User Guide
2
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 Prodigy Plus 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 Stratas ys per softwa re copyright. No par t
of this document may be photocopied, reproduced or translated into another language
without the prior written consent of Stratasys, Inc. Printed in the USA.
Prodigy Plus, Insight and Waterworks are trademarks of Stratasys, Inc.
Stratasys is a registered trademark of Stratasys, Inc.
Krytox, Windows NT, Windows 2000, and Windows XP are registered trademarks of their
respective companies.
© Copyright 2000-2005 Stratasys, Incorporated.
October 2005
The Prodigy Plus 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
Prodigy Plus User Guide
3
Introduction
Prodigy Plus is designed with ultimate simplicity in mind. Prodigy
Plus enables you to build parts quickly, even if you’ve never used a
modeler before. Its display panel prompts you to press a few keys
to get you modeling quickly.
The system models with ABS plastic, so modeled parts are strong
and durable. ABS also ensures you’ll be able to drill, tap, sand, and
paint your creations.
Prodigy Plus is an innovative combination of proprietar y hardwar e,
software, and material technology.
Congratulations…
you’ve made a smart choice!
Prodigy Plus User Guide
4
Prodigy Plus User Guide
5
Table of Contents
Introduction................................................................................3
Installation Checklist.................................................................9
Overview...................................................................................11
Finding More Information.......................................................13
Setting up Prodigy Plus................................................................ 13
Using Prodigy Plus....................................................................... 13
Consumables.........................................................................14
Setup.........................................................................................15
Workspace.............................................................................15
Unpacking..............................................................................16
Power Connections................................................................17
Powering On Prodigy Plus ........................................................... 18
Powering Off Prodigy Plus ........................................................... 19
Cycling Power .............................................................................. 20
Setting Network Addresses......................................... .... ... ... .20
Installing Software..................................................................22
CD-ROM Software Contents........................................................ 22
Workstation Requirements.......................................... ................. 23
Operation..................................................................................25
Display Panel and Keypad.....................................................25
Inserting a Plastic Modeling Base..........................................26
Loading Material............................. .... ... ... ... ...........................27
Unloading Material.................................................................31
Verifying Tip Depth.................................................................31
Building a Test Part .. ................................................... .... ... ... .33
Sending Your CAD File to the System...................................33
Building a Part from Your CMB File .......................................35
Prodigy Plus User Guide
6
Machine Chamber Light.........................................................35
Pausing Build .........................................................................36
Resuming Build from Pause Mode.........................................36
Resuming Operations from Standby Mode............................36
Canceling a Job............................. ... ... .... ...............................37
Removing a Completed Part..................................................37
WaterWorks............................................................................38
Maintenance.............................................................................43
Startup Kit Tools.....................................................................43
Daily Maintenance..................................................................44
Empty Purge Container........................................................... ... .. 44
Remove Debris Buildup ............................................................... 44
Weekly Maintenance..............................................................44
Vacuum Build Chamber............................................................... 44
Quarterly Maintenance...........................................................45
Axis Maintenance................................................................. ... ..... 45
Axis Lubrication............................................................................ 45
Clean fan filter.............................................................................. 46
Tip Cleaning Assembly .............................................................. .. 46
As Needed Maintenance........................................................47
Chamber Lamp ...................................................... ...................... 47
Tip Shroud.................................................................................... 48
Troubleshooting.......................................................................53
Troubleshooting Checklist......................................................53
Fault Determination Codes.....................................................54
Loss of Extrusion....................................................................55
Diagnosing Loss of Extrusion....................................................... 55
Recovering From Loss of Extrusion............................................. 56
Prodigy Plus User Guide
7
Table of Procedures
To unpack the machine: ............................................................16
To prepare all power connections:.............................................17
To cycle power:..........................................................................20
To set the network addresses:...................................................20
To install Insight:........................................................................24
Verifying the controller software version:...................................24
To reuse a plastic modeling base:.............................................26
To load material cartridges:.......................................................27
To unload material cartridges:...................................................31
To verify tip depth:.....................................................................32
To build a test part:............... .... .................................................33
To send a “job” to Prodigy Plus: ................................................33
To build a part:............................................. ... .... ... ... ... ... ...........35
To read the display panel while building:...................................35
To continue operation from Standby mode:...............................36
To cancel a job: .........................................................................37
To remove a completed part:.....................................................37
To remove a completed part from the plastic modeling base:...38
To check the part and water level:.............................................40
To remove the part from the tank: .............................................40
To rinse or soak parts:...............................................................40
To dry parts:...............................................................................41
To change the solution in the tank:............................................41
To dispose of the soluble concentrate:......................................41
Soluble Solution Drain Effluent..................................................42
Neutralization.............................................................................42
Prodigy Plus User Guide
8
To clean the fan filter: ................................................................46
To replace the extrusion head’s tip cleaning assembly: ............46
To replace the chamber lamp:...................................................47
To diagnose loss of extrusion: ...................................................55
To recover from loss of extrusion:..............................................57
Clearing drive block obstructions: ..........................................60
Clearing the support liquefier inlet tube:.................................61
Clearing the model liquefier inlet tube:...................................62
Prodigy Plus User Guide
9
Installation Checklist
This guide is designed to help you set up and configure your new
Prodigy Plus modeling system. The following steps include easyto-follow instructions.
Step 1 Workspace 15
Step 2 Unpacking 16
Step 3 Power Connections 17
Step 4 Powering On Prodigy Plus 18
Step 5 Setting Network Addresses 20
Step 6 Loading Material 27
Step 7 Installing Software 22
Step 8 Building a Test Part 33
Step 9 Removing a Completed Part 37
Step 10 Sending Your CAD File to the System 33
Step 11 Building a Part from Your CMB File 35
Step 12 Powering Off Prodigy Plus 19
Prodigy Plus User Guide
10
Prodigy Plus User Guide
Overview
r
l
h
e
Prodigy Plus builds models, including internal features, directly
from CAD .stl files. The system builds three-dimensional parts by
extruding a bead of ABS plastic through a computer-controlled
extrusion head, producing high quality parts that are ready to use
immediately after completion. With three layer resolution settings,
you can choose to build a part quickly for design verifica tion, or you
can choose a finer setting for higher quality surface detail.
Extrusion
Head
Extrusion
Tips
Guide Rods
Lead Screw
Model Material
Cartridge
Support Material
Cartridge
Figure 1: Prodigy Plus front view
Tip Cleaning
Assembly
Purge Containe
Plastic Modeling
Base
Z-Axis Table
Display Pane
Power Switc
Context-sensitiv
display and keys
Prodigy Plus User Guide
12 Overview
The Prodigy Plus system consists of two main components — the
machine itself and Insight, the preprocessing software that runs on
a Windows NT, Windows 2000, or Windows XP platform.
Prodigy Plus’s build envelope measur es 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 fou r days
without reloading.
Prodigy Plus User Guide
Overview 13
Finding More Information
Several references are available for use with Prodigy Plus.
Setting up Prodigy Plus
Prodigy Plus User Guide
Step-by-step instructions for
installing, setting up and operating
the Prodigy Plus system.
Using Prodigy Plus
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).
Insight Training CD
For more detailed training on the
many advanced features within
Insight, a training CD may be
purchased.
World Wide Web
Additional information is available at:
http://www.stratasys.com
Prodigy Plus User Guide
14 Overview
Consumables
This section lists all replaceable consumables used by the Prodigy
Plus modeling system.
Part Number Description
Modeling Material
340-20000 White ABS Filament Cartridge
340-20200 Black ABS Filament Cartridge
340-20300 Red ABS Filament Cartridge
340-20400 Blue ABS Filament Cartridge
340-20500 Green ABS Filament Cartridge
340-20600 Yellow ABS Filament Cartridge
WaterWorks Support Material/Concentrate
340-30200 WaterWorks Support Cartridge
300-00600 WaterWorks Soluble Concentrate (12 bottles)
Modeling Base
340-00200 Plastic Modeling Base (qty. 24)
Miscellaneous
300-00100 Krytox Grease
540-00101 Tip Cleaning Kit (1 brush, 5 flickers)
540-10000 Tip Shroud
300-01100 ABS Glue (case of 12)
340-02000 24 V 20 W Halogen Bulb (qty. 4)
To order consumables for your Prodigy Plus 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
Prodigy Plus User Guide
Setup
Workspace
Observe the following when placing Prodigy Plus in its operating
location:
• Prodigy Plus 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:
110-120 VAC, 60 Hz, 15 A min. (20 amp recommend ed)
–or–
220-240 VAC, 50/60 Hz, 7 A min. (10 amp recommended)
• Temperature: 18–32°C (65-90°F)
• Relative Humidity: 30-80%, 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
Prodigy Plus User Guide
16 Setup
Unpacking
This section describes the recommended procedures for
unpacking and preparing Prodigy Plus for its first use.
T o unpack the machine:
1. Before unpacking machine, use a forklift to move it near it s
intended location.
2. Remove the plastic banding from around the cardboard,
and slide the cardboard up and off the pallet.
3. Using the forklift, place the unit in its final location.
4. Cut and remove the cable ties that secure the extrusion
head to the Z-axis frame (see Figure 2).
Figure 2: Cable ties securing the extrusion head to the Z-axis frame
WARNING
Before powering on Prodigy Plus, if you
have not yet done so, cut and remove the
plastic cable ties that secure the extrusion
head to the Z-axis frame (see Figure 2).
The machine will be damaged if powered
on while the head is tied to the frame.
Prodigy Plus User Guide
Setup 17
5. After uncrating and removing the cable ties, inspect the
machine and report any shipping damage to the carrier.
Power Connections
This section discusses the procedure for preparing all power
connections for the machine.
Important
Before connecting power to the machine,
ensure that the circuit breaker located in the
rear of the machine is in the off (down)
position.
Prodigy Plus is provided with two power cords: one for 110 V and
one for 220 V.
To 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
below. If using a UPS, connect the cord directly into the
UPS.
Figure 3: Connecting to a grounded electrical outlet
Connect the cord directly into the
receptacle or UPS. Do not use an
extension cord or power strip.
Prodigy Plus User Guide
WARNING
18 Setup
2. Connect the female end of the power cord directly into the
rear of the cabinet.
3. Switch the circuit breaker to the on (up) position.
The machine is now ready for powering on.
Powering On Prodigy Plus
WARNING
Prodigy Plus’s build chamber and
extrusion-head tip get very hot! The
chamber and head tip reach temperatures
of approximately 75° C (167° F) and 280° C
(536° F) respectively. Use the leather safety
gloves provided in the Startup Kit when
working inside the machine.
To power on Prodigy Plus, simply flip the large red power switch on
the lower right side of the machine (see Figure 4). Prodigy Plus
boots up in three to seven minutes.
Figure 4: Location of Power Switch
Prodigy Plus User Guide
Setup 19
Note
If the machine 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 Prodigy Plus
is warming up and cooling down.
Note
For safety, the head and platen does not move while the
chamber door is open. During warm-up and operation, a
solenoid triggers the door lock. The door can be opened
only when Prodigy Plus is not building a part, getting
ready to build a part, or in pause status.
Powering Off Prodigy Plus
Note
If the system is powered off during a build, the part will
be lost. You should complete the current build and
unload the material before a planned power-off.
If you wish to power-off Prodigy Plus, simply flip the large red
power switch on the lower right side of the cabinet (see Figure 4 on
page 18). You can do this at any time withou t harming the machine.
No other steps are necessary. If this is done while the machine is
building a part, the part will be lost. System cooling fans continue to
operate for several minutes ensuring a safe, systematic power
down and cooling of the system.
Note
For extended non-use periods, unload the material
cartridges and then power off the system.
Prodigy Plus User Guide
20 Setup
Cycling Power
Situations may occur that require completely shutting off and then
restarting the Prodigy Plus system. This section discusses the
procedure for cycling the electrical system.
T o cycle power:
1. Flip the power switch located at the lower right side of the
cabinet (Figure 4 on page 18) to the OFF (down) position.
Wait for the machine to completely power down.
2. Flip the circuit breaker located on the rear of the cabinet to
the OFF (down) position.
3. Wait ten seconds and then flip the circuit breaker to the ON
(up) position.
4. Flip the power switch to the ON (up) position.
5. Wait 15 minutes for the system to prepare itself for normal
operation.
Setting Network Addresses
Y ou will need to set up your network addresses before sending files
from the workstation to Prodigy Plus. If this has not been done
already follow the steps below. Ask your IT department for your
network addresses before beginning this process.
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.
T o set the network addresses:
1. From Idle or Ready to Build, press Maintenance.
The panel then displays System Maintenance and
displays the software version.
Prodigy Plus User Guide
Setup 21
2. Press Set Network. These 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.
3. 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.
4. Use the three functions above to set your IP address.
5. 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.
6. When you have finished setting addresses, press Done.
The panel displays Change IP, Netmask, Gateway?
7. Press Yes. The panel then displays Resetting Network
and after a moment returns to Idle or starts warming up.
8. If you have not done so already, plug in the network patch
cable from your network to the rear of Prodigy Plus.
9. From any workstation on your network, open a DOS
window and type: “ping...” followed by Prodigy Plus’ 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.
Prodigy Plus User Guide
22 Setup
Installing Software
Insight is the preprocessing software that controls Prodigy Plus. If
you have not already done so, you will need to install the Insight
software and optional utilities on your workstation. You will find the
Insight disk 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 Prodigy Plus
FDM Modeler Status Not applicable to Prodigy Plus
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
Prodigy Plus User Guide
Files provided to allow you to quickly understand and use
your system.
Setup 23
Workstation Requirements
The following is a list of requirements for operating the Insight
workstation:
Operating System Microsoft Windows XP/2000/NT 4.0 (SP6 or higher)
Distribution Media CD-ROM
Processor Intel Pentium III 500 MHz minimum.
Recommended: Pentium 4 1.0 GHz, AMD Athlon
RAM 256 MB minimum, 512 MB recommended, 1 GB
recommended for large or complex jobs, and jobs with
high detail or small slice intervals
Hard Disk Installation: 15 MB (30 for full install)
Paging File System: 300 MB (minimum,
dependant on amount of
installed RAM)
Monitor 17 inch or larger
Graphics Resolution 800 x 600 (minimum)
1024 x 768
1280 x 1024 (optimal and recommended)
Video Card Requires OpenGL-compliant accelerated graphics card
Preferred Vendors:
Nvidia based cards (GeForce and above)
Permedia based cards (Elsa, Diamond)
ATI Radeon based cards
Network Interface Card Ethernet 10/100 Base T
Keyboard 101 key or equivalent
Mouse 2 button or 3 button
Web Browser Internet Explorer 5.5 or later for online help
Note: Changes to supported platforms, operating systems and graphics cards are
periodically updated. Visit the customer login section at www.stratasys.com for the
latest supported versions.
Prodigy Plus User Guide
24 Setup
T o 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 . T o 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.
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.
Prodigy Plus User Guide
Operation
Display Panel and Keypad
The main interface to Prodigy Plus is the Display Panel and
Keypad (see Figure 5).
Display Panel
Context-sensitive
displays
Keypad
buttons
Figure 5: Prodigy Plus 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 machine status. The lower three
lines show details related to the current operation .
Normally there will be an item blinking in the lower (contextsensitive) displays. This item is usually the most logical selection.
Prodigy Plus User Guide
26 Operation
Inserting a Plastic 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.
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 6). 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.
Slide modeling
base into the
side tray guides
(2 on other side).
Figure 6: Inserting a plastic modeling base
To reuse a plastic modeling base:
The square outlines on the modeling base represent modeling
areas. The base is intended for single-use on each modeling ar ea.
Building on a used modeling area may cause a p art to curl or break
loose from the modeling base.
Before inserting a used modeling base into the machine, make
sure that all material above the previous part’s first layer is
removed from the base.
Prodigy Plus User Guide
Operation 27
Failure to completely remove all other layers from a previous build
can cause a head collision and result in system damage.
A modeling base may become worn or distorted after several
builds. The machine performs a modeling base levelness check at
the start of every part build; upon detection of a faulty modeling
base, the machine pauses and allows you to install a new one.
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.
To load material cartridges:
1. Remove packaging.
2. If present, remove the red sealing plug from the cartridge:
(see Figure 7)
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 7: Remove red plug before loading
Prodigy Plus User Guide
28 Operation
Note
The instructions for removing the red sealing plug are
also shown graphically on the cartridge (see Figure 8).
Figure 8: Plug removal instructions on cartridge
3. Find the end of the material filament taped with a “flag”.
Important
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 on page 29
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.
Prodigy Plus User Guide
Operation 29
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.
5. With the cutter from your Startup Kit, snip the filament at an
angle, leaving 6 mm (¼”) of material protruding from the
cartridge (see Figure 10).
Figure 10: Snipping the material filament to 6 mm (1/4 in) length
6. Press the Material Load button, which will be blinking. The
panel first displays Unloading and then it instructs you to
insert the cartridges with the prompt Replace Both
Cartridges.
7. Insert each cartridge. The panel displays Ready to
Load.
Prodigy Plus User Guide
30 Operation
8. Press Load. The panel then displays Loading. After the
material loads, the panel displays Material Loaded.
Note
You might get the message, Model 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. Watch the appropriate extrusion tip (see Figure 11) to see
if material extrudes (purges) after loading. The panel will
then display Did material purge?
Support Tip
Figure 11: Close-up of extrusion tips
Model Tip
10. Press Yes or No as appropriate — or press Purge Again if
you’re unsure which to choose.
•Pressing No returns the machine to the Load
Material state.
•Pressing Yes returns the machine to the Ready to
Build state.
Note
If the display shows Load Failed, press Retry. If load
fails again, remove the cartridges, snip the material at an
angle (see Figure 10 on page 29), and reinsert the
cartridge.
Prodigy Plus User Guide
Operation 31
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 machine 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.
T o unload material cartridges:
1. Press Material Load.
The panel displays Load material and prompts with,
Replace model?
2. Press Yes.
The panel displays Replacing model, and asks if you
want to replace the support material also. It also displays
the remaining percentage of support material.
3. If you want to replace the support material cartridge also,
press Yes.
The panel displays Unloading for approximately 15 to 20
seconds, and then displays Remove cartridge.
4. Remove the model material cartridge by first pushing it
forward gently, and then pulling it out of the slot.
5. Remove the cartridge(s) and approximately 180 cm (6
feet) of material.
6. To store a partially used cartridge, place a small flag of
tape on the filament near the cartridge, and cut off and
discard the remaining material. The tape flag ensures the
filament does not roll back into the cartridge.
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
Prodigy Plus User Guide
32 Operation
result in models not adhering to the plastic modeling base or a loss
of extrusion.
To verify tip depth:
1. Install an unused plastic modeling base (substrate).
2. Press Maintenance.
3. Press Test Parts, and select test_tipdep_plstc.cmb.
The model will create six pairs of numbers at different Z-
heights as shown in Figure 12. Each pair will have an
extruded set of numbers on the left and an etched set of
numbers on the right. The left set are extruded at a very
low flow rate and may not show up clearly. The right set
are etched into the modeling base by the idle support tip. It
is normal for only some of these numbers to be visible.
Extruded Numbers
(left side)
Etched Numbers
(right side)
-5
-5
0
0
+5
+5
+10
+10
-5
+10
-5
-5
0
0
+5
+5
+10
+10
-5
-5
0
0
+5
+5
+10
+10
-5
-5
0
0
+5
+5
+10
+10
-5
0
0
+5
+5
+10
-5
-5
0
0
+5
+5
+10
+10
Figure 12: Plastic modeling base with test_tipdep_plstc.cmb model
4. Evaluate the right (etched) set of numbers. These numbers
can be difficult to see. It may be necessary to tilt the
modeling base to the light to inspect. The etched set must
meet the following criteria to pass:
• -5 must be visible in at least one set of numbers.
• +10 must not be visible in any set of numbers.
Prodigy Plus User Guide
Operation 33
Note
It is acceptable for some sets to have NO visible etched
numbers.
5. 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.
6. If the tip depth again fails the above criteria, contact
Stratasys Customer Support for more information on
adjusting tip depth.
Building a Test Part
Stratasys has factory-preloaded test parts into Prodigy Plus. It is
recommended that you build a test part as your first build to
familiarize yourself with the system.
Once the machine 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.
Prodigy Plus automatically starts building the part.
3. When the part is finished, follow the steps under Removing
a Completed Part on page 37.
Sending Your CAD File to the System
This section describes the procedures used for sending your own
CAD files to Prodigy Plus.
To send a “job” to Prodigy Pl us:
1. Create an .stl file with your CAD software.
Prodigy Plus User Guide
34 Operation
2. Click on the Insight icon on the desktop of your
workstation.
The Insight main window opens (see Figure 13).
Figure 13: Insight main window
3. Fro m the File me nu , 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
Prodigy Plus
7. Click on the Status icon on the desktop of your
workstation to send your file to Prodigy Plus. For more
information on Status, refer to the Insight help files.
Prodigy Plus User Guide
Operation 35
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.
To 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, Prodigy
Plus begins building the part.
T o read the display panel while building:
The top display panel shows machine-status messa ges on the first
two lines (see Figure 14). The material amounts remaining in the
cartridges is shown on the next two lines of the panel.
Machine Status
Model File Name
Model Material
Remaining
Support Material
Remaining
Figure 14: Display panel during build
Machine Chamber Light
When a part is building, the chamber light activates and stays on
for 30 minutes. You can manually control the light by pressing
Lights On. The light remains on for five minutes.
To turn the lights on continuously until the power is cycled, you
must be in the Idle or Ready to Build mode. Press Maintenance
and then press Next until Setup Maintenance is displayed.
Press Lights Always.
Prodigy Plus User Guide
36 Operation
Pausing Build
While building a part, you may want to pause operations for some
reason, such as to replace a material cartridge. To pause the build
operation at any time, press Pause. On your workstation, Status
displays the following information:
• Pause status
• Modeler’s name
• Type of modeler (Prodigy Plus)
•Job name
• Build time remaining
• Percentage of part built
Note
When the build process is paused, Prodigy Plus
completes the current tool path before pausing.
Resuming Build from Pause Mode
If you have pressed Pause, and are ready to resume building the
part, press Resume. Prodigy Plus resumes modeling.
Resuming Operations from Standby Mode
After several minutes of inactivity, Prodigy Plus enters Standby
mode. During Standby, the head and build envelope temperatures
lower to save energy.
To 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.
Prodigy Plus User Guide
Operation 37
2. Press Start Model to start modeling.
Prodigy Plus may require a few minutes to warm up to
build temperatures. You can view the temperature values
rising 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 Prodigy Plus stops building, press Cancel Build.
The panel displays Are you Sure?
3. Press Yes. The panel displays Build Stopped and the
part name. The panel prompts you to remove the part and
replace the substrate (plastic modeling base). Once the
chamber door has been opened and closed, the panel
asks: Part Removed?
4. Press Yes only after removing the part using the
instructions in the following section, Removing a
Completed Part.
WARNING
If you press Yes before removing the part,
the machine can be da maged, and a service
call will be required.
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 Substrate.
To remove a completed part:
1. Open the modeling chamber door.
Prodigy Plus User Guide
38 Operation
2. Release the modeling base retainers and pull the plastic
modeling base (substrate) towards you, out of the tray
guides.
3. Close the modeling chamber door.
4. After you have opened and closed the door, the panel
displays Part Removed? Only after removing the part,
press Yes.
WARNING
The machine can be damaged if the part
hasn’t been removed!
After you press Yes, the panel displays the status as
Ready to Build for the next part in the queue, if there is
one.
To remove a completed part from the plastic modeling base:
1. After removing the base from the machine, firmly flex the
modeling base back and forth with your hands to loosen
the part. For best results, flex the modeling base
perpendicular to the first layer raster direction (front-right to
back-left).
2. Pull the part off the base or use a putty knife to pry the part
completely off.
Note
Supports are much easier to remove when the plastic
modeling base is still warm.
For information on reusing a plastic modeling base, see
page 26.
WaterWorks
Prodigy Plus uses WaterWorks, a water-based solution designed
to simply wash away the support material. Your part is left smooth
and clean with the fine details intact. The soluble support material
Prodigy Plus User Guide
Operation 39
can be removed by hand with relative ease, but is designed to be
dissolved off of your parts for hands-free part finishing.
CAUTION
Wear the safety goggles and the leather
safety gloves, provided in the Startup
Kit, when removing supports by hand.
CAUTION
Wear the safety goggles and rubber
gloves, provided in the Startup Kit, when
removing supports with the soluble
concentrate.
Dissolving supports is affected by four parameters:
• Chemistry: Stratasys produces soluble concentrate in
packages of 12 bottles. Each bottle of soluble concentrate
is designed to produce the optimal concentration when
mixed with 40 liters (approx. 11 US gallons) of water. More
or less concentrate can be used at once, however, 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. Do not run the cleaning
tank above 70° C (158° F), as setting the temperatu re
higher can warp or damage parts. If using an ultrasonic
tank, it is recommended to run the tank without a lid to
avoid over-temperature conditions.
• Mechanical Energy: Dissolving 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 dependant 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 of
the solution.
Prodigy Plus User Guide
40 Operation
T o check the p art and water level:
Various factors determ in e ho w lon g 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 ne cessary, but do not add
more soluble concentrate.
IMPORTANT
Adding more soluble concentr a te than recommended
can damage parts.
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.
T o rinse or soak part s:
Rinse white parts thoroughly with water until su rfaces 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. Surface abnormalities can
also be caused from using inadequate solution . Chec k the solution
and change it if necessary.
If you build parts using the Sparse build style, allow them to fully
drain, since the solution gets trapped inside the part. Allow parts to
dry thoroughly. Then quickly rinse parts under hot water to keep
the water out. If water gets inside, repeat this step.
Prodigy Plus User Guide
Operation 41
T o dry parts:
Dry parts with paper towels, compressed air, or let them air-dry. If
colored parts turn slightly white after drying, re-rinse them under
hot water or soak them again.
To change the solution in the tank:
How often you change the solution is dependant on how much
support material has been dissolved, which tank you use, how you
maintain it, 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 scenarios are also indicators to change the solution:
• White ABS parts turn brown or yellow.
• Parts have a sticky residue and/or stick together.
• Functional parts with moving features do not work
properly.
• Parts have shiny surfaces.
• Small pieces of plastic stick securely 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.
Product pH Level
Fresh soluble solution 12.6
Laundry detergent 11-12
Household cleaners 9-12
Dishwasher detergent 10-11
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.
Prodigy Plus User Guide
42 Operation
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 releas e
material dissolved in 11 gallons of water.
Parameter Test Method Units
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
Tank
Value
Diluted
Value*
*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.
Prodigy Plus User Guide
Maintenance
Follow the simple procedures within this chapter to ensure
continued proper operation of Prodigy Plus.
Startup Kit Tools
Provided in your Prodigy Plus 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
Prodigy Plus User Guide
44 Maintenance
Daily Maintenance
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).
1. Remove the purge container by grasping it and pushing it
upward to release it from the three mounts.
2. Pull the container towards you and out of the chamber to
empty it.
WARNING
When reinstalling the container, ensure that
it locks in all three mounts and hangs flush
with the chamber wall to avoid damage .
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
unleveled or, if the buildup is large enough, it could cause the Zstage to jam at its upper limit.
Weekly Maintenance
Vacuum Build Chamber
Vacuum the build chamb er to remove all foreign particles and
purged material.
Prodigy Plus User Guide
Maintenance 45
Quarterly Maintenance
Axis Maintenance
Clean the items below using Isopropyl alcohol. See Figure 15 for
locations.
• Z-axis lead screw (or drive screw)
• All X and Y-axis guide rods
• Z-axis guide rods
Y -axis Guide Rod
(1 of 2)
Z-axis Guide
Rods
Z-axis Lead
Screw
Figure 15: Lead screw and guide rod identification
X-axis Guide
Rods
Axis Lubrication
Lubricate the following items using the Krytox grease provided in
the Startup Kit. Use the grease sparingly. See Figure 15 for
locations.
• Z-axis lead screw
• Both Z-axis guide rods
• All X and Y-axis guide rods
Prodigy Plus User Guide
46 Maintenance
Clean fan filter
To clean the fan filter:
1. Locate the lower fan on the rear panel of Prodigy Plus and
snap off the plastic frame that secures the fan filter.
2. Clean the filter with soap and water, and blot it dry.
3. Reassemble.
Tip Cleaning Assembly
To replace the extrusion he ad’s tip cleaning assembly:
1. Completely power down Prodigy Plus. See Powering Off
Prodigy Plus on page 19.
2. Remove the purge container.
3. Remove the old flicker by loosening the rear screws and
pulling up on the flicker.
4. Insert the new flicker and tighten the rear screws while
gently pushing down on the flicker.
5. Remove the old tip cleaning brush by loosening the two
mounting screws (See Figure 16) 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.
Prodigy Plus User Guide
Maintenance 47
8. Adjust the tip cleaning assembly until the brush just
touches the tips but just misses the bottom of the tip
shroud (see Figure 16) and tighten mounting screws.
Top of brush
just misses
flat portion of
tip.
Figure 16: Replacing the tip cleaning brush
Bottom of nipples
must hit brush
and top half of
exposed flicker.
Mounting Screws
As Needed Maintenance
The following maintenance items have no routine schedule but
should be tended to as needed.
Chamber Lamp
Replace the chamber lamp when it burns out.
To replace the chamber lamp:
1. Power down the system.
2. Locate the lamp socket plug about 3 inches beneath the
lamp socket. Unplug lamp socket from wire harness.
3. Lightly pull the socket wires away from the socket while
pulling lamp straight out of the socket.
Prodigy Plus User Guide
48 Maintenance
WARNING
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.
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.
5. Plug the socket wires back into the wire harness.
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
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.
CAUTION
Head area is very hot! Use gloves when
installing a new shroud!
1. Enter Maintenance and access the Table Maintenance
function.
The head temperature decreases.
Prodigy Plus User Guide
Maintenance 49
2. Using a 1/8-inch hex wrench, back out the two head-plate
mounting screws approximately 1/8 inch (see Figure 17
below), but do not remove the screws.
Extrusion
Head
Figure 17: Head plate mounting screw location
Head Plate Mounting
Screws (2)
3. Pull the head plate slightly away from the head until the
right side of the plate is clear of the mounting screw head.
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 18. There is a small notch on the bottom
of the plate for this purpose.
Mounting Screw
in Retaining
Notch
Figure 18: Head plate in shroud replacement position
Prodigy Plus User Guide
50 Maintenance
5. Locate the shroud, the shroud-mounting screws, and
shield, as shown in Figure 19.
Shroud
Shroud
Shield
Figure 19: Shroud and shield location
Mounting
Screws (2)
6. Remove the two shroud mounting screws using a 3/32 inch
hex wrench.
CAUTION
Screws are very hot!! Use gloves when
working in this area of machine!
7. Once the screws are removed, pull the metal shield down
to remove. Be careful not to bend or damage the shield.
8. Pull th e sh ro ud dow nw ard 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.
IMPORTANT
Apply a thin coat of anti-seize compound to the threads
of the shroud mounting screws.
Prodigy Plus User Guide
Maintenance 51
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 33.
Prodigy Plus User Guide
52 Maintenance
Prodigy Plus 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
Material not extruding Filament may be jammed in extrusion head (see
No text displayed on Display
Panel
Cannot communicate with system
through network
Error Code displayed on Display
Panel
Display Panel displays
Build Error
Verify the system is not connected to an
extension cord or power strip.
Loss of Extrusion on page 55).
Cycle power (see Cycling Power on page 20).
Incorrect IP address – check that the IP
addresses within the Prodigy Plus system and
Insight are the same values (see Setting Network
Addresses on page 20).
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.
Call for customer service. For more information,
see Fault Determination Codes on page 54.
Partial or bad part file sent to system. Check STL
file validity in CAD software; reprocess STL in
Insight and redownload to system.
Prodigy Plus User Guide
54 Troubleshooting
Problem or error message Solution
Display Panel displays
Can’t Find Home –
Check Substrate
Display Panel displays
Communication lost
at HR:MN UCT
Display Panel displays
Could Not Read
Cartridge
Display Panel displays
Load Failed
Verify a plastic modeling base (substrate) is
inserted.
Plastic modeling base may be used or defective.
Replace it.
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.
Remove cartridge and cycle power (see Cycling
Power on page 20); reload cartridge.
Try a different cartridge.
Retry with same cartridge.
Try a different cartridge.
Filament may be jammed in extrusion head (see
Loss of Extrusion on page55).
Fault Determination Codes
If a fault occurs, which would prevent Prodigy Plus 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 machine has finished cooling, the only option displayed
is Continue. Press Continue and the machine reboot s and tries to
return to normal operation. If pressing Continue does not recover
the machine, the machine should be power cycled using the red
power switch on the right side of the machine (see Cycling Power
on page 20); wait 60 seconds before switching power on again. In
most cases you will be able to continue operation. However, if the
machine continues to shut down and display the same error, call
your service representative.
Prodigy Plus User Guide
Troubleshooting 55
Loss of Extrusion
Diagnosing Loss of Extrusion
Occasionally, the machine’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
WARNING
The head area is very hot!! Use gloves
when working in this area of machine!
To diagnose loss of ex trusion:
1. Press Cancel and remove any parts from the machine.
2. Insert a new plastic modeling base (substrate).
3. From Idle, enter Head Maintenance
a. Using the keypad, press Maintenance.
b. Press Next. The head will come to re st in the center of
the chamber and the Z-axis table will move. The
display now displays Head Maintenance.
4. Determine if there is an extrusion problem by pressing
Forward. Watch both tips for several seconds, looking for
extrusion.
5. Press Stop to stop the extrusion.
If material steadily flowed from both tips, the head is not
experiencing loss of extrusion. Push Done to return the
machine to an idle state. If material did not extrude from
both tips follow the procedure in the following section,
Recovering From Loss of Extrusion.
Prodigy Plus User Guide
56 Troubleshooting
Recovering From Loss of Extrusion
Note
Before proceeding, read through the entire procedure.
Overview
1. Enter Maintenance mode.
2. Attempt to re-establish extrusion.
3. Snip both filaments approximately 1 inch from the fixed
part of the head.
4. Remove the filament from both drive block assemblies
if there is enough to remove by hand.
5. Remove both drive block assemblies from the swivel
part of the head.
6. Inspect the drive block funnels for obstructions.
7. Inspect the liquefier inlets for material buildup.
8. Clean the inside of the liquefier inlets.
9. Replace both drive-block assemblies.
10. Clean the drive wheels.
11. Check for extrusion.
Prodigy Plus User Guide
Troubleshooting 57
T o recover from loss of extrusion:
1. Enter Maintenance mode.
a. Press Maintenance and then press Next.
b. Press Select Drive repeatedly until Both Drive
Motors is displayed.
c. With the Phillips-head screwdriver provided in the
Startup Kit, release the two screws securing the head
assembly (see Figure 20) and swing open the front
half of the head. The screws require only ¼ rotation to
release.
Swivel Head
Screws (2)
Figure 20: Location of swivel head ¼ turn screws (2)
2. Attempt to re-establish extrusion.
Note
Both materials must be coming out of the feed tubes at
the back of the head (see Figure 21) and going into the
drive block funnels in order to proceed with this step. If
not, continue with step 3.
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.
Prodigy Plus User Guide
58 Troubleshooting
b. If the pu rg e was suc cessful:
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. Press Yes. The panel displays Exiting
maintenance and you can now resume normal
operation.
c. If material did not purge, continue with the following
steps.
3. Snip both filaments approximately 1 inch from the fixed
part of the head (see Figure 21).
Figure 21: Materials coming out of feed tubes
Prodigy Plus User Guide
Troubleshooting 59
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 about 6 inches of filament through the head to make
sure the filament is not caught at the receiver. Then snip
the filament approximately 1 inch from the fixe d part of
the head.
4. 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. Gra sp th e filam e nt fro m th e dr ive blo ck s with yo ur
fingertips, and gently pull it out of the drive wheels.
Repeat for second filament. If you are unable to easily
remove either filament, leave the filament in the drive
block for now.
5. 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.
Prodigy Plus User Guide
60 Troubleshooting
Dri
y
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 22.
Drive Block Assembl
Support driveModel drive
ve Wheels
Mounting Screws
Drive Wheels
Figure 22: Removing the drive block assemblies to check for buildup
Filament Guide Funnel and
Mounting Screw
c. Set the drive block assembly on the material cartridge.
d. Remove the Model drive block assembly the same
way.
6. With the drive blocks removed, look through both filament
guide funnels for obstructions. If an obstruction is present
in either drive block, follow the procedure for clearing drive
block obstructions.
Clearing drive block obstructions:
a. Remove the filament guide.
Use the 7/64” Allen wrench provided in the S t artup
Kit by removing the filament-guide mounting screw
as shown in Figure 22.
b. Remove any excess material; use the needle-nose
pliers if necessary.
c. Replace the filament guide.
Prodigy Plus User Guide
Troubleshooting 61
7. With the drive blocks removed, inspect the model liquefier
inlet tube and the inlet funnel covering the support liquefier
inlet tube (see Figure 23) for material buildup. If material is
visible, proceed to the appropriate clearing liquefier inlet
tube procedure.
Liquefier Inlet Funnel
(shown with support
drive block removed)
Figure 23: Inspecting the liquefier inlet tubes
WARNING
Liquefier inlet tubes are fragile. Be careful
not to damage them when removing
material.
Clearing the support liquefier inlet tube:
a. If material is extended out from the inlet funnel,
gently remove material with the bronze brush or
needle-nose pliers, if necessary.
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 (see Figure 23).
Dissolve support material from the funnel with the
Waterworks solution.
Prodigy Plus User Guide
62 Troubleshooting
Note
It is typical for material to build up around the support
liquefier inlet tube under the inlet f unnel. Do not remove
this material unless it interferes with reinstallation of the
inlet funnel.
d. Inspect for damage to the inlet tube.
e. Replace the liquefier inlet funnel.
Clearing the model liquefier inlet tube:
a. If material is extended out from the inlet tube,
gently remove material with the bronze brush or
needle-nose pliers, if necessary.
b. Inspect for damage to the inlet tube
8. Clean the inside of the liquefier inlet tubes.
Carefully insert a 1/16” Allen wrench into each liquefier
inlet tube and gently push forward until it stops (about 1/4
inch).
9. Replace both drive-block assemblies.
Install the model drive block assembly first. Make sure the
block is seated flush against the swivel plate.
IMPORTANT
Be careful not to pinch the assembly’s
wiring harness under the block or behind
the motor before replacing and tightening
the mounting screws.
10. Repeat for the support drive block assembly.
11. 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.
Prodigy Plus User Guide
Troubleshooting 63
12. 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 3.
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.
IMPORTANT
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.
i. Once the head is closed, tighten both ¼ turn
screws.
ii. Verify material continues to extrude through both
tips for an additional 30 seconds, and then press
Stop to halt extrusion.
iii. Push Done. The panel displays Is material
loaded?
iv. Press Yes. The panel displays Exiting
maintenance and you can resume normal
operation.
Prodigy Plus User Guide
64 Troubleshooting
Prodigy Plus User Guide
14950 Martin Drive
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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