
unloading canisters.

2. Snout, Cap and Seal:

• Maintains correct alignment of drive block to canister filament hole.

• Provides moisture seal to prevent filament contamination.

3. Canister Drive Wheels and Motor:

• There are two canister drive wheels - a driven (serrated) wheel and an
idler wheel.

• The idler wheel maintains pressure against the filament to prevent
slippage.

• A constant current DC drive motor, operated at constant torque, powers
the driven wheel.

• Filament Present Switch (Canister Drive)

• Detects presence of filament in drive block.

• Normally Open (NO) - switch closes when filament is loaded

in drive block.

4. Pogo Pins:

• Provide electrical contact for canister EEPROM between canister drive
and system.

FORTUS 360mc/400mc Service Manual 2-32

5. Cassette Board:

• There is one cassette board for each drive block - the boards are identical.

• Monitors material information, filament present switch, and canister drive
motor.

• Reads from (and writes to) the canister EEPROM - the

EEPROM is the canister memory chip that holds material type
and quantity information.

6. Cassette Board Cable (Address of Board):

• Uses a daisy chain set-up that allows each bay cassette board to connect to
the single cable.

• The system needs to know the bay location (address) of a board with
which it is communicating.

• Because each bay uses an identical board, the bay location of a board is
determined by its cable connection.

• Each connector on the cable has a unique configuration (jumper wire) that
determines the bay location of the connector (Table 2-9).

Table 2-9: Board Cable Connector Configuration

Bay Location Jumper Wire Configuration

Model Bay 1 No Jumper

Model Bay 2 Pin 1 to Pin 12

Support Bay 1 Pin 2 to Pin 13

Support Bay 2 Pin 1 to Pin 12 and Pin 2 to Pin 13

FORTUS 360mc/400mc Service Manual 2-33

Operation

1. Loading a canister:

A. Drive block communication (and control) of the canister begins

when the drive block detent lever is pulled out and the drive block
is dropped onto the canister.

• The pogo pins contact the canister EEPROM on the canister.

• The drive block cassette board detects the canister, polls the

canister, and collects material type and quantity information.

B. After successful smartspool read, the cassette board commands the

canister drive motor to run in the forward direction (up).

• Operator must rotate the canister thumbwheel to feed filament

to the drive wheels (roll wheel down).

• Drive wheels control filament feed at this point.

C. The filament present switch closes when filament reaches the

switch arm.

D. The cassette board stops the drive motor, turns on the status LED

(slow flashing green), and sends a ‘READY’ command to the MIO
board.

E. Remove the brake from the filament feed door and then close the

door.

F. Loading material to the head can now be accomplished. (See

“Loading/Unloading Filament to the Head” on page 2-36.)

2. Removing a canister:

A. Canister drive block must be in READY state (slow flashing

green).

• Material unloaded from the head. (See “Loading/Unloading

Filament to the Head” on page 2-36.)

• LED slow flashing green.

Caution: There may be 9 feet (2700 mm) of filament material
remaining in the filament tube system when canister removal is
performed. This material will be unloaded from the system during
this process. It must not be allowed to rewind into a canister that will
be reused. Moisture contamination and cross-winding of the filament
within the canister will likely cause the canister to be unusable.

B. Install brake in filament feed door and then close the door to make

sure material does not feed back into the canister.

FORTUS 360mc/400mc Service Manual 2-34

C. Drive block is lifted from canister.

• Pogo pins lose contact with canister EEPROM interface.

• This tells the cassette board that a canister is no longer present.

D. The cassette board checks the status of the drive block filament

present switch.

E. If the filament present switch is closed, the board commands the

canister drive motor to run in the reverse direction and monitors
the filament present switch.

F. Remove the canister from the system slowly. Do not pull on the

filament.

G. The filament present switch opens when filament no longer

contacts the switch arm.

H. The cassette board detects the open filament switch, stops the

drive motor, turns off the status LED, and sends a ‘No Filament’
command to the MIO board.

FORTUS 360mc/400mc Service Manual 2-35

Loading/Unloading Filament to the Head

Purpose

Automated process for loading and unloading filament material to the head and liquefier
tips. Four bay systems (2 model, 2 support) have an Automatic Filament Changeover
function. This process will detect an empty canister and automatically unload, then reload
filament (if the canister is in the ready state) from the other material bay without the aid of an
operator.

Components

1. Canister drive block:

• See “Canister Drive Block” on page 2-32.

2. Filament tube system:

A. Provides path for filament material from drive block to head.

B. Two tubes supply filament to the head - one tube supplies model

C. Four-bay systems use two Y-blocks to merge the supply tubes

D. Two-bay systems have the two Y-blocks installed with one side of

E. Y-blocks also intersect with the air dryer system to supply dry air

3. Head assembly:

• See “Head” on page 2-22.

Operation

1. Load filament to head:

Filament canister must be loaded in drive block (canister drive block
in ‘Ready’ mode) to load material to the head.

material, one tube supplies support material.

from the drive blocks into the supply tubes to the head (one Y­block merges the two model material supply tubes, one Y-block
merges the two support material supply tubes).

each Y-block plugged.

to the filament tubes. (See “Air Dryer System” on page 2-41.)

A. The operator chooses a material bay to load. (Operator > Load/

Unload Mat. > Load Material).

On a four-bay system the status of the second bay of the same
material type (model or support) is checked.

• If the status is ‘Ready’ or ‘Empty’, the Y-block is assumed to be

free of material and the load process continues.

FORTUS 360mc/400mc Service Manual 2-36

• If the status is ‘Loaded’, the Y-block is assumed to be blocked

and the load will not continue. Material must be unloaded
from the head before continuing.

B. Once Load is initiated by the operator, the following three steps

initiate simultaneously:

• The canister drive motor starts to run in the forward direction -

filament is pushed into the filament tube and up to the head as
the head board monitors the head filament present switch. This
is indicated by a fast flashing green light on the drive block.

• The head heater for the loading material is raised to its

modeling temperature.

• The head moves into the purge position.

C. Filament arrives at the head and actuates (closes) the head filament

present switch.

D. The canister drive motor stops and halts the filament movement.

E. The load pauses to allow the liquefier to heat to Modeling

temperature - the head cooling fan is also cycled OFF. (See “Head

Cooling Fan” on page 2-25.)

F. Once the liquefier reaches temperature, the canister drive motor

and the head drive wheels start to run forward.

G. When the filament reaches the head drive wheels, the head drive

wheels take control of filament load.

The head drive motor is stronger than the drive block motor causing
the drive block constant torque motor to stall, but still maintains
forward pressure on the filament.

H. In a series of short, pulsed moves the head drive wheels push

filament into the liquefier tube.

I. The cooling fan cycles ON and a series of tip purges and tip wipes

are performed.

J. The head is moved to its parked position and the tip temperature

is reduced to Standby.

K. The canister drive is turned OFF and the canister status LED

displays steady green.

FORTUS 360mc/400mc Service Manual 2-37

2. Unload filament from head:

Material must be in the ‘Loaded’ mode (steady green LED at canister
bay) to unload material from the head.

A. The operator chooses a material to unload (model or support)

(Operator > Load/Unload Mat. > Unload Material).

B. The temperature of the liquefier tip to be unloaded starts to

increase to Modeling temperature.

C. If the system is loaded with SR20 or SR30, the system will conduct

a purge routine before proceeding to the next step. This is
indicated by a fast flashing green LED on the drive block.

D. The canister drive motor receives a command to run in reverse.

• The canister drive motor is a low torque motor that cannot

overcome the head drive wheel grip and the resistance of the
filament loaded into the liquefier.

• The canister drive is stalled but maintains a reverse pull on the

filament.

E. When the liquefier tip reaches Modeling temperature, the filament

drive motor receives a command to run in reverse.

F. Filament is pulled from the heated liquefier.

G. The canister drive motor continues to pull the filament after it exits

the head drive wheels.

H. The head drive motor AND the canister drive motor are stopped

when the filament exits the head filament switch.

I. The head is moved to its parked position and the tip temperature

is reduced to Idle.

J. The canister status LED displays a slow flashing green light

indicating that the unload is complete.

K. Install the brake in the filament feed door and then close the door.

L. Lift the drive block and slowly remove the canister.

The unload process stops when filament is pulled from the head
drive wheels. When the unload process stops, approximately 9 feet
(2700 mm) of material remains within the filament tube system. This
material will be unloaded from the system when the canister is
removed. (See “Removing a canister:” on page 2-34.)

FORTUS 360mc/400mc Service Manual 2-38

3. Automatic Filament Changeover

Automatic changeover is used on four-bay systems.

A. The canister EEPROM determines the volume of material in the

loaded canister is zero.

B. The system is placed in a ‘pause’ mode.

• The current tool path is completed.

• The head is moved to its parked position

• The Z stage is lowered.

C. The system initiates an unload of filament from the head.

D. The canister drive motor continues to run at this point - pulling the

material from the filament tube system and past the drive block
filament present switch.

The material in the filament tube system is pushed into the empty
canister.

E. When the canister filament present switch opens, the canister drive

block is placed in ‘Empty’ mode (LED displays a steady red).

F. The system performs the load process for the other readied

canister bay. (See “Load filament to head:” on page 2-36.)

G. When material load is complete, the system exits ‘pause’ and the

build will continue from the point at which it was paused.

FORTUS 360mc/400mc Service Manual 2-39

Door Interlock

Purpose

Locks the oven door and top hood so they cannot be opened during part build. Operator
safety is compromised if doors are opened during operation due to high temperatures and
the movement of mechanical components. Temperature fluctuation from an open oven door
will affect part build quality.

Components and Operation

1. Door switches:

• Three identical, magnetic vane sensors - one mounted to the door frame at
each door location - oven, top front door, top lid.

• Each switch is Normally Open (NO).

• The magnetic switches require the use of brass mounting screws.

2. Door sensor flags:

• One flag is mounted to each door.

• Closing a door positions the flag between the arms of the door magnetic
switch - activating (closing) the switch.

3. Door lock solenoids:

• Two door lock solenoids are used - one at the oven door, one at the top
front door.

• The activated solenoid drives a pin into a slot on the door - locking the
door.

• The top lid interlocks with the top front door. It does not have a separate
lock solenoid.

4. The door switches are electrically connected to the MIO board.

• The top front door and top lid switches are wired in series to one another.

• The oven door is wired separately to the MIO board.

5. With the door closed, the flag breaks the magnetic field of the switch - causing the switch

to close. (See Figure 2-6.)

6. After the MIO board senses the closed state of all switches, it notifies the system.

7. The system sends an ‘Enable Lock’ command to the MIO board.

8. If a Move command is initiated, the MIO board applies voltage to the interlock solenoids

- locking the doors.

• The MIO also enables the three servomotors amplifiers.

FORTUS 360mc/400mc Service Manual 2-40

Air Flowmeter
Air Dryer Assembly

Filter

Pressure Adjustment

Air Compressor

Air Pressure Gauge

Air Dryer System

Purpose

Maintains a moisture-free environment for the filament tube system. Moisture can cause
oozing and back flow from the tip due to pressure caused by the expanding moisture in the
filament.

Figure 2-5: Air Dryer System Component Locations

Components

There are two air systems available: Internal and External

1. Internal:

• 230V air compressor, diaphragm pump.

• The pump runs constantly when the system is powered-on.

FORTUS 360mc/400mc Service Manual 2-41

2. External:

• Air supplied by an external source.

3. Pressure adjustment:

• Sets air dryer system pressure as specified for proper operation.

4. Air pressure gauge:

• Used to set and verify correct air pressure.

• Mounted behind canister bay doors.

5. Air flowmeter:

• Airflow is used in conjunction with pressure to keep the filament dry.

• Used to set and verify correct airflow volume.

6. Air dryer assembly:

• Dries the compressed air.

• Capable of drying air to a dew point of -40°F (-40°C).

7. Filter:

• Mounted between the compressor and the air dryer assembly.

• Traps debris and some moisture before compressed air enters the air dryer
assembly.

8. Filament tube system - dry air is supplied to the filament tube system at the Y-blocks.

(See “Filament tube system:” on page 2-36.)

Operation

1. Pressurized air from the air source is supplied to the two-element air dryer.

• The air tube from the air source to the air dryer is designed to act as a
radiator. Extra length allows heat generated during compression to
dissipate before entering the dryer. Heat can cause the dryer to degrade
rapidly.

• The pressurized air enters pre-filters before entering the dryer. The pre­filters remove debris and some moisture.

• The dryer consists of two dryer elements. Only one dryer element is active
at a time. When a dryer is inactive, the element is purged of moisture by
the active dryer element.

• The system switches the active and inactive elements with each other
using an air valve in timed cycles of 30 seconds.

2. The fine mesh filter of the element traps moisture.

3. 95% of the dryer air is supplied to the filament tube system at the Y-block.

FORTUS 360mc/400mc Service Manual 2-42

4. 5% of the dryer air is used to dry the inactive air dryer element - preparing it for the next

drying cycle.

Vacuum System

Purpose

Provides a reliable method of securing the build sheet to the platen during modeling.

An unsecured sheet will cause loss of part build and possibly damage the oven or head
components.

Components

Internal Air System

1. Vacuum pump:

• 230V AC, diaphragm pump.

• The pump runs constantly when the system is powered ON.

• The exhaust port vents to atmosphere. A filter on the exhaust port acts as a
muffler to reduce noise.

External Air System

1. Vacuum is created by using compressed air through a vacuum generator.

• The generator is passive and creates vacuum as long as compressed air is
passed across it.

2. Vacuum gauge:

• Provides visual verification that vacuum is applied to the build sheet.

• Mounted behind canister bay doors.

3. Surface:

• A screened vacuum port provides vacuum to the top side of the platen.

• A series of intersecting channels, terminating at the vacuum port, ensure
that the vacuum is evenly applied across the entire underside of the build
sheet.

• A gasket along the edge of the platen allows the build sheet to seal against
the surface.

4. Vacuum filter:

• Traps debris that may enter the vacuum system from the oven.

• Located in-line and ahead of the intake for the vacuum system.

FORTUS 360mc/400mc Service Manual 2-43

Y Block

Y Block

Air In

Vacuum Gauge

Muffler

Vacuum

Generator

Pressure

Gauge

Air Dryer

Vacuum

Sensor

Air Flow

Air Regulator

and Filter

Air

Solenoid

Vacuum

F

i

l

t

e

r

Looped Tube to

Reduce Heat

5. Vacuum switch:

• Normally Closed (NC) vacuum switch electrically connected to the MIO

• The MIO board will not allow a part to build if the vacuum switch circuit

• The switch will open once the vacuum has reached -10 Hg or greater.

6. Vacuum tube system:

• Plastic tubes, stainless steel flex hose, brass fittings, and quick-disconnect

• The vacuum tube, from the platen to the filter, is designed to act as a

board.

is closed.

plastic fittings connect individual vacuum system components.

radiator. Extra length allows heat generated from the oven to dissipate
before entering the system.

Figure 2-6: External Vacuum System Block Diagram

FORTUS 360mc/400mc Service Manual 2-44

Y Block

Vacuum Gauge

Vacuum

Generator

Pressure

Gauge

Air Dryer

Vacuum

Sensor

Air Flow

Air Regulator

Vacuum

F

i

l

t

e

r

Looped Tube to

Reduce Heat

Y Block

Air

Compressor

Operation

Internal Vacuum

• The vacuum pump runs constantly when the system is powered ON.

External Air

1. Vacuum is generated by compressed air and the vacuum generator.

2. A build sheet placed on the platen seals the vacuum system and the vacuum pressure

will increase. This is shown on the gauge as a more negative reading.

3. When the vacuum reaches -10 Hg, the vacuum43 switch will open and the MIO board

will allow a model to build.

4. If vacuum drops below -10 Hg (more positive), the vacuum switch closes - signaling the

MIO board to pause the build.

It is recommend to build only if the vacuum is -15 Hg or greater
(more negative).

Figure 2-7: Internal Vacuum System Block Diagram

FORTUS 360mc/400mc Service Manual 2-45

Oven Temperature Control

Purpose

1. Controls the cooling rate of the extruded filament.

A. Cooling rate too slow:

• Individual layers will ‘spread’ - will not have the correct slice

height.

• Upper layers will sink into lower layers creating part

distortion.

B. Cooling rate too fast:

• Layers will not adhere to one another.

• Material shrinkage occurs - parts can warp, curl, and fail to

adhere to build sheet.

2. Components (Figure 2-8):

A. Oven chamber:

• The build area of the system.

B. Oven heaters:

• Six 230V AC heater elements wired in three groups of two

elements.

• The two elements of a group are wired in parallel.

• Each group of two is connected to the AC board with a high

temperature wiring harness.

• Ground is attached to the heater assembly frame.

C. Oven plenum:

• A series of three ducts used to channel and circulate heated air.

• Ducts intersect at bottom corners of oven.

D. Oven heater fans:

• Two 230V AC, high temperature fans circulate air through

oven.

• Located at bottom right side of plenum.

FORTUS 360mc/400mc Service Manual 2-46

Right Plenum

Intake Vent

Exhaust Vent

Left Plenum

Bottom Plenum

Oven Fans

Heaters

Oven
Thermocouple

E. Oven thermocouple (TC):

• Senses oven temperature.

• Located inside the top, left corner of oven - directly in airflow

of plenum exhaust vent.

• Connects to MIO board.

Figure 2-8: Oven Components - Viewed from Front of Oven

Operation

1. Each material that can be modeled in the system has its own set of oven temperature set-

2. Oven fans always run to maintain oven air circulation.

3. The air used to control the oven temperature is the airflow across the top of the oven.

4. After power up and operating system load, the MIO board and thermocouple constantly

points with which it is associated.

This allows the air used to control oven temperature to be concentrated at the point of
material extrusion.

polls and monitors oven temperature - sending the heat on or heat off signal to the
computer. The computer then sends the duty cycle to the AC PIC, which commands the
three solid state relays to power the heater elements.

FORTUS 360mc/400mc Service Manual 2-47

5. Oven temperature is compared to the set-point temperature of the chosen material.

• If oven temperature is below the set-point temperature, the heaters are
turned ‘on’.

• If oven temperature is at the set-point temperature, the heaters are turned
‘off’.

• The heaters are constantly cycled ‘on’ and ‘off ‘to maintain a constant
temperature.

6. Heaters are controlled with a Pulse Width Modulated (PWM) mode of operation for

accurate and efficient temperature control.

• When the heaters are ‘on’, voltage is applied in cycles to the heater
elements.

Thermal Safety Circuit

Purpose

Automatically shuts down the system if it detects high heat conditions at the upper gantry or
oven. The thermal safety circuit is 24V DC.

Components (Figure 2-8)

1. Upper Gantry Thermal Fuse:

• Thermally activated fuse is mounted in the back of the gantry.

2. Oven Thermal Breaker:

• Thermally activated breaker mounted on the outside of the oven. (The
probe is mounted inside the heater compartment above the heaters.)

3. AC board:

• Monitors state of thermal safety circuit.

4. MIO Board:

• Interfaces with thermal safety devices and AC board.

FORTUS 360mc/400mc Service Manual 2-48

Oven Thermal
Breaker

Coil of Main
Contactor

F6

MIO

AC Board

JP2-2

JP2-1

J24-1

J24-2

J30-1

J30-2

J25-9

JP18-20

J25-2 JP18-10

Fuse

Upper Gantry
Thermal Fuse

Operation

1. The thermal fuse, thermal breaker, MIO board, and AC board are wired in series. If either

thermal device opens, the modeler is signaled to power down.

Figure 2-9: Thermal Safety Circuit

FORTUS 360mc/400mc Service Manual 2-49

Calibration and Sensors

Homing

Purpose

1. The system must know the position of the Head relative to the Z stage and in the X and

Y-Axis.

2. The system should only require a homing process under the following conditions:

• When power is cycled to the system.

• When the BE software is shut down.

3. When the BE software is shut down, a “Homing Flag” is set in the software to the “NOT

HOMED” State.

4. At the next power up, the software checks the state of this flag.

5. If the state is seen as NOT HOMED, the system assumes it does not know its X, Y and Z

positions, and will not allow any motion until a homing process is completed.

During operation, the system looks at the homing flag every time an
axis move is attempted.

6. At completion of the homing process, the Homing flag is set to “HOMED”.

7. Z stage is always “Homed” first.

Components

1. Motion Control Board (PMDs - Installed in the computer).

2. Servo amplifiers (Installed on the MIO board).

3. Servomotors.

4. XY Gantry.

5. Z stage.

6. Z stage homing switch.

FORTUS 360mc/400mc Service Manual 2-50

Z Stage Homing

1. Homing position is at bottom of travel.

• Z stage homing switch is located on right side of the system - at bottom of
Z stage travel.

• Z stage end plate is sloped at switch contact point.

• Switch position relative to Z stage end plate can be adjusted.

• Homing switch is normally open (NO).

• Switch leads connect to MIO board.

2. MIO board activates hood solenoid and determines current state of Homing switch.

A. If switch is closed (Z stage end plate is contacting switch):

• The Z stage is raised as the switch state is monitored by the

MIO board.

• The MIO board will stop raising the Z stage when the switch

opens.

• Homing proceeds per step 3.

B. If switch is open (Z stage end plate is not contacting switch):

• Homing proceeds per step 3.

3. The Z stage moves down in short incremental moves (approximately 0.400 inches ((10

mm)) at a time) as the switch state is monitored by the MIO board.

4. When the switch closes, the MIO board informs the Motion Control board through the

serial communication interface cable.

5. The Motion Control board stops the downward move of the Z stage, and the Z stage

begins a slow “creep” upward again.

6. Z stage moves up in increments of 0.0005 inches (0.0127mm) as the switch state is

monitored by the MIO board.

7. Z stage movement is stopped when the homing switch opens.

8. This position is saved in Memory as the Z home position.

Z home values are normally set between 16.2 (41.148 cm) to 16.5
inches (41.91 cm).

FORTUS 360mc/400mc Service Manual 2-51

Gantry Homing

1. The Motion Control System detects home position by driving each axis into its negative

hard travel limit - the hard travel limit is recorded.

• There are no mechanical homing switches mounted on the gantry.

• Servo amplifiers have software controlled torque adjustment capability
that allow the system to vary the amount of current to the servomotors.

• During the homing process, the current to the X and Y servomotors is
reduced to approximately 50ma (normal operation is 4 amps).

• A following error from the motor encoders accumulate quickly when the
axis hits the travel limit. (Following error is the location the axis is
expected to be - somewhere past the hard stop in this case - versus its
actual location. With time, the expected location continues to advance,
while the axis does not, increasing the following error.) In essence, the
motor is commanded to move and there is no response from the encoder
confirming the move.

• Detection of the increase in following error is used to establish the home
position.

2. The X and Y axes are homed simultaneously.

• Zero-zero position for XY is front, left corner of gantry.

3. Current (torque) of the servo amplifier is lowered to approximately 50ma.

4. The axis motor is commanded to move incrementally in a negative direction (Y-axis -

toward the front of the system; X-axis - toward left of the system) as the Motion Control
board monitors encoder feedback following error.

5. When the hard limit is reached, the increase in following error is detected and axis

movement is stopped by the Motion Control board.

The success of the gantry homing process is dependent on there
being no mechanical binding in the gantry. If, during the homing
process, an axis develops a bind, excessive following error may
develop and cause an erroneous home position.

6. A positive direction motion command is applied in increments of 0.0005 inches (0.127

mm).

7. Following error decreases with each incremental move.

8. When following error reads zero, the hard stop has been found.

9. Both the X and Y-axis are moved in a positive distance of 0.5 inches (12.7mm). This

position becomes the Global Zero position of the axis.

10. The homing process is completed by moving the head to the park position.

FORTUS 360mc/400mc Service Manual 2-52

• The park position places the model tip approximately 0.5 inches (12.7mm)
from the right edge of the platen and 2 inches (50.8 mm) back from the Tip
Wipe waste chute.

• The Homing flag in the software is set to “HOMED”.

Auto Z Zero

Purpose

Determines the point of first contact between the model tip and the build sheet. This point is
the Zero point for the Z-axis. Auto Z Zero is affected by thermal expansion. (See “Thermal

Expansion” on page 2-16.)

Operation (See“Auto Z Zero Calibration” on page 6-4.)

This procedure is performed with a build sheet in place.

1. The head is moved to the center of the platen and the Z stage is raised to approximately

0.050 inches (1.27 mm) below the edge of the model tip.

2. The X and Y motors are placed in a low torque mode.

3. The X and Y motors begin a series of short moves across the platen.

• The system is looking for an increase in following error - increased
following error indicates tip contact with the build sheet.

• If following error is zero, then it is assumed that the tip is not in contact
with the build sheet.

4. If following error is zero, the Z stage is raised 0.002 inches (0.0508 mm) and another

sweep of the platen is made by the X-axis.

• Auto Z Zero will fail if more than 30 iterations are required to locate Z
Zero. If this occurs, a manual Z Zero calibration must be performed.

5. This process of raising the Z stage and performing X and Y series of short moves across

the platen continues until the following error increases.

6. When contact of the tip to the build sheet is determined due to an increase in following

error, the Z stage position is recorded as Z Zero.

7. The Z stage is lowered, full torque is applied to the X and Y motors, and the head is

returned to its parked position.

FORTUS 360mc/400mc Service Manual 2-53

Measure Flatness

Purpose

Determines the level condition of the platen. Flatness of the platen surface is critical for first
layer adhesion. Measuring flatness is an automated procedure. Adjusting the platen to meet
flatness limits is a manual procedure.

Operation

1. The system performs an Auto Z Zero in 5 locations on the platen surface - Lower Left

(LL), Lower Right (LR), Upper Left (UL), Upper Right (UR) and Center.

2. The Z Zero value for each location is recorded and compared against the last Auto Z Zero

performed by the system.

3. The difference at each location is displayed on the operator’s panel.

4. The platen must be manually adjusted to meet limits for the 5 locations. (See “Platen

Level Adjustment” on page 6-12.)

Tip Sensor

Purpose

Used to measure and apply the offset distance between the model and support tip in the Z­axis.

Components

1. The tip sensor is a mechanical switch with normally closed (NC) contacts.

2. A plunger, with a flat contact surface, opens the switch contact when a tip presses down

on the plunger.

3. Two electrical leads (one white, one black) complete the electrical circuit to the MIO

board (J9).

• The polarity of the circuit must be observed - black lead to contact screw
and pin 1; white lead to contact plate and pin 2.

FORTUS 360mc/400mc Service Manual 2-54

Tip

Plunger

Contact Screw

Sensor Block

Contact Plate

Black Lead

White Lead

Figure 2-10: Cone Sensor Diagram

Operation - AutoCal Procedure

1. Finds Z position for the model tip.

• For Z calibration, the process is done 3 times and an average taken for
better accuracy.

2. Toggles support tip, runs across tip wipes, moves to support tip to plunger center.

3. Finds Z position for support using the same method as model.

FORTUS 360mc/400mc Service Manual 2-55

Linear Compensation

Purpose

Linear compensation is a method of scaling the machine in both the X and Y-axis. XY tables
may incorporate some non-linear positioning which is introduced during the manufacturing
process. This can lead to a system building parts outside of the dimensional accuracy
specification. Systems build a Pulses Per Unit (PPU) part which is measured and used to
calibrate the system through operator input.

Operation

1. A scaling part is built and cooled. Once cooled for a minimum of 30 minutes, it is

measured in the X and Y axis. These measurements are entered in the system to
compensate for any dimensional accuracy errors.

2. The actual values are entered into the system and the system calculates the new PPU

values.

FORTUS 360mc/400mc Service Manual 2-56

Chapter 3: Setup and Installation

This chapter describes setup and installation procedures for the
Fortus 360mc/400mc systems.

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

FORTUS 360mc/400mc Service Manual 3-1

Stabilizing Pad

Locknut

General Information

Installation Checklist

Complete and return the Installation Checklist (107168-XXXX) for Fortus 360mc/400mc
systems when the Setup and Installation is accomplished.

Installation

Un-Crate the System

Refer to the Site Preparation Guide for detailed information on site requirements and
uncrating.

Stabilize System

1. Roll the system into the desired operating position.

The stabilizing pads are not intended to be used as level adjustments
for the platen. They are to be used to stabilize the system after it has
been moved to its operating location.

Figure 3-1: Stabilizing Pads

2. Loosen the locknuts on the four stabilizing pads (one in each corner of the system).

3. Lower each pad until they touch the floor.

4. Turn each pad an additional 1 turn after it contacts the floor.

5. Tighten the stabilizing pad locknuts against the bottom of the system frame.

FORTUS 360mc/400mc Service Manual 3-2

Interlock Flag

(3X)

Sensor
Vanes

Interlock Flag

Pre-Power Up Checks

1. Locate the installation items; materials, startup kit, etc., and compare the contents against

the packing slip.

2. Inspect the exterior doors and panels for proper alignment and shipping damage.

3. Make sure the oven, canister bay, and the upper doors appear properly aligned and

open/close freely.

4. Verify that the top panel, top door, and oven door interlock flags appear to be centrally

aligned to the sensor vanes on the system.

Figure 3-2: Interlock Flags

FORTUS 360mc/400mc Service Manual 3-3

Main Circuit Breaker

(Down is OFF)

Safety Cover

Safety Cover
Screws

5. Make sure the main circuit breaker on the system is turned OFF (down).

Figure 3-3: Main Circuit Breaker

6. Remove the lower back panel from the system. (See “Panel Removal” on page 5-6.)

7. Remove the upper and lower side panels from both sides of the system.(See “Panel

Removal” on page 5-6.)

8. Remove the safety cover from the AC board using a 5/32-inch hex key.

Figure 3-4: Safety Cover

FORTUS 360mc/400mc Service Manual 3-4

Left Front

Right Back

There are two TiltWatch
sensors which are located
on the right back of the
system.

Normal position

9. Record the state of the frame mounted tilt and shock indicators. These measurements will

need to be entered in the System Installation Report Card.

A shock indicator that is “red” indicates excessive impact to the
system.

Figure 3-5: TiltWatch® and ShockWatch® Indicators

10. Remove the box containing the head from the oven and set aside.

11. Cut and remove the cable ties securing the UPS cover and air fitting in the oven.

FORTUS 360mc/400mc Service Manual 3-5

Cut Cable Ties

UPS Cover

Transit Tape

Air Fitting
(under foam)

Cut Cable Ties

Waste Chute
Funnel

12. Remove the UPS cover and air fitting from the oven and set aside. (See Figure3-6.)

13. Remove the transit tape securing the tip sensor plunger in place.

Figure 3-6: Internal Shipping Restraints

14. Cut and remove the cable ties securing the waste chute funnel.

Figure 3-7: Waste Chute Funnel

FORTUS 360mc/400mc Service Manual 3-6

Cut Cable Ties

Cut Cable Ties

15. Cut and remove the cable ties securing the gantry’s Y Bridge.

Figure 3-8: Gantry Y Bridge

16. Install the head in the system. (See “Head Installation” on page 5-20.)

17. Install the T16 model and support liquefier tips for the material to be used for building

parts later. (Installation test parts require the use of T16 tips).

18. Manually move the gantry (Y bridge) to verify full and free travel in the X and Y

direction.

19. Cut and remove the cable ties securing the Z stage end plates.

Figure 3-9: Z Stage End Plates

FORTUS 360mc/400mc Service Manual 3-7

Locknuts

Hard Stop Bolt

Purge Bucket

O-Ring

UPS Spacer Bracket

20. Verify that the locknuts for the Z stage upper hard stop bolts are secure.

Figure 3-10: Z Stage Upper Hard Stop Bolts

21. Remove the O-ring from the purge bucket and install it on the platen.

Figure 3-11: O-Ring in Purge Bucket

22. Inspect the vacuum and compressed air lines; there should be no bends or kinks.

Connections must be secure and fully inserted into the fittings.

23. Make sure all internal wiring connectors are fully seated.

24. Remove the screws securing the UPS/PS tray and slide the tray out.

Figure 3-12: UPS/PS Tray

FORTUS 360mc/400mc Service Manual 3-8

UPS Spacer
Bracket (Flipped)

Power In

Serial Communication Cable

Power Out
To Computer

Flicker/Brush
Assemblies

25. Flip the UPS spacer brackets over so the tab will stop the UPS tray from being pushed all

the way into the system. Loosely install the screws.

Figure 3-13: UPS Spacer Brackets

26. Connect both power cables and the serial communication cable to the back of the UPS

system.

Figure 3-14: UPS System Connections

27. Slide the UPS/PS tray back into the system unit it contacts the UPS spacer bracket.

Tighten the UPS spacer bracket screws.

28. Inspect the back of computer making sure all connections are secure.

29. Install the two flicker/brush assemblies from the Startup Kit.

Figure 3-15: Flicker/Brush Assemblies

FORTUS 360mc/400mc Service Manual 3-9

Purge Ledge

Flicker/Brush
Assembles

30. Install the Teflon purge ledge assembly from the Startup Kit.

Figure 3-16: Purge Ledge Assembly

31. Check the flicker/brush height and adjust if necessary. (See “Tip Wipe Height

Adjustment” on page 6-30.)

Figure 3-17: Flicker/Brush Height

32. If a large oven option was purchased, install the filament drive kit.

FORTUS 360mc/400mc Service Manual 3-10

RJ45 Connection

External Air Hose

33. Make the air connection to the system using the air fitting that was previously removed

from the oven chamber.

Figure 3-18: Air and Network Connections

34. Connect the system to the RJ45 connection on the lower left back of the system. (See

Figure3-18.)

35. Check XY gantry belt tensions at room temperature. (See “XY Gantry Belt Tension” on

page 6-24.)

FORTUS 360mc/400mc Service Manual 3-11

Ground

AC Power Verification

A licensed electrician must make all connections from the power
supply to the system. This including connectors, cables, and proper
strain relief.

1. Make sure the main AC electrical service to the system is disconnected from the facility

power.

2. Open the high-voltage AC access door and make sure the incoming AC and ground lines

are secure.

Figure 3-19: System AC Power Connections

3. Close and secure the high-voltage AC access door and connect AC power to the system.

FORTUS 360mc/400mc Service Manual 3-12

A

B

C

GND

4. Turn the system main circuit breaker to ON and measure the AC voltage levels at the AC

board lugs. Verify that the voltage is within specification.

Warning: High voltage is present when the main circuit breaker is
ON. Use extreme caution when working around uncovered circuit
board.

The proper electrical connection for the system is the responsibility
of the customer.

Figure 3-20: AC Board

• A to B:230 VAC ±5%

• A to C:230 VAC ±5%

• B to C:230 VAC ±5%

• A to GND:100 to 160 VAC

• B to GND:100 to 160 VAC

• C to GND:100 to 160 VAC

5. Turn OFF the main circuit breaker and re-install the AC board safety cover.

Warning: Verify that AC voltage is not present at the AC board
before re-installing the safety cover.

FORTUS 360mc/400mc Service Manual 3-13

UPS

UPS On/Off Button

System Circuit
Breaker

Switch

Green Start
Button

Initial Power Up, Network Configuration and System Activation

1. Turn the system circuit breaker to ON.

2. Turn the UPS switch to ON.

3. Verify that the UPS has powered ON and that the computer has booted.

Figure 3-21: System Power Up

4. Press the green start button on the operator panel.

Figure 3-22: Operator Panel

• The operator panel will display the following message when the computer
boot up is complete:

FDM 360mc or 400mc

*Download a Setup Code to Proceed*
>Network Configuration

5. Obtain the setup code from the customer or from Stratasys.

FORTUS 360mc/400mc Service Manual 3-14

6. Obtain IP Address, Network Mask and Gateway information from the customer if using

static IP configuration.

*Download a setup code to proceed*
>Network Configuration>

7. Enter the IP Address, Network Mask and Gateway information into the system.

A. Press Enter to set network configuration.

>Dynamic IP: YES <E>

UpnP: ON <E>
*Configure Static Network Address

• If using Dynamic IP, select Dynamic and then press the Enter

button until “YES” appears on the screen. This will allow the
network to assign an IP address to the system. Selecting UpnP
“on” will allow the system to broadcast the IP address to the
network and can be seen by the Control Center software on the
workstation computer.

• If using Static IP, select Dynamic IP: NO. This will cause the“*”
to disappear in front of the “Configure Static Network
Address.” Move the cursor “>” to “Configures Static Network
Address” and then press Enter.

>IP: [172.14.16.70]
MASK: [255.255.0.0]
GW: [172.14.16.1]

B.

Select “IP” by moving the cursor “>” to the IP address and then
enter the customer IP address.

> IP: [172.14.16.70] 195.165.30.15

Press Enter.
Move the cursor down to “MASK:”. Enter the mask value and then
press Enter.
Move the cursor down to “GW:”. Enter the GW value and then
press Enter.

FORTUS 360mc/400mc Service Manual 3-15

C. Press Esc to return to the main screen.

*Download a setup code to proceed
>Network configuration..

8. Install the Insight CD in the customer’s workstation. Follow the prompts to install

Insight.

Both Insight and Control Center software will be installed during
this process.

9. On the workstation, open the Control Center software (Start > Programs > Stratasys >

Insight X.X > Control Center).

10. Setup machine in “Manage FDM System”.

A. Select Manage FDM System.

B. If UPnP is ON, select Add from Network. If the UPnP is OFF, see

step D below.

FORTUS 360mc/400mc Service Manual 3-16

C. After clicking the “Add from Network” button, the following

screen will be displayed. Select a Network FDM System and then
click Add System.

D. If the UPnP is OFF, click Add Manually.

E. Fill in the appropriate information for the system being connected

to and click, Add System.

F. Close the FDM System menu.

FORTUS 360mc/400mc Service Manual 3-17

11. Send the Setup Code to the system.

A. Select the Services Tab.

B. Select the machine from the drop-down list.

C. Select Setup Code.

FORTUS 360mc/400mc Service Manual 3-18

D. Input the 16-digit alphanumeric Setup Code and click OK.

12. Using the operator panel on the machine, select Install New Setup Code.

• The operator panel will display the following while the code is loading.

*Configure System*

Please Wait...

• After successfully installing the setup code, the system will display the
following message.

>AutoHome XYZ

Unlock Door

13. Press Enter on the operator panel to perform the Autohome XYZ calibration.

14. In the Control Center Services Tab, select System Time and update the system time to

the current time in your zone.

FORTUS 360mc/400mc Service Manual 3-19

Upgrade Controller Software

1. Install the Controller Software CD on the workstation.

2. Check the system Back-End software version (Modeler Status > Machine State). The last

row of the display will show the loaded BE version.

• If the loaded version is not the most current, continue to step 3.

• If the loaded version is current, continue to “System Verification and

Calibration” on page 3-21.

3. Place the modeler in the Upgrade mode (Maintenance > Administration > Receive

Software Upgrade or Code).

• Operator panel will display the following message.

>Waiting for Software Upgrade or Code
Press MENU key to Cancel

4. From the Control Center, Services Tab, select Update Software.

5. Navigate to the location of the upgrade file.

• C: Program Files (x86)/Fortus/360_400mc Controller Software x.x.x/
tclass-x.x.xxxx.x 360-400mc.upg

• If downloaded from the Internet, the upgrade files are located in the
‘Stratasys’ folder on the workstation.

6. Select the Upgrade file (.UPG file) from the dialog box and then press Enter.

7. From the modeler, select Reboot and Install Software Upgrade <E> and then press

Enter.

• The system reboots and upgrades the file.

FORTUS 360mc/400mc Service Manual 3-20

System Verification and Calibration

1. Perform an Autohome XYZ calibration.

2. Verify that the head cooling, oven blower, and top ventilation fans are operating

normally.

3. Verify that the air pressure and flow is set to specifications. (See “Air Pressure and Air

Flow Adjustment” on page 6-34.)

• Internal Air 36-40 psi.

3.5 and 4.0 SCFH

• External Air 48-52 psi.

3.5 and 4.0 SCFH

4. Make sure the air drying unit cycles in 30 second intervals.

5. Place the canisters in all available bays and verify that all canisters are being read

correctly (Modeler Status > Material Status).

6. Load and unload material from each bay to verify that all material bays successfully load

to the head.

7. Verify the platen level. (See “Platen Level Adjustment” on page 6-12.)

8. Very the upper Z stage hard stop adjustment. (See “Upper Z Stage Hard Stop

Adjustment” on page 6-16.)

9. Set machine default (Maintenance > Modeler Default):

• Inches or centimeters.

• User placement to ON (recommended).

10. Load model and support material to the head.

11. Perform an Auto Tip-to-Tip Calibration (Operator Control > Calibrate > AutoCal Tips).

(See “Z Zero Calibrations” on page 6-3.)

12. Perform the XYZ tip offset calibration. (See “XYZ Tip Offset” on page 6-6.)

FORTUS 360mc/400mc Service Manual 3-21

Final Test

1. Check the XY gantry belt tensions for the material/oven temperature being used. Adjust

if necessary. (See “XY Gantry Belt Tension” on page 6-24.)

2. Install all external system panels. (See “Panel Installation” on page 5-7.)

3. Perform the PPU/Scaling Calibration. (See “PPU/Scaling Calibration” on page 6-10.)

4. Build the Installation Test Part. (Build Job > Show Sample JobQueue.. >

Ins_Test_”Loaded Material”.) Analysis of the completed part can be used to confirm
proper system operation.

Some part curl is expected on the model until support material is
removed from the underside (most pronounced with PC-ABS
material).

Do not submerse a model created using soluble supports in a
cleaning tank until after the support material on the topside of the
model has been examined.

A. Check for material overfill. (Figure3-23 Area A.)

• Strings of material (‘hairs’) around pins (large or small set)

indicates overfill.

• An improper surface finish on diagonals or spokes indicates

overfill.

Raster angle will cause some differences in surface finish and
appearance from diagonal-to-diagonal or spoke-to-spoke.

B. Check quality of support material build (Figure3-23 Area B).

• Support material should not display gaps or open areas.

• Support material should correctly bond with base layer on top

side of model.

• Support material around the perimeter edge should be

smooth.

• For BASS material, layer on underside of model should peel off

easily.

For PPSF, this check must be made before the model has cooled.

FORTUS 360mc/400mc Service Manual 3-22

AREA A - Check
for material strings
(‘hairs’).

AREA B - Check

quality of support
material.

AREA C - Check
quality of fill
around holes.

A

A

A

B

B

C

B

C

C

C

C

A (spokes)

B (edge)

C. Check the quality of all fill around holes (Figure3-23 Area C).

• Check holes for amount of material porosity around holes.

Some porosity around small holes is expected. Porosity should
be limited around large holes.

• Inspect part quality.

Figure 3-23: Installation Test Part

5. Complete all the fields in the System Installation Report Card. The Report Card should

be submitted electronically and can be found on the Stratasys website.

FORTUS 360mc/400mc Service Manual 3-23

Chapter 4: Software

This chapter provides information on using Insight Software for
the Fortus 360mc/400mc systems.

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
Procedures ___________________________________________________ 4-24

FORTUS 360mc/400mc Service Manual 4-1