User Guide
2
FDM 200mc User Guide
Notice
The information in this document is subject to change without notice.
STRATASYS, INC. MAKES NO WARRANTY OF ANY KIND WITH REGARD TO THIS
MATERIAL, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. Stratasys, Inc. shall
not be liable for errors contained herein or for incidental or consequential damages in
connection with the furnishing, performance, or use of this material.
This equipment has been tested and found to comply with the limits for a Class A digital
device, pursuant to part 15 of the FCC Rules. These limits are designed to provide
reasonable protection against harmful interference when the equipment is operated in a
commercial environment. This equipment generates, uses and can radiate radio
frequency energy and, if not installed and used in accordance with the instruction
manual, may cause harmful interference to radio communications. Operation of this
equipment in a residential area is likely to cause harmful interference in which case the
user will be required to correct the interference at his own expense.
Changes or modifications to the FDM 200mc system not expressly approved by
Stratasys, the party responsible for compliance, could void the user’s authority for use.
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. Printed in the USA.
FDM 200mc, Insight and Waterworks are trademarks of Stratasys, Inc.
Stratasys is a registered trademark of Stratasys, Inc.
Krytox, Windows 2000, and Windows XP are registered trademarks of their respective
companies.
© Copyright 2007 Stratasys, Incorporated.
PN: 204689-0001
April 2007
ETL Listed
Conforms to ANSI/UL STD. 60950-1-2003
Certified to CAN/CSA C22.2 No.60950-1-03
The FDM 200mc system conforms with the following standards, in
accordance with the EU Machinery, Low Voltage and Electromagnetic
Compatibility Directives: EU 89/392/EEC, EU 98/37/EEC, EU 73/23/EEC
amended by 93/68/EEC, EU 89/336/EEC
3
FDM 200 mc User Guide
Introduction
The FDM 200mc is designed with ultimate simplicity in mind. It
allows you to build parts quickly, even if you have never used a
modeler before. Its display panel prompts you to press a few keys
to get you modeling quickly.
The system models with P430 ABSplus, so modeled parts are
strong and durable. P430 ABSplus also ensures you’ll be able to
drill, tap, sand, and paint your creations.
FDM 200mc is an innovative combination of proprietary hardware,
software, and material technology.
Congratulations…
you made a smart choice!
4
FDM 200mc User Guide
How To Use This Manual
This User’s Guide is laid out in easy to follow sections which cover
Set-up, Operation, Maintenance, and Troubleshooting of your FDM
200mc system. Be sure to read each section carefully so that you
will get the best performance from your system.
Highlighted Information
The manual is written in a step-by-step format so as to guide you
through a variety of operational tasks. Information of particular
importance is presented in one of three formats
NOTE
A NOTE is used to highlight a specific point or to provide an
operational tip. While useful, a NOTE does not indicate a
procedure that can cause injury or damage if it is not
followed. A NOTE will follow the paragraph of instruction to
which it relates.
The FDM 200mc guides you through operational tasks from a User
Interface (UI) on the front panel of the system. Throughout the
User Guide, text representing messages that appear on the UI are
presented in a specific format. Interface Messages appear as
a bold, serif, fixed-pitch (mono-space) font.
WARNING
A WARNING indicates a procedure that
may cause Injury to an operator if the
procedure is not followed. A WARNING
will precede the paragraph of instruction
to which it relates.
CAUTION
A CAUTION indicates a procedure that
may cause Damage To Equipment if the
procedure is not followed. A CAUTION
will precede the paragraph of instruction
to which it relates.
5
FDM 200 mc User Guide
Sections Of The Manual
Overview...
Provides a quick reference for the layout of the system and its
operating components. Overview also provides a quick reference
for sources of additional information and supplies.
Setup...
Guides you through the initial system installation and setup. Topics
include unpacking, connecting power, installing software, and
connecting to a computer network. Generally, topics in setup are
only accomplished during installation or relocation.
Operation...
Further develops your understanding of the FDM 200mc by
presenting the User Interface, Loading and Unloading of Material,
Building Parts, Removing Completed Parts, and Removing
Support Material. The tasks presented are common procedures
accomplished during normal operation.
Maintenance...
Lists several tasks that you will need to perform to keep your FDM
200mc performing at its best. ‘House Cleaning’, Axis Maintenance,
Tip Cleaning Assembly Replacement, Chamber Lamp
Replacement, and Tip Shroud Replacement are procedures that
you can perform with the help of the User Guide.
Troubleshooting...
Allows you to perform some problem diagnosis and correction
procedures in the event that your system has a problem. A
Troubleshooting Checklist, Fault Determination Codes, and a
procedure to recover from a Loss of Extrusion are provided.
6
FDM 200mc User Guide
Table of Contents 7
FDM 200mc User Guide
Table of Contents
Introduction................................................................................ 3
How To Use This Manual.........................................................4
Highlighted Information .................................................................. 4
Sections Of The Manual................................................................. 5
Overview...................................................................................11
Finding More Information ....................................................... 12
Setting up the FDM 200mc........................................................... 12
Using the FDM 200mc.................................................................. 12
Consumables .........................................................................13
Setup.........................................................................................15
Workspace .............................................................................15
Unpacking ..............................................................................16
Power Connections ................................................................18
Powering On the FDM 200mc................................................19
Insert Modeling Base .............................................................20
Installing Software.................................................................. 21
CD-ROM Software Contents ........................................................ 21
Workstation Requirements........................................................... 22
Setting Network Addresses....................................................24
Verifying Tip Depth.................................................................26
Operation..................................................................................29
Display Panel and Keypad .....................................................29
Inserting a Modeling Base...................................................... 30
Powering On the FDM 200mc................................................30
Powering Off the FDM 200mc................................................31
Cycling Power ........................................................................31
8 Table of C on t e n t s
FDM 200mc User Guide
Loading Material.....................................................................32
Unloading Material .................................................................35
Building a Test Part ................................................................37
Sending Your CAD File to the System ...................................37
Building a Part from Your CMB File ............................................. 39
Chamber Lights ......................................................................39
Pausing Build .........................................................................40
Resuming Build from Pause Mode.........................................40
Resuming Operations from Standby Mode ............................40
Canceling a Job......................................................................41
Removing a Completed Part ..................................................41
Soluble Supports ....................................................................42
Maintenance .............................................................................47
Startup Kit Tools.....................................................................47
After Each Build......................................................................48
Empty Purge Container................................................................ 48
Remove Debris Buildup ............................................................... 48
Weekly Maintenance ..............................................................48
Vacuum the Build Chamber ......................................................... 48
Quarterly Maintenance ...........................................................49
Axis Maintenance......................................................................... 49
Clean fan filter.............................................................................. 50
Tip Cleaning Assembly (Brush/Flicker Assembly) ....................... 50
As Needed Maintenance ........................................................51
Clean Door Glass......................................................................... 51
Chamber Lamp Replacement ...................................................... 51
Tip Shroud Replacement ............................................................. 52
Table of Contents 9
FDM 200mc User Guide
Troubleshooting ......................................................................55
Troubleshooting Checklist......................................................55
Fault Determination Codes ....................................................57
Loss of Extrusion....................................................................58
Diagnosing Loss of Extrusion....................................................... 58
Recovering From Loss of Extrusion ............................................. 59
10 Table of Contents
FDM 200mc User Guide
FDM 200mc User Guide
Overview
FDM 200mc builds models, including internal features, from CAD
STL files. The system builds three-dimensional parts by extruding
a bead of P430 ABSplus through a computer-controlled extrusion
head, producing high quality parts that are ready to use
immediately after completion. With two layer resolution settings,
you can choose to build a part quickly for design verification, or you
can choose a finer setting for higher quality surface detail.
Figure 1: FDM 200mc Front View
The FDM 200mc system consists of two main components — the
modeler and the Insight software. Insight is the preprocessing
software that runs on a Windows 2000 or Windows XP platform.
FDM 200mc’s build envelope measures 203 x 203 x 305 mm (8 x 8
x 12 in). Each material cartridge contains 922 cc (56.3 cu. in.) of
usable material — enough to build continuously for about four days
without reloading.
Z-Axis Table
Tip Cleaning
Assembly
Plastic Modeling
Base
Purge Containe
r
Display Pane
l
Power Switc
h
Context-sensitiv
e
display and keys
Extrusion
Head
Extrusion
Tips
Guide Rods
Lead Screw
Model Material
Cartridge
Support Material
Cartridge
12 Overview
FDM 200mc User Guide
Finding More Information
Several references are available for use with the FDM 200mc.
Setting up the FDM 200mc
FDM 200mc User Guide
Step-by-step instructions for
installing, setting up and operating
the FDM 200mc system.
Using the FDM 200mc
Insight Online Users Guide
Simple operating instructions for
Insight are online. You can access
them at any time by clicking Help.
You can also print the Insight
instruction file, (approximately six
pages).
World Wide Web
Additional information is available at:
http://www.stratasys.com
Overview 13
FDM 200mc User Guide
Consumables
This section lists all replaceable consumables used by the FDM
200mc modeling system.
Part Number Description
Modeling Material
340-21200 Natural P430 ABSplus Filament Cartridge
Soluble Support Material / WaterWorks Concentrate
340-30200 Soluble Support Cartridge
300-00600 WaterWorks Soluble Soluble Concentrate (12 bottles)
Modeling Base
340-00200 Plastic Modeling Base (qty. 24)
To order consumables for your FDM 200mc system, contact:
North America: Stratasys, Inc.
Consumable Orders
+1.800.937.3010 (US toll-free)
+1.952.906.2727 (fax)
consumables@stratasys.com
International: Your regional distributor
14 Overview
FDM 200mc User Guide
FDM 200mc User Guide
Setup
Workspace
Observe the following when placing FDM 200mc in its operating
location:
• FDM 200mc has an approximate weight of 128 kg (282
lbs.) and requires a table capable of safely supporting 300
lbs.
• System Dimensions:
864 x 686 x 1041 mm (34 x 27 x 41 in)
Four-inch minimum space behind unit for air circulation
• Dedicated outlet requirements: (Nominal)
110-120 VAC, 60 Hz, 15 A min. (20 amp recommended)
–or–
220-240 VAC, 50/60 Hz, 7 A min. (10 amp recommended)
• Temperature: 18–32°C (65-90°F)
• Relative Humidity: 30-70%, Non-condensing
• Ethernet 10/100 Base T network
• Network patch cable with RJ45 connectors
• Optional UPS for power interruptions (brown-out
conditions):
Rated Power – 2200 VA
Output Power – 1600 watts
16 Setup
FDM 200mc User Guide
Unpacking
This section describes the recommended procedures for
unpacking and preparing the FDM 200mc for its first use.
Unpack the system:
1. Before unpacking the system, move it near to its operating
location.
2. Remove the plastic banding from around the cardboard.
3. Remove the top cover. Set aside the fork access covers (2)
and bag of screws (2).
4. Remove screws (4) that attach cardboard to pallet and remove
the cardboard side panels.
5. Remove the top foam.
6. Remove outer plastic wrap - use care if using a knife so as to
not scratch the system.
7. Remove the foam door channels (2) and tape.
WARNING
The FDM 200mc weighs approximately 128 kg
(282 lbs). Use proper moving and lifting
techniques when positioning the unit. For your
convenience, there are forklift pads built into
the bottom of the unit. They are accessible
from the side of the unit.
WARNING
The Lead Screw and Guide Rods are lubricated
with a thin coat of Krytox grease. Krytox grease
can cause skin irritation. Be careful not to get
the grease on your hands or clothing.
CAUTION
Remove the foam tubes that isolate the
extrusion head from the frame (see
Figure 2).
The system will be damaged if powered on with
the foam tubes in place.
Setup 17
FDM 200mc User Guide
8. Remove the foam tubes that isolate the extrusion head from
the frame (see Figure 2).
Figure 2: Foam tubes isolating the extrusion head from the Z-axis frame
9. After unpacking, inspect the system and report any shipping
damage to the carrier.
CAUTION
Be careful not to damage the rod sensors when
removing the foam tubes (see
Figure 2).
Circles indicate Rod
Sensor locations.
There are also two
sensors on the back
side of the Extrusion
Head.
Foam Tubes (4)
Extrusion Head
18 Setup
FDM 200mc User Guide
Power Connections
This section discusses the procedure for preparing all power
connections for the system.
FDM 200mc is provided with two power cords: one for 110 V and
one for 220 V.
Prepare all power connections:
1. Connect the male end of the supplied power cord directly
into a grounded electrical outlet, as shown in Figure 3. (If
using a Uninterrupted Power Supply (UPS), connect the
cord directly into the UPS).
Figure 3: Connecting to a grounded electrical outlet
2. Connect the female end of the power cord directly into the
rear of the cabinet.
CAUTION
Before connecting power to the system, make
sure that the FDM 200mc circuit breaker is in the
off (down) position. It is located at the rear of
the system, next to the power cord attachment
point.
WARNING
Do not use an extension cord or power strip
with the FDM 200mc system. Connect the cord
directly into the receptacle or UPS.
Setup 19
FDM 200mc User Guide
3. Switch the FDM 200mc circuit breaker to the on (up)
position. Power is now supplied to the system. The system
is ready to be ‘Powered ON’.
Powering On the FDM 200mc
The FDM 200mc power switch is located on the right (viewed from
the front) side cover of the cabinet, near the bottom front corner
(see Figure 4). After the switch is pushed, the FDM 200mc boots
up in three to seven minutes.
Figure 4: Location of Power Switch
WARNING
The FDM 200mc build chamber and extrusionhead tip get very hot! The chamber and head tip
reach temperatures of approximately 75° C (167°
F) and 280° C (536° F) respectively. Personal
injury can occur if proper techniques and safety
materials are not used. Use the leather safety
gloves provided in the Startup Kit when working
inside the system.
CAUTION
Remove the foam tubes that isolate the
extrusion head from the frame (see
Figure 2 on
page 17
). The system will be damaged if
powered on with the foam tubes in place.
Front of System
20 Setup
FDM 200mc User Guide
Note
If the system was off and is at room temperature, it requires
approximately 30 minutes to warm up before you can perform
any functions. Temperatures are factory-preset and not
adjustable. The panel displays the head and envelope
temperatures while the FDM 200mc is warming up and cooling
down.
Note
For safety, the head and platen do not move while the chamber
door is open. During warm-up and operation the door is
locked. The door can be opened only when the FDM 200mc is
not building a part, getting ready to build a part, or in Pause
mode...
Insert Modeling Base
Make sure retainers are turned ‘down’ - so as not to interfere with
the modeling base installation. Set the modeling base down on the
Z-platform allowing the four outer tabs to drop into the cutouts in
the sheet metal tray. Slide the modeling base forward until it is flush
with the front edge of the tray (see Figure 5). Secure the base with
the two retainers.
Note
When inserting and removing the modeling base, use the
handle to avoid touching the top surface. Grease and oil that
contact the top build surface could cause poor part adhesion.
You can clean the top build surface with isopropyl alcohol if
necessary.
Figure 5: Inserting a plastic modeling base
Slide modeling
base into the
side tray guides
(2 on other side).
Setup 21
FDM 200mc User Guide
Installing Software
There are two software programs that work with the FDM 200mc.
• Insight is the preprocessing software that controls the FDM
200mc. If you have not already done so, you will need to
install the Insight software on your PC workstation. You will
find the Insight software on the CD-ROM included in your
Startup Kit (See “To install Insight:” on page 23.).
• There is also ‘controller’ software loaded directly onto your
FDM 200mc system from the factory. Because we do
occasionally make changes to this software, you will need
to verify that you have the latest version installed (See
“Verifying the controller software version:” on page 23.). A
controller software CD is included in your Startup Kit.
CD-ROM Software Contents
The following table displays the contents of the distribution CD
including typical and custom options.
Typical Installation
Insight Preprocessing software that controls FDM 200mc
FDM Modeler Status Not applicable to FDM 200mc
Status Status is used to manage all interaction with your network
modeler from your PC workstation. Using Status, you will
download jobs to be built, monitor the build status, and
modify the pending jobs queue. The modeler and job status
is updated continuously during a part build. The main Status
window displays the Job Name, remaining time to complete,
and the percent of job completed.
Administration Offers control over administrative tasks
Custom Installation
CMBView The CMB viewer program can be used to view STL or CMB
files.
Sample and Training
Files
Files provided to allow you to quickly understand and use
your system.
22 Setup
FDM 200mc User Guide
Workstation Requirements
The following is a list of requirements for operating the Insight
workstation:
Operating System Microsoft Windows XP or Windows 2000
Distribution Media CD-ROM
Processor
Minimum:
Recommended:
Intel Pentium-4, 1.8 GHz; AMD Athlon XP 2400
Intel Pentium-4, 2.8 GHz; AMD Athlon XP 3200 or better
(Faster processors will shorten job processing times)
RAM
Minimum:
Recommended:
1.0 GB
2.0 GB
Hard Disk
Installation:
Paging File Space:
Installation: 45 MB
300 MB (minimum)
Monitor 17 inch or larger
Graphics Resolution
Minimum:
Recommended:
1024 x 768
1280 x 1024 or higher
Video Card
Required:
Recommended:
Preferred Vendors:
OpenGL compliant accelerated graphics card.
Hardware support for OpenGL.
Nvidia based cards (Geforce and above)
ATI Radeon based cards
recommend minimum of 128 MB graphics card memory
Ethernet Ethernet 10/100 Base T
Keyboard 101 key or equivalent
Mouse 2 button or 3 button with wheel
Web Browser Internet Explorer 5.5 or higher for online help
Changes to supported platforms, operating system, and graphics cards are periodically
updated. Please call Customer Service for latest supported version.
Setup 23
FDM 200mc User Guide
To install Insight:
1. At your workstation, log on as the Administrator or with a
user name that has administrative privileges.
2. Insert the Insight installation disc into your CD-ROM drive.
The installation menu automatically appears.
3. Click the Install button.
4. Follow the prompts to finish installing the software.
Note
Insight’s installation setup allows you to change or confirm
the target installation directory. To install Insight in a directory
other than the default, type the path and directory name in the
dialog box when prompted.
5. If you want to customize your installation, select the
Custom option. Custom options include the following:
• Insight Files
• CMB Utilities
• Training Files
Verifying the controller software version:
6. Check the version displayed on the system keypad.
• From Idle, press Maintenance. The version
number will be listed in the top display window under
System Maintenance.
7. Compare the version number to the controller software CD
provided in the Startup Kit.
8. If the version on the controller software CD is newer than
the system version, follow the controller software upgrade
process instructions provided in the Startup Kit.
24 Setup
FDM 200mc User Guide
Setting Network Addresses
You will need to set up your network addresses before sending files
from the workstation to FDM 200mc.
The network address can be Dynamic or Static.
• Dynamic address - the system will generate its own
random IP address. A different IP address may be
generated each time the system is powered down and restarted.
Note
It is recommended that the Static option be used for network
addresses. The Insight work station software does not
currently implement features that take advantage of the
Dynamic option. A future release of Insight will fully support
the Dynamic function.
• Static address - your system administrator must provide an
IP address that will be entered into the system. Once
entered, the address will not change.
If your IT department requires a NIC MAC address to assign a
static IP address:
1. From Idle or Ready to Build, press Maintenance.
Press Next until the panel displays Setup Maintenance.
2. Read the serial number and the NIC MAC address from
the display.
3. Press Next to return to Idle or Ready to Build.
To set the network addresses:
1. From Idle or Ready to Build, press Maintenance.
The panel then displays System Maintenance and
displays the software version.
2. Press Set Network.
3. Choose Static IP...
Setup 25
FDM 200mc User Guide
4. Three network addresses appear:
IP Address:198.000.000.001
NM Address:255.255.000.000
GW Address:198.000.000.001
These are the factory default addresses; they must be
changed for your network.
5. Look for the cursor beneath the first digit of the IP address.
The cursor does not blink. To update the IP address:
Press Increment to increase the value, one digit at a time.
Press Next Digit to move the cursor one place to the right.
Press Last Digit to move the cursor one place to the left.
6. Use the three functions above to set your IP address.
7. After setting the final digit of the IP address, move the
cursor one more place to the right. The cursor moves to
the NM (or Netmask) address. Follow the same steps for
all addresses.
8. When you have finished setting addresses, press Done.
The panel displays Change IP, Netmask, Gateway?
9. Press Yes. The panel then displays Resetting Network
and after a moment returns to Idle or starts warming up.
10. If you have not done so already, plug in the network patch
cable from your network to the rear of the FDM 200mc.
11. From any workstation on your network, open a DOS
window and type: “ping...” followed by ‘200mc’ new IP
address (e.g. ping 198.000.000.001). You should receive a
reply from your network. If you do not, contact your IT
department for assistance.
26 Setup
FDM 200mc User Guide
Verifying Tip Depth
The system’s tip depth has been set at the factory and normally
does not need adjustment. During shipment, however, tip depth
may be altered. Customers that self-install need to verify the tip
depth setting prior to building. Building with the wrong tip depth can
result in models not adhering to the plastic modeling base or a loss
of extrusion.
To verify tip depth:
1. Install an unused modeling base (substrate).
2. Load Model and Support material (see “Loading Material” on
page 32.
3. Press Maintenance.
4. Press Test Parts, and select test_tipdep_plstc.cmb.
The system will create six groups of numbers on the modeling
platform. Each individual group will consist of four number
pairs. Each number pair will have an extruded number and an
etched number. Each number pair is created at one of four Zheights: -5, 0, +5, and +10 (in .001 inches from ‘home’ level).
See Figure 6 on page 27.
Setup 27
FDM 200mc User Guide
NOTE
The etched number is created by the idle tip. It is normal for
only some of these numbers to be visible.
The extruded number is created at a very low flow rate and
may not show up clearly.
Figure 6: Plastic modeling base with test_tipdep_plstc.cmb model
-5
0
+5
+10
-5
0
+5
+10
-5
0
+5
+10
-5
0
+5
+10
-5
0
+5
+10
-5
0
+5
+10
-5
0
+5
+10
-5
0
+5
+10
-5
0
+5
+10
-5
0
+5
+10
-5
0
+5
+10
-5
0
+5
+10
Extruded Numbers
(left side)
Etched Numbers
(right side)
28 Setup
FDM 200mc User Guide
5. Evaluate the etched numbers in each of the six groups. The
etched numbers must meet the following criteria:
• -5 must be visible in at least one of the six groups.
• +10 must not be visible in any of the six groups.
NOTE
The etched numbers can be difficult to see. It may be
necessary to tilt the modeling base to the light for
inspection.
It is acceptable for some groups to have NO visible etched
numbers. To meet the criteria, only one of the six groups
must have a visible -5.
6. If the tip depth does not meet the above criteria, run the
model a second time on a second unused modeling base
and evaluate again.
7. If the tip depth again fails the above criteria, contact
Stratasys Customer Support for more information on
adjusting tip depth.
FDM 200mc User Guide
Operation
Display Panel and Keypad
The main interface to FDM 200mc is the Display Panel and Keypad
(see Figure 7).
Figure 7: FDM 200mc display panel and keypad
The display panel and keypad is very easy to use. It consists of a
larger multiple-line LCD display on top, and four single-line contextsensitive displays, each with one button (or key). The top line in the
large display always reveals the system status. The lower three
lines of the large display show details related to the current
operation.
At times there will be an item blinking in the lower (contextsensitive) displays. The blinking item is usually the most logical
selection.
Keypad
buttons
Contextsensitive
displays
Display Panel
30 Operation
FDM 200mc User Guide
Inserting a Modeling Base
Prior to inserting a plastic modeling base (substrate) into the tray,
remove any material buildup on and behind the Z-platform and
around the lead screw. Failure to do so could cause the modeling
base to be unlevel or, if the buildup is large enough, cause the Zstage to jam at its upper limit.
Install the modeling base (See “Insert Modeling Base” on page 20.
- "Setup").
Reusing a modeling base:
The square outlines on the modeling base represent modeling
areas. The base is intended for single-use on each modeling area.
Building on a used modeling area may cause a part to curl or break
loose from the modeling base.
Before inserting a used modeling base into the system, make sure
that all material above the previous part’s first layer is removed
from the base.
A modeling base may become worn or distorted after several
builds. The system performs a modeling base levelness check at
the start of every part build; upon detection of a faulty modeling
base, the system pauses and allows you to install a new one.
Powering On the FDM 200mc
Refer to “Powering On the FDM 200mc” on page 19 for
instructions.
CAUTION
Failure to completely remove all other
layers from a previous build can cause a
head collision and result in system
damage.
Operation 31
FDM 200mc User Guide
Powering Off the FDM 200mc
If you wish to power-off the FDM 200mc, move the power switch to
the OFF position (see Figure 4 on page 19). You can do this at any
time without harming the system. No other steps are necessary. If
this is done while the system is building a part, the part will be lost.
System cooling fans continue to operate for several minutes. This
ensures a safe, systematic power down.
Note
For extended non-use periods, unload the material cartridges
and then power off the system.
Cycling Power
Situations may occur that require completely shutting off and then
restarting the FDM 200mc system. This section discusses the
procedure for cycling the electrical system.
To cycle power:
1. Move the power switch to the OFF position (Figure 4 on
page 19) to the OFF (down) position. Wait for the system to
completely power down.
2. Move the circuit breaker located on the rear of the cabinet
to the OFF (down) position.
3. Wait ten seconds and then move the circuit breaker to the
ON (up) position.
4. Move the power switch to the ON position.
5. Wait 15 minutes for the system to prepare itself for normal
operation.
NOTE
When the system is ‘cycled’ in this manner, it may take up to 15
minutes for it to reach its normal operating state.
32 Operation
FDM 200mc User Guide
Loading Material
Material cartridges are factory packaged in a box and an anti-static,
moisture-proof bag to preserve shelf life. Material will stay humidity
free inside the cartridge for at least 30 days after opening. Shelf life
is more than one year if the cartridge package remains sealed.
Load material cartridges:
1. Remove packaging.
2. If present, remove the red sealing plug from the cartridge: (see
Figure 8)
NOTE
Plug must be removed before cartridge can be installed.
A. Turn the plug a quarter turn counter clockwise.
B. Lift up the plug to remove it from the cartridge - discard (or
recycle) the plug.
Figure 8: Remove red plug before loading
3. Find the end of the material filament taped with a “flag”.
Operation 33
FDM 200mc User Guide
Figure 9: Direction to move cartridge roller
4. Pull filament out of cartridge to expose about 12 inches of
material. You should easily be able to pull out the material.
NOTE
The above step makes sure that the filament will feed freely from
the spool.
5. With the cutter from your Startup Kit, snip the filament flush
with the end of the cartridge (see Figure 10 on page 34).
CAUTION
Be careful when touching the pinch roller
on the side of the cartridge. If you roll it
backwards, you could draw the material
into the cartridge (see Figure 9 for the
correct direction to move the cartridge
roller).
If this occurs, there is no way to retrieve
the filament without opening the
cartridge and exposing the material to
humidity, which reduces shelf life to a
few days.
34 Operation
FDM 200mc User Guide
Figure 10: Snipping the material filament
6. If the system is in Idle, press the Material Load button,
which will be blinking.
7. Display will prompt with Load Model - Replace Both
Cartridges (flashing)
8. Insert material cartridges into their appropriate slot from the
front of the system (Model material cartridge goes in the Top
slot; Support material goes in the Bottom slot).
NOTE
You might get the message, Cartridge Not Replaced Or
Invalid. This occurs if you do not insert the new cartridges
within 30 seconds. In this case the cartridge will not lock into its
slot. You must press the
Retry button before continuing the
process.
9. The panel will display Load Material - Ready To Load.
Press Load to load material.
10. Watch the extrusion tips (see Figure 11 on page 35) to see if
material extrudes (purges) after loading. The panel will then
display Did Material Purge?
• Press Yes (to continue) or No (to return to Load Material)
as appropriate — or press Purge Again if you’re unsure
which to choose.
Operation 35
FDM 200mc User Guide
Figure 11: Close-up of extrusion tips
NOTE
If the display shows Load Failed, press Retry. If load fails
again, remove the cartridge, snip the material (see
Figure 10 on
page 34
), remove filament in the system, and reinsert the
cartridge.
Unloading Material
The model and support material cartridges may be replaced
separately or at the same time. In idle-, load-, or build-related
modes, the panel displays the percentage of material remaining in
the cartridges. If the system will be operating unattended for a long
period, and the material level is getting low, you may want to
replace the cartridges before starting a new part. Of course, you
will also need to replace the cartridges when they are empty.
Unload material cartridges:
1. From Idle (or Ready To Build), Press Material Load.
A. The panel displays Load Material and prompts with,
Replace model?
• Press Yes. to unload the Model Material.
The panel displays Replacing model,
• Press No if you do not wish to unload the model
material.
Model Tip
Support Tip
36 Operation
FDM 200mc User Guide
B. The panel then prompts with, Replace support?
• Press Yes. to unload the Support Material.
The panel displays Replacing support,
• Press No if you do not wish to unload the support
material.
C. After you have made the above choices, the panel displays
Unloading for approximately 60 to 75 seconds (the
selected materials will be unloaded from the extrusion
head).
D. When unloading is complete, the panel will prompt you to
remove a cartridge based upon your choices - i.e.,
Replace Both Cartridges, Replace Model
(Top) Cartridge, or Replace Support (Bottom)
Cartridge.
2. Remove the material cartridge(s) by first pushing it forward
gently, and then pulling it out of the slot.
• When you remove a cartridge there will be approximately
180 cm (6 feet) of filament that will need to be pulled from
the system. (This is normal. Material is only retracted from
the extrusion head during ‘unloading’.)
3. To store a partially used cartridge, place a small flag of tape on
the filament near the cartridge. Cut off and discard the
remaining material. The tape flag ensures the filament does
not retract into the cartridge.
CAUTION
Do NOT try to rewind the filament that
remains in the system. This will cause
material to cross-wind in the cartridge
causing cartridge failure.
Operation 37
FDM 200mc User Guide
Building a Test Part
Stratasys has factory-preloaded test parts into the FDM 200mc. It
is recommended that you build a test part as your first build to
familiarize yourself with the system.
Once the system has warmed up, material has been loaded, and a
plastic modeling base is in place, you can build a test part.
To build a test part:
1. Press Maintenance.
2. Press Test Parts, and select one of the available sample
parts.
FDM 200mc automatically starts building the part.
3. When the part is finished, follow the steps for “Removing a
Completed Part” on page 41.
Sending Your CAD File to the System
This section describes the procedures used for sending your own
CAD files to FDM 200mc.
Send a “job” to the FDM 200mc:
1. Create an .stl file with your CAD software.
2. Click on the Insight icon on the desktop of your
workstation.
38 Operation
FDM 200mc User Guide
The Insight main window opens (Figure 12).
Figure 12: Insight main window
3. From the File menu, click Open.
4. Choose an .stl file from your CAD package, and open it.
5. Orient your part. For more information on part orientation,
refer to the Insight help files.
6. Prepare the part by either clicking on the green flag button
, or by manually processing the file. This step:
• “Slices” your part into layers
• Calculates support geometry
• Generates toolpaths (motions the head makes while
extruding)
• Completes all processing to create a .cmb file for FDM
200mc
7. Click on the Status icon on the desktop of your
workstation to send your file to FDM 200mc. For more
information on Status, refer to the Insight help files.
Operation 39
FDM 200mc User Guide
Building a Part from Your CMB File
After Status has sent a .cmb file, the panel displays Ready to
Build and your file’s name.
Build a part:
Press Start Model. The system will warm up to correct build
temperatures. The panel displays Finding Home, meaning the
head is currently finding the top of the plastic modeling base on
which the part is to be built. After finding its starting point, FDM
200mc begins building the part.
Read the display panel while building:
The two lines of the display panel show system-status messages
on the first two lines (Figure 13). The bottom line of the panel
shows the material amounts remaining in the cartridges.
Figure 13: Display panel during build
Chamber Lights
When a part starts to build, the chamber lights are automatically
ON. You can toggle lights ON or OFF through the Display Panel.
You can also turn the light on continuously. Go to the Idle or
Ready to Build mode. Press Maintenance and then press
Next until Setup Maintenance is displayed. Press Lights
Always. The light will remain ON until the system is powered OFF.
System Status
Model File Name
Model Material
Remaining
Support Material
Remaining
40 Operation
FDM 200mc User Guide
Pausing Build
While building a part, you may want to pause the operation - e.g, to
allow for replacement of a material cartridge. To pause the build
operation at any time, press Pause.
NOTE
When the build process is paused, the FDM 200mc completes the
current tool path before pausing.
On your workstation, Status displays the following information:
• Pause status
• Modeler’s name
• Type of modeler (FDM 200mc)
•Job name
• Build time remaining
• Percentage of part built
Resuming Build from Pause Mode
If you have pressed Pause, and are ready to resume building the
part, press Resume. FDM 200mc resumes modeling.
Resuming Operations from Standby
Mode
After several minutes of inactivity, FDM 200mc enters Standby
mode. During Standby, the head and build envelope temperatures
lower to save energy.
Continue operation from Standby mode:
1. Press Resume.
• The panel displays Ready to Build and your part’s
name (if there is a part in the queue). It also shows the
amount of material remaining in the model material
cartridge and the support material cartridge
(e.g. Mod 90 %, Sup 85 %).
• Start Model begins blinking.
Operation 41
FDM 200mc User Guide
2. Press Start Model to begin modeling.
(The FDM 200mc may require a few minutes to warm up to
proper build temperatures. You can view the temperature
values in the display.)
Canceling a Job
You can cancel a job at any time while the part is being built.
To cancel a job:
1. Press Pause.
2. Once FDM 200mc stops building, press Cancel Build.
The panel displays Are you Sure?
3. Press Yes. The panel displays Build Stopped followed
by the part name.
4. The panel prompts you to remove the part and replace the
modeling base (See “Insert Modeling Base” on page 20.).
Once the chamber door has been opened and closed, the
panel asks: Part Removed?
5. Press Yes only after removing the part - refer to
"Removing a Completed Part".
Removing a Completed Part
When the part has completed, the panel displays Completed
Build, and the file’s name. It also shows Remove Part and
Replace Modeling Base.
Remove a completed part from the FDM 200mc system:
1. Open the modeling chamber door.
CAUTION
If you press
Yes before removing the part,
the system can be damaged, and a service
call will be required.
42 Operation
FDM 200mc User Guide
2. Release the modeling base retainers and pull the modeling
base towards you, out of the tray guides.
3. Insert a new modeling base.
4. Close the modeling chamber door.
5. After you have opened and closed the door, the panel
displays Part Removed? Only after removing the part,
press Yes.
After you press Yes, the panel displays the status as
Ready to Build for the next part in the queue.
Remove a completed part from the modeling base:
1. After removing the base from the system, firmly flex the
modeling base back and forth with your hands to loosen
the part. For best results, flex the modeling base front-right
to back-left.
2. Pull the part off the base or use a putty knife to pry the part
completely off.
NOTE
Parts are much easier to remove when the modeling base is still
warm.
Soluble Supports
FDM 200mc uses a soluble support material. WaterWorks Soluble
Support Concentrate is a water-based solution designed to simplify
the removal of the support material. Your part is left smooth and
clean with the fine details intact. The soluble support material can
be removed by hand with relative ease, but is designed to be
dissolved off of your parts for hands-free part finishing.
CAUTION
The system can be damaged if you answer
Yes and the part has not been removed!
Operation 43
FDM 200mc User Guide
Dissolving supports is affected by four parameters:
• Chemistry: Each bottle of soluble concentrate is designed
to produce the optimal concentration when mixed with 40
liters (approx. 11 US gallons) of water. Always maintain the
correct ratio of concentrate to water. Always add the
concentrate to water, never add water to the concentrate.
• Temperature: The warmer the water used for dissolving,
the faster the parts are cleaned. To avoid warped or
damaged parts, do not use the cleaning tank above an
operating temperature of 70° C (158° F). If using an
ultrasonic tank, it is recommended to the tank be operated
without a lid to avoid over-temperature conditions.
• Mechanical Energy: The dissolving of material is
enhanced by agitating the solution. Using a circulation or
ultrasonic tank is the fastest and surest method of
removing soluble support material. Commercial ultrasonic
units are available in both 25 Khz and 40 Khz; either
frequency can be used.
• Time: Support removal time is dependent on various
factors. It can be reduced significantly by breaking off
much of the support by hand before putting the part in the
solution. This also extends the working concentration level
of the solution.
WARNING
Wear the safety goggles safety gloves
(provided in the Startup Kit) when
removing supports.
When removing soluble supports by
hand, wear leather gloves.
When removing soluble supports with
the soluble concentrate, wear rubber
gloves.
44 Operation
FDM 200mc User Guide
To check the part and water level:
Various factors determine how long it takes to remove supports in
the tank. These factors include: tank type, tank usage, part size,
and part geometry.
For best part quality, check parts as follows:
• Check parts after two hours and then periodically until
complete. Due to air pockets and circulation patterns,
rotating the part may help shorten dissolving time.
• Check the tank periodically for over-heating and
evaporation. The water level always needs to be above the
parts. You can add more water if necessary, but do not add
more soluble concentrate.
To remove the part from the tank:
Carefully remove parts from the tank using either plastic or
stainless steel removal tools, as they need to withstand the water
temperature and high alkaline solution.
To rinse or soak parts:
Rinse white parts thoroughly with water until surfaces are no longer
slippery (1-2 minutes). Some white parts may need to soak for an
hour to help pull the concentrate from surface to reduce possible
staining. Soak color parts in water for one hour to pull and dissolve
the concentrate.
Not rinsing or soaking parts long enough can leave them with a
white residue, and/or streaks. To remove the residue, re-rinse or
soak parts in a solution of dish washing rinse aid and water. Then
re-rinse to break the surface tension.
If you build parts using the Sparse build style, allow solution to fully
drain from them. Rinse parts thoroughly under hot water to remove
trapped solution.
CAUTION
Adding more soluble concentrate than
recommended can damage parts.
Operation 45
FDM 200mc User Guide
To dry parts:
Air-dry, use paper towels, or use compressed air to remove
moisture.
To change the solution in the tank:
How often the solution must be changed is dependent upon the
quantity of dissolved support material, the tank type, and the
complexities of the parts you build. We recommend changing the
solution after using approximately 25 cubic inches (410 cc) of
material.
The following indicate the need to change solution:
• Parts turn brown or yellow.
• Parts have a sticky residue and/or stick together.
• Parts with moving features that do not function.
• Parts have shiny surfaces.
• Small pieces of plastic stick firmly to the part and cannot be
removed. (This is more common with circulation tanks.)
• Supports won’t remove after soaking parts.
To dispose of the soluble concentrate:
The soluble solution has been specially formulated to be safely
disposed after dilution or neutralization to an acceptable pH level.
The pH level of fresh solution is similar to dishwasher and laundry
detergents, and household cleaners.
Check your local, state, and/or international regulatory statutes for
what pH level is acceptable for disposal. Stratasys recommends
that disposal procedures be verified by the proper authorities in
your region.
Product pH Level
Fresh soluble solution 12.6
Laundry detergent 11-12
Household cleaners 9-12
Dishwasher detergent 10-11
46 Operation
FDM 200mc User Guide
Stratasys cannot anticipate local, state, or international regulatory
statutes. Stratasys cannot be held liable if the solution is not
disposed of properly. You may need to document how you dispose
of the concentrate.
Soluble Solution Drain Effluent
You can dilute the solution with water using the appropriate ratio to
meet your acceptable pH level. The Drain effluent data below is
based on a dilution of 1 part soluble concentrate to 5 parts water
containing approximately 28 cubic inches of soluble release
material dissolved in 11 gallons of water.
*These values remain constant if the same ratios apply (e.g. 5.5
gallons cleaning device containing approximately 14 cubic inches
of soluble release material with the same dilution ratio of 1 part
soluble concentrate to 5 parts water).
**Chemical Oxygen Demand
***Biological Oxygen Demand
Neutralization
The solution can be further neutralized to lower the pH level by
slowly adding acid (e.g. malic acid) to the tank before draining the
solution.
Parameter Test Method Units
Tank
Value
Diluted
Value*
pH EPA 150-1 12.6 11.8
COD** EPA 410-1 mg/L 14,000 2,400
BOD*** SM 5210B mg/L 820 250
Total Solids EPA 160.3 mg/L 27,000 4,400
Total Suspended Solids EPA 160.2 mg/L 430 54
Cadmium SW-846, 6010A ug/L <5 <5
Chromium SW-846, 6010A ug/L <5 <5
Copper SW-846, 6010A ug/L <10 <10
Nickel SW-846, 6010A ug/L <10 <10
Lead SW-846, 6010A ug/L <40 <40
Zinc SW-846, 6010A ug/L <20 <20
Mercury SW-846, 7470A ug/L <2 <2
FDM 200mc User Guide
Maintenance
Follow the simple procedures within this chapter to ensure
continued proper operation of FDM 200mc.
Startup Kit Tools
Provided in your FDM 200mc Startup Kit is a set of tools used to
help you maintain the system, as well as replacement parts.
The following list is of the tools contained in the Startup Kit that are
used in Maintenance and Troubleshooting procedures.
• Needle Nose Pliers
• Leather Insulated Gloves (Pair)
• Putty Knife
• Cutters
• Soft-bristled Glue Brush
• Brush (bronze)
• #2 Phillips Head Screwdriver
• Allen Wrench Set
• Tube Anti-Seize Compound
• 2 oz. Tube Krytox Grease
WARNING
Krytox grease can cause skin irritation.
Avoid contact with skin and clothing
when it is being handled.
48 Mai n tenance
FDM 200mc User Guide
After Each Build
Empty Purge Container
The black, plastic purge container is attached to the rear wall of the
modeling chamber, on the right side (see Figure 1 on page 11).
NOTE
A full purge container may impact part quality.
1. Remove the purge container by grasping it and pushing it
upward to release it from its three mounts.
2. Pull the container towards you and out of the chamber.
3. Empty the container and reinstall on 3 mounts.
Remove Debris Buildup
Remove any material buildup on the Z-platform and around the
lead screw. Failure to do so could cause the base to become
unlevel or, if the buildup is large enough, it could cause the Z-stage
to jam at its upper limit.
Weekly Maintenance
Vacuum the Build Chamber
Vacuum the build chamber to remove all foreign particles and
purged material.
CAUTION
When reinstalling the container, make sure
that it locks on all three mounts and hangs
flush with the chamber wall to avoid
damage.
Mainte nance 49
FDM 200mc User Guide
Quarterly Maintenance
Axis Maintenance
1. Clean and lubricate the Z-axis lead screw (drive screw), X-axis
guide rods (2), Y-axis guide rods (2), and Z-axis guide rods (2).
See Figure 14 for locations.
• Clean with isopropyl alcohol.
• Lubricate using the Krytox grease provided in the Startup
Kit. Use the grease sparingly.
Figure 14: Lead screw and guide rod identification
WARNING
Krytox grease can cause skin irritation.
When it is being handled, use impervious
gloves and avoid contact with skin and
clothing.
Y-axis Guide Rod
(1 of 2)
Z-axis Guide
Rods
Z-axis Lead
Screw
X-axis Guide
Rods
50 Mai n tenance
FDM 200mc User Guide
Clean fan filter
To clean the fan filter:
1. Locate the lower fan on the rear panel of the FDM 200mc
and remove the plastic frame (snaps on and off) that
secures the fan filter.
2. Clean the filter with soap and water, and blot it dry.
3. Reassemble.
Tip Cleaning Assembly (Brush/Flicker Assembly)
(Refer to Figure 15 on page 51).
NOTE
The flicker should be replaced after 500 hours. It is only
necessary to replace the brush after 2000 hours.
1. Completely power down the system. See “Powering Off
the FDM 200mc” on page 31.
2. Remove the purge container. See “FDM 200mc Front
View” on page 11.
3. Remove the old flicker. - loosen the flicker attachment
(rear) screws and pull up on the flicker.
4. Insert the new flicker and tighten the rear screws while
gently pushing down on the flicker.
NOTE
The bottom of the material tip must hit in the top 75% of the
flicker.
5. Remove the old tip cleaning brush by loosening the two
mounting screws and pulling up on the brush.
6. Install the new tip cleaning brush, but do not tighten the
mounting screws.
7. With a glove on your hand, move the head so that the tips
are above the tip cleaning brush.
8. Adjust the tip cleaning assembly until the brush lightly
touches the bottom of the Model Tip Shroud. Tighten the
brush mounting screws to 12 in-lbs (1.356 Nm) of torque.
Mainte nance 51
FDM 200mc User Guide
NOTE
Ideally, the top of the brush and the top of the flicker should be
the same height. Brush height, however is more important to tip
maintenance than the flicker height.
Figure 15: Replacing the tip cleaning brush
As Needed Maintenance
The following maintenance items have no routine schedule but
should be tended to as needed.
Clean Door Glass
The door glass can be cleaned with any commercial glass cleaner.
Chamber Lamp Replacement
Replace the chamber lamp when it burns out.
NOTE
There are two chamber lamps in the modeling chamber. They are
located on the front wall of the chamber. One to the upper right,
the other to the upper left.
To replace the chamber lamp:
1. Power down the system.
2. Pull the lamp straight out of the socket.
Bottom of nipple
must hit brush
and top half of
exposed flicker.
Top o f
brush just
touches
bottom of
Tip Shroud
Flicker Screws
Brush
Flicker
Mounting Screws
52 Mai n tenance
FDM 200mc User Guide
3. Find the socket wires leading away from the socket.
4. Pull on the socket wires while inserting the two prongs of
the new lamp into the two holes of the socket. When the
lamp is seated into the socket, release the socket wires.
NOTE
Pulling on the socket wires releases the spring-loaded contacts
in the socket. If the lamp is installed without pulling on the
socket wires, the lamp might not be held securely in the socket.
Tip Shroud Replacement
Due to repeated contact with the tip-wipe brush, it is normal for the
tip shroud to become worn. When chronic build up of material
around the tip area or clumps of burnt material become imbedded
in the part, replace the tip shroud.
1. Enter Maintenance, press Next, and access the Table
Maintenance function.
The head temperature decreases.
2. Using a 1/8-inch hex wrench, back out the two head-plate
mounting screws approximately 1/8 inch (see Figure 16).
Do not remove the screws.
3. Pull the head plate slightly away from the head until the
right side of the plate is clear of the mounting screw head.
CAUTION
Do not touch the new bulb with bare
fingers. The natural oil of your skin can
cause premature bulb failure. Grasp the
base of the bulb instead.
Use only 24 V, 20 W bulbs.
WARNING
Head area is very hot! Use gloves when
installing a new shroud!
Mainte nance 53
FDM 200mc User Guide
4. Pivot the right side of the head plate upwards, and rest the
right side of the plate on the right mounting screw, as
shown in Figure 16. There is a small notch on the bottom
of the plate for this purpose.
Figure 16: Head plate in shroud replacement position
5. Locate the shroud, the shroud-mounting screws, and
shield, as shown in Figure 17.
Figure 17: Shroud and shield location
6. Remove the two shroud mounting screws using a 3/32 inch
hex wrench.
WARNING
Screws are very hot! Use gloves when
working in this area of system!
Right Side
Mounting
Screw in
Retaining
Notch
Left
Side
Head
Plate
Mounting
Screw
Shroud
Shroud
Mounting
Screws (2)
Shield
54 Mai n tenance
FDM 200mc User Guide
7. Remove the metal shield - pull the metal shield down to
remove it. Be careful not to bend or damage the shield.
8. Pull the shroud downward to remove it.
9. Clean the exposed tip with the bronze brush provided in
the Startup Kit.
10. Install the new shroud by pushing it up onto the tip.
NOTE
The shroud is keyed and can only be installed with the holes
offset to the rear.
11. Slide the metal shield back over the shroud.
12. Check that both the shroud and shield are positioned
correctly.
NOTE
Apply a thin coat of anti-seize compound to the threads of the
shroud mounting screws.
13. Drive the two shroud-mounting screws into the shroud and
tighten, but do not over-tighten the screws!
14. Lower the head cover into position, and tighten both head
cover screws.
15. Exit the Table Maintenance function.
16. Build a test part to verify system is operating correctly. See
“Building a Test Part” on page 37
FDM 200mc User Guide
Troubleshooting
Troubleshooting Checklist
Problem or error message Solution
No power Verify power cord is securely plugged in.
Verify circuit breaker (at rear of system) and
power switch (right side of system) are both in
the ON (up) position.
Verify AC power is present at wall outlet.
System fails to reach operating
temperatures
Verify the system is not connected to an
extension cord or power strip.
Material not extruding Filament may be jammed in extrusion head (
See “Loss of Extrusion” on
page 58.
).
Purge material accumulating on
part.
Make sure that the flicker and brush are set to the
proper height. (
See “Tip Cleaning
Assembly (Brush/Flicker Assembly)”
on page 50.
)
Check condition of Flicker and Brush. Replace if
worn. (
See “Tip Cleaning Assembly
(Brush/Flicker Assembly)” on
page 50.
)
No text displayed on Display
Panel
Cycle power (See “Cycling Power” on
page 31.
).
56 Troubleshooting
FDM 200mc User Guide
Cannot communicate with system
through network
Incorrect IP address – check that the IP
addresses within the FDM 200mc system and
Insight are the same values (
See “Setting
Network Addresses” on page 24.
).
Make sure IP address is static on your network
(contact your IT department).
Verify IP address entered in Insight “Status” or
“Admin” has the same value as system but
contains no zero’s in the first position within each
section of the IP address.
Error Code displayed on Display
Panel
Call for customer service. For more information,
See “Fault Determination Codes” on
page 57.
.
Display Panel displays
Build Error
Partial or bad part file sent to system. Check STL
file validity in CAD software; reprocess STL in
Insight and redownload to system.
Display Panel displays
Can’t Find Home –
Check Substrate
Verify a plastic modeling base (substrate) is
inserted.
Plastic modeling base may be used or defective.
Replace it.
Display Panel displays
Communication lost
at HR:MN UCT
The system stopped reporting its status at the
UCT (Universal Coordinated Time) shown. Wait
for the system to complete building the part. The
system will automatically restart and display Build
Complete. It is then safe to remove the model.
Display Panel displays
Could Not Read
Cartridge
Remove cartridge and cycle power (See
“Cycling Power” on page 31.
); reload
cartridge.
Try a different cartridge.
Problem or error message Solution
Troubleshooting 57
FDM 200mc User Guide
Fault Determination Codes
If a fault occurs, which would prevent FDM 200mc from executing
an operator request, the system begins shutting down and cooling.
The panel then displays one or two error codes. An error-code list
(with the filename “error.txt”) can be found on the CD-ROM for the
controller software. Since this list changes with each new software
version, make sure to use your most recent version of the
controller software on CD-ROM.
When the system has finished cooling, the only option displayed is
Continue. Press Continue and the system reboots and tries to
return to normal operation. If pressing Continue does not recover
the system, the system should be power cycled using the red
power switch on the right side of the system (See “Cycling Power”
on page 31.); wait 60 seconds before switching power on again. In
most cases you will be able to continue operation. However, if the
system continues to shut down and display the same error, call
your service representative.
Display Panel displays
Load Failed
Retry with same cartridge.
Try a different cartridge.
Filament may be jammed in extrusion head
(
See “Loss of Extrusion” on
page 58.
).
Problem or error message Solution
58 Troubleshooting
FDM 200mc User Guide
Loss of Extrusion
Diagnosing Loss of Extrusion
Occasionally, the system’s head may experience loss of extrusion.
This will be evident by observing one of the following:
• Seeing the head moving with no material coming out of
either liquefier tip
• The height of the model and support materials are not
equal
• Sagging structures due to lack of support materials
Diagnose loss of extrusion:
1. Press Cancel and remove any parts from the system.
2. Insert a new modeling base.
3. From Idle, enter Head Maintenance
A. Using the keypad, press Maintenance.
B. Press Next. The head will come to rest in the center of the
chamber and the Z Platform will change position. Choose
Head Maintenance.
4. Determine if there is an extrusion problem by pressing
Forward (command will be available after Head reaches
operating temperature). Watch both tips for several seconds,
looking for extrusion (material purge).
NOTE
The tip may not immediately extrude material if it was at a cool
temperature. After the tip reaches operating temperature you
may need to wait up to 30 seconds before extrusion will begin.
5. Press Stop to stop extrusion.
WARNING
The head area is very hot! Use gloves
when working in this area of system!
Troubleshooting 59
FDM 200mc User Guide
6. If material steadily flowed from the tips, the head is not
experiencing loss of extrusion.
7. Return the system to the Maintenance state - Push Done, then
answer Yes when the system displays Is Material
Loaded?
8. If material did not extrude from both tips follow the procedure in
the following section, "Recovering From Loss of Extrusion".
Recovering From Loss of Extrusion
NOTE
It is recommended that you read and understand this entire
procedure before performing any of the work.
1. Enter Head Maintenance mode.
• From Idle, press Maintenance > then Next > then
Head Maintenance.
2. With the Phillips-head screwdriver provided in the Startup Kit,
release the two screws securing the head assembly (see
Figure 18 - the screws require only ¼ turn to release). Swing
open the front half of the head.
NOTE
You may feel resistance when you swing open the front half of
the head. One, or both, of the material filament lines are likely to
still be routed into the head and held by the drive motor. This is
normal. Swing the door open slowly, but firmly.
WARNING
The head area is very hot! Use leather
gloves when working in this area of
system!
60 Troubleshooting
FDM 200mc User Guide
Figure 18: Location of swivel head screws (2)
3. Attempt to re-establish extrusion.
NOTE
Both material filaments must be coming out of the feed tubes at
the back of the head (see
Figure 19) and still be going into the
drive block funnels in the front half of the head in order to
proceed with this step. If not, skip to step
4.
A. Run both filament motors forward while gently pushing the
filament that stopped extruding into the filament guide
rollers. Do so for about three seconds.
B. If the purge was successful:
i. Continue to run both filament motors forward and
slowly swivel the head closed. Be careful to not pinch
the filament or the head wiring when closing the head.
ii. Once the head is closed, tighten both of the swivel
head screws, ¼ turn.
iii. Verify material continues to extrude through both tips
for an additional 30 seconds, then press Stop to halt
extrusion.
iv. Push Done. The panel displays Is material
loaded?
v. Pres s Yes. The panel displays Exiting
maintenance and you can now resume normal
operation. (Skip Steps 4 through 13.)
Swivel Head
Screws (2)
Troubleshooting 61
FDM 200mc User Guide
C. If material did not purge, continue with the following steps.
4. Snip both filaments approximately 1 inch from the fixed part of
the head (see Figure 19).
Figure 19: Materials coming out of feed tubes
NOTE
On rare occasions, the material may NOT be extending out from
the feed tubes. If this occurs, push in the appropriate cartridge to
unlatch it. Pull out the cartridge to expose the filament and
manually feed the filament through the feed tubes until the
filament comes through the back of the head. Pull the filament
from the head while inserting the cartridge. Once the cartridge
latches, pull an additional 6 inches of filament through the head
(to make sure the filament is not caught at the cartridge receiver).
Then snip the filament approximately 1 inch from the fixed part of
the head.
5. Remove the filament from both drive block assemblies if there
is enough to remove by hand.
A. Select Reverse.
This causes the drive wheels to reverse, so the material
filaments can be backed out of the liquefier.
B. Grasp the filament from the drive blocks with your
fingertips, and gently pull it out of the drive wheels. Repeat
for second filament. If you are unable to easily remove
62 Troubleshooting
FDM 200mc User Guide
either filament, leave the filament in the drive block for
now.
6. Remove both drive block assemblies from the swivel part of the
head.
A. Set a material cartridge on top of the tray to support the
removed drive block assemblies.
B. Remove the support drive block first. Use a 7/64” Allen
wrench to remove the two screws securing the motor
assembly as shown in Figure 20.
Figure 20: Removing the drive block assemblies to check for buildup
C. Set the drive block assembly on the material cartridge.
D. Remove the model drive block assembly the same way.
7. With the drive blocks removed, look through both filament
guide funnels for obstructions. If an obstruction is present,
clear the drive block obstruction:
A. Remove the filament guide funnel.
Use the 7/64” Allen wrench provided in the Startup Kit to
remove the filament-guide mounting screw as shown in
Figure 20.
B. Remove any excess material; use the needle-nose pliers if
necessary.
Drive Block Assembly
Mounting Screws
Drive Wheels
Filament Guide Funnel
and Mounting Screw
Support DriveModel Drive
Troubleshooting 63
FDM 200mc User Guide
C. Replace the filament guide funnel.
8. With the drive blocks removed, inspect liquefier tube inlet area.
A. (Inspect the liquefier inlet tubes (Figure 21).
i. If material is extended out from an inlet tube, gently
remove material with the bronze brush or needle-nose
pliers.
ii. Inspect for damage to the inlet tube.
Figure 21: Inspecting the liquefier inlet tubes
B. Inspect the model liquefier inlet tube, and the support inlet
funnel covering the support liquefier inlet tube (Figure 22).
i. If material is extended out from the inlet tube:
a. Gently remove material with the bronze brush or
needle-nose pliers, if necessary.
b. Inspect for damage to the inlet tube.
ii. If material is extended out from the support inlet
funnel:
a. Gently remove material with the bronze brush or
needle-nose pliers, if necessary.
CAUTION
Liquefier inlet tubes are fragile. Be
careful not to damage them when
removing material.
Support Liquefier Inlet Tube
(shown with only the support
drive block removed)
Model Liquefier Inlet Tube
will look the same.
64 Troubleshooting
FDM 200mc User Guide
b. If the material buildup in the inlet funnel is difficult
to remove, insert a 1/16” Allen wrench into the
liquefier inlet funnel and try pushing the
obstruction forward.
c. If this doesn’t work, remove the liquefier inlet
funnel using a 1/4” nut driver. Dissolve support
material from the funnel with the soluble support
solution.
NOTE
It is typical for material to build up around the
support liquefier inlet tube under the inlet funnel. Do
not remove this material unless it interferes with
reinstallation of the inlet funnel.
d. Inspect for damage to the support inlet tube.
e. Replace the liquefier inlet funnel.
Figure 22: Inspecting the support liquefier inlet funnel and model liquefier
9. Clean the inside of the liquefier inlet tubes.
Carefully insert a 1/16” Allen wrench into the liquefier inlet
tubes and gently push forward until it stops (about 1/4 inch).
10. Replace both drive-block assemblies.
Install the model drive block assembly first. Make sure the
block is seated flush against the swivel plate.
Support Liquefier Inlet
Funnel
(shown with only the support
drive block removed)
Model Liquefier Inlet Tube
does not have a funnel.
Troubleshooting 65
FDM 200mc User Guide
11. Repeat for the support drive block assembly.
12. Clean the drive wheels.
A. Press Select Drive repeatedly until the display shows
Both Drive Motors.
B. Press Reverse.
C. With the glue brush provided in the Startup Kit, clear any
material buildup from each drive by brushing its serrated
drive wheel.
13. Check for Extrusion.
A. Press Forward.
Pull out 6 inches of material from the fixed head housing.
Feed the filament into the drive blocks and look at the tips
to verify material is extruding through both liquefiers.
B. If the filament does not extrude:
i. Stop the motors and return to Step 4.
ii. If, after two tries the material fails to extrude, call your
service provider.
C. If the purge was successful, continue to run both filament
motors forward and slowly swivel the head closed.
D. Once the head is closed, tighten both ¼ turn screws.
CAUTION
Be careful not to pinch the assembly’s
wiring harness under the block or behind
the motor before replacing and
tightening the mounting screws.
CAUTION
While closing the head, be careful not to
crimp the filament, and make sure that
the head wiring doesn’t get pinched
between the swivel head and the rear
head housing.
66 Troubleshooting
FDM 200mc User Guide
E. Verify material continues to extrude through both tips for
an additional 30 seconds, and then press Stop to halt
extrusion.
F. Push Done. The panel displays Is material loaded?
G. Pr e ss Yes. The panel displays Exiting maintenance
and you can resume normal operation.
Troubleshooting 67
FDM 200mc User Guide
7665 Commerce Way
Eden Prairie, MN 55344 USA
Telephone: (952) 937-3000
Fax: (952) 937-0070
E-mail: support@stratasys.com
Web Site: www.stratasys.com
Stratasys Document # 105833-0007
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