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3D Systems ProX 500 User Manual Download Page 33

3D Systems, Inc.

33

ProX 500 START-UP SEQUENCE

If you’re starting the printer from it’s powered-off state, you must first perform the following machine start-up sequence before you start 

a print:

• 

Start the chiller

• 

Verify the system’s compressed air

• 

Verify the system’s nitrogen supply

• 

Verify the system’s material supply

• 

Put Sinter in Manual Operations (Man Ops) mode

• 

Move the part piston to its Home position

• 

Move the roller to its Home position

• 

Move the piston back to its Start position

Instructions for each step in this sequence are described next . 

If you’re starting the printer from its powered-off state, do not attempt to start a print before you perform the startup 
sequence . Also, never attempt to start a print if the dsp button is not shown in the taskbar .  (Putting Sinter in Build 
mode then opening a build packet starts a build .) - see latest customer release notes for starting Sinter and system 
(dsp) initialization .

1 .  Start the Chiller .

a .  Press the power (

I/O

) button on the chiller front panel .

b .  Check that the chiller 

COOLANT INLET 

flow gauge at the SLS system gauge panel reads 6 lpm or more.

c .  Check that the chiller temperature setpoint is 20C .

2 .  Verify the printer’s compressed air supply .

a .  Verify that facility compressed air is on and connected to the gauge panel 

AIR INLET

 .

b .  The air pressure gauge label indicates the correct reading . This should be: 500 KPa (72psi) .

3 .  Verify that the system has an adequate supply of nitrogen and that it is running .

NOTE: Skip Step (a) if you have a nitrogen dewar or bulk tank connected to your SLS system instead of a nitrogen 
generator .

a .  Open the compressed air supply valve at the bottom of the N

2

 generator .

b .  Make sure the 

NITROGEN INLET 

ball valve on printer’s gauge panel is open . It needs to be turned at a 90° angle so that 

it is aligned with the direction that the nitrogen is flowing.

c .  Verify that the regulated 

N

2

 PRESSURE 

gauge on gauge panel reads 140 KPa (20psi) .

4 .  Verify the material supply using either of the following two ways .

• 

In SinterDiag, check the MQC window in the Man Ops screen . This displays the MQC System’s status, including the amount of 

available powder .

or . . .
• 

Check the MQC status in the Sinter Status window which also displays the amount of available powder .

Summary of Contents for ProX 500

Page 1: ...ProX 500 3D Production Printer User Guide Original Instructions ...

Page 2: ...18 Training and Instructions 18 Machine Handling 18 Material Handling 18 Laser 18 Alarms and Warnings 18 Safety Symbols and Definitions 19 First Aid Section What to do 20 Burns 20 Reporting Laser Radiation Exposure 20 Electrocution 20 SLS Equipment Safety Features 21 Safety Interlocks 21 SLS System Response if an Interlock Fails 21 Limited Access and Barrier Shielding 21 Other Active Safety Featur...

Page 3: ...e and Verify Build Packet 35 Run Sinter Application 36 Preparing the Print Chamber 36 Running the Build 36 Breaking Out Parts 36 PROX 500 SYSTEM OPERATIONS 37 ProX 500 Start Up Sequence 37 Build Setup and Sinter Applications 37 Messages in the Sinter Application 37 About the Message List Window 37 Restarting a Terminated Build 38 Viewing a Build In Progress 38 Viewing Options on the Toolbar 38 Opt...

Page 4: ...ts 47 Part Finishing After Breakout 47 MQC System User Interface Settings 48 MQC System Main Control Screen 48 Operational Mode Screen 48 System Setup Service Screen 48 MQC System User Interface Settings 49 Display Legend 49 MQC System Main Status Screen 49 MQC Main Control Screen 50 Operational Mode Screen 51 To Load Fresh Powder 51 3 Quickly press and release knob to display the following screen...

Page 5: ...rocessing Module Filters 63 Electrical Enclosure Filter 64 Replacing Electrical Enclosure Filter 64 2 Stage Powder Filter Sock Filter and Hepa Filter 64 Cleaning or Replacing the 2 Stage Powder Filter 64 Cleaning or Replacing Hepa Filter 64 Chiller Maintenance 65 Chiller Fluid Replacement 65 Cleaning the Chiller Air Vent and Changing the Air Vent Filter 65 Drain Filter Replacement 65 ...

Page 6: ...d injury or equipment damage Read this section before you switch on power to any SLS equipment or handle any material Printing Parts with the ProX 500 This section gives you an outline of the entire part printing process ProX 500 System Operations This section describes the printer and provides operating instructions for manual control of the machine MQC System Operations This section details the ...

Page 7: ...uction control and material recycling functions so it pays you back faster F B A D E C Stacklight Indicates the state of the system Print Chamber Area There are two doors in front of the Print Chamber the outer locking door and the inner print chamber door The parts are printed inside the Print Chamber E Stop The Emergency Stop button is a safety mechanism used to shut off the machine in an emerge...

Page 8: ...material is loaded at this location The user must scan the material tag on the container across the Reader See letter I below to open the doors Breakout Controls This wheel switch allows the user to turn the sifter on and off Reject Chute Spent material as determined by the user is loaded into the reject chute Sifter The user removes the parts from the print cake in the breakout area and places th...

Page 9: ... Reader The tag reader is used to scan the tag on the lid of the material container This ensures that the system keeps track of material quantity and fresh to new material ratios The tag must be scanned to unlock the Fresh Material Input doors and add the material to the system MQC System Operator Controls User interface for operation of the MQC System J K L ...

Page 10: ...om oxygen monitor is connected here Compressed Air CDA Inlet Input for compressed air coming into the MQC System Nitrogen Inlet Input for nitrogen supply Material Output A Material transfer connection for Printer A A B C D E F MQC System Rear View A B C D E F G H Material Output B Material transfer connection for Printer B AC Inlet Power connection for MQC System Dust Collector Port Connection for...

Page 11: ...ms manufactures a High Performance Nitrogen Generator Part Number 104011 02 The generator is ideal for SLS applications Bead Blaster Optional If you plan to use DuraForm SLS material 3D Systems recommends you install a pneumatic abrasive blast cabinet bead blaster in the part finishing area separate from the ProX 500 SLS 3D Printer process station room 3D Systems Nitrogen Compressed O2 exhaust N2 ...

Page 12: ...pen state User Interface The user controls the system using a touchscreen located on the front panel Buttons Indicators USB Ports Chamber Lights This button turns the chamber lighting on or off LED Indicators The LED indicators under the touchscreen indicate the system s power and safety status Each indicator operates as follows Laser Blue LED A B C ProX 500 User Interface The User Interface locat...

Page 13: ... still initializing System Amber LED ON Solid All E stop buttons are reset and system power is enabled OFF An E stop button is pressed or system power is not enabled System Enable This button re enables the system following an emergency stop which occurs after the emergency stop switch returns to the open state USB A standard auxiliary USB port connected to the control PC is located under the LED ...

Page 14: ...ter Reset Button ProX 500 Rear View Power Supply This module distributes all the AC power that the system needs Circuits for the various subsystems are located in this module Main Power Disconnect The main power disconnect located on the left side of the system enables you to turn on and off all power to the system Do NOT position the equipment so that it is difficult to operate this device There ...

Page 15: ...e mode System warning active and or message present on touchscreen E Stop condition or normal Green Print job active System Active not printing manual operations possible E Stop condition or normal Part Transfer Cart Assembly The print cake Extraction Cylinder Part Transfer Tray and Part Transfer Cart are used to remove the print cake from the ProX 500 print chamber and transport it to the MQC Sys...

Page 16: ...ont panel of the MQC System consists of a dial operated menu screen that allows the user to access the functionality of the system An E Stop control is located to the right of the screen and the system power switch is located to the left For detailed information on the interface screens refer to the section MQC System User Interface Settings on page 48 B C D A MQC SYSTEM COMPONENTS MQC System Stac...

Page 17: ...sifter during breakout Move the switch to the bottom position to stop the sifter Fresh Material Input The material input hatch takes fresh material from the user and feeds it to the MQC System To unlock the hatch the user must first swipe the tag of the material container across the tag reader Sifter Tag Reader Breakout Area Material Hatch Thermocouple ...

Page 18: ...us levels and servicers should only perform tasks they are authorized and certified to complete MACHINE HANDLING Do not try to access service or adjust any components inside any SLS equipment enclosure Do not try to open any panel or door while a machine is running Do not access any area of the machine near the print chamber during printing Use special caution when handling a heated print cake and...

Page 19: ...e burns and blindness Access panels are for service only and should be opened only by certified service personnel ELECTRIC SHOCK HAZARD High voltage electricity is accessible in the vicinity of this sign or behind the access panel High voltage can cause severe burns or death Access panels are for service only and should be opened only by certified service personnel or trained maintenance personnel...

Page 20: ... Rock Hill South Carolina 29730 USA Include the following information in your report Nature of the accident and circumstances surrounding it Where the accident occurred Model and serial number of the machine Number of people involved Any other pertinent information Please send this information to 3D Systems within a day of the accident Electrocution The SLS system contains equipment energized at 2...

Page 21: ...e External oxygen monitor connected to SLS system detects too little oxygen in room Print will not start Warning message appears on SLS system display Red Stacklight illuminates Nitrogen generator if in use shuts down Warning message appears on SLS system display Red Stacklight illuminates Laser motors and valves disabled Nitrogen supply shuts off E Stop Only CDA supply shut off System power disab...

Page 22: ...eaker panel All SLS equipment was designed to minimize operator exposure to electrical hazards during normal operations All exposed electrical circuits are inside limited access cabinets This is to separate the operator from service and maintenance areas When operating any SLS equipment keep the following electrical safety points in mind Only 3D Systems certified service personnel should operate S...

Page 23: ...s IV laser designations also comply with DIN VDE 0837 02 86 A1 07 90 You can read more about laser safety and classifications in ANSI Z136 1 1993 the American National Standards Institute standard for the safe use of lasers Laser Safety Labels on the SLS system The SLS system has the two types of laser safety labels below Laser safety label locations on the SLS system are shown in the figures that...

Page 24: ...3D Systems Inc 24 Laser Radiation Hazard Label Locations Interlocked Protective Housing Laser Label Locations Print Chamber Enclosure Blackbody Sensor Laser Panels Print Chamber Door ...

Page 25: ...3D Systems Inc 25 Laser Certification And Machine Identification Label Location Air Processing Module ...

Page 26: ...ion on specific materials CAUTION Using materials that have not been certified for use in the SLS equipment may cause health or safety hazards and may damage the equipment and void the warranty Material Ignition Information Powdered materials can be flammable and can be ignited by static electricity in a non inert environment Refer to each material s SDS for specific information CAUTION The operat...

Page 27: ...ired to wear a dust mask or special personal protection equipment unless specifically designated Check the SDS of the material used for the specific precautions you should observe Use the following table of precautions as a general guide Safe Material Handling Guidelines CATEGORY PRECAUTION FIRE HEAT Never smoke or ignite anything around powdered materials Maintain proper clearance from materials ...

Page 28: ... make sure you comply with the following items If at any time you feel you are experiencing symptoms of oxygen deprivation leave the area immediately You have received oxygen nitrogen safety training The room is well ventilated at least 4 air exchanges per hour Self contained breathing apparatus is available and easily accessible The room oxygen alarm monitor is functioning and audible Leave the S...

Page 29: ...HAZARDS AND HOT SURFACES You should be aware of the following pinch crush rotating blade heat and electrical hazard locations on the SLS equipment Print Chamber Enclosure Disconnect Switch Hopper Feed Module Blackbody Sensor Inner Print Chamber Door ...

Page 30: ...These are indicated by warning labels Avoid those surfaces when moving the heater assembly and removing parts from the print chamber In particular avoid the floor of the print chamber Use appropriate gloves when removing the print cake from the print chamber or let the print cake cool for several hours before you touch it Inside of Print Chamber IR Sensor Feed Hopper Heaters Allow system to cool w...

Page 31: ...em detects a valid tag the doors above the interface will unlock CLEANING AND CHECKING Follow these procedures to clean the SLS equipment before you print parts For detailed cleaning instructions refer to the sections indicated 1 Clean the print chamber See the section Cleaning the Print Chamber on page 57 2 Clean laser window See the section Cleaning the Laser Window on page 59 3 Check the overfl...

Page 32: ...nd push the knob You will see the following a s indicates that you may select the value located beneath b Turn the knob to move the selection to the next value c Push the knob to select the value The screen will change as shown on the right S N2 B fresh 50 B lo lvl L 5 000 Blending on B recirc on s 00050 Ok Cancel c 00050 Ok Cancel Blended Bin Ratio Blended Bin fresh selection Select Percentage d ...

Page 33: ...the chiller COOLANT INLET flow gauge at the SLS system gauge panel reads 6 lpm or more c Check that the chiller temperature setpoint is 20C 2 Verify the printer s compressed air supply a Verify that facility compressed air is on and connected to the gauge panel AIR INLET b The air pressure gauge label indicates the correct reading This should be 500 KPa 72psi 3 Verify that the system has an adequa...

Page 34: ...utomatically unzips the files and places them in the appropriate directories To set up a build packet you need to do the following Run the Build Setup application Add STL files parts to your build Reposition parts in the build volume Set build and part parameters Save the build packet file If Build Setup is run on a standalone computer export the bpf file to convert it to a bpz file and copy it to...

Page 35: ...ts of how a part is built You set scale and offset values in Scale Offset editor Scale compensates for material shrinkage Offsets compensates for width of laser beam As with part placement see Material Guide for more information about specifics for build part and scale values 3D Systems supplies sample build packets which can be used for reference when getting started Save and Verify Build Packet ...

Page 36: ... the section Set the MQC System to Full Cycle Mode on page 32 2 Close and latch the inner print chamber door and close the outer door All interlocks must be engaged to move the piston or roller 3 If the piston is not homed go to Sinter ManOps Piston Control and select Home Piston 4 If the roller has not been homed press the Roller button on the toolbar then press the Home Limit button in the dialo...

Page 37: ...appear in pop up windows you must acknowledge Message Types in Sinter TYPE COLOR DEFINITION Message Black Informational only or tells of a minor error These generally occur when you enter different data than the system expects or when a dependency is not met Advisory Yellow Something occurred that can turn into an alarm condition if not corrected in a specified time Warning Yellow Something seriou...

Page 38: ...ning you exit Build mode You cannot close this window while a build is running but you can minimize it Viewing Options on the Toolbar While the system is in Build mode the Build toolbar appears at the top of the main window as shown Click the Grid button to turn the display of grid marks on or off Click the zoom buttons to expand or contract the scale of the Build Viewer window Options on the View...

Page 39: ... dialog box Modifying Part and Build Profiles Click the Modify Build Profile or Modify Part Profile button to display a profile editor dialog box from the Build Setup application Modify parameters as described in the Build Setup Help NOTE You can find definitions of the parameters in the Build Setup Help In most respects these dialog boxes work just as they do in the Build Setup software with the ...

Page 40: ... below the plane such as adding or moving parts will not affect the current build although they will be saved and will affect future runs of this build packet Parts are initially displayed in Box view Running a Prime Cycle The Prime Cycle can only be run if the user has paused the build Click the Prime Cycle button in the Build Modify dialog to spread powder across the print bed without moving the...

Page 41: ...ng and Leveling Powder Just before you run your print use the Add Powder dialog box in Man Ops mode to add and level powder in the print chamber Adding powder creates a smooth powder bed on the floor of the print chamber To Add and Level Powder Use the Add Powder button to manually add a layer of powder to the print bed Before you can add a powder layer all these dependencies must be met The rolle...

Page 42: ...the machine NOTE You must perform an initial offline IR calibration to enable automatic real time recalibration during the print If recalibration requires too great an adjustment a message pops up advising you to perform offline calibration again when the print completes NOTE Once you perform a manual IR calibration the settings are saved in the system A manual IR calibration does not need to be p...

Page 43: ...of the lid must be scanned by the reader on the interface of the MQC System before it can be fed into the system For instructions on loading fresh material refer to the section Load Material from Material Container on page 31 Blending and Sending Material The MQC System automatically initiates a blend cycle when it has at least 20 kg of material At a 50 fresh ratio it requires 10 kg in the fresh b...

Page 44: ...b you can use either of the two following methods 1 In Build Setup check the MQC window in the Man Ops screen This displays the MQC System s status including the amount of available powder or 2 Check the MQC status in the Sinter Status window which also displays the amount of available powder REMOVING THE PRINT CAKE FROM THE PRINT CHAMBER The print cake can be removed from the print chamber either...

Page 45: ...ove the Laser Window by turning it counterclockwise turn and pulling it out of the top of the chamber Put it in a safe clean location and clean it before reinstalling it into the print chamber See the section Cleaning the Laser Window on page 59 5 Press the red Laser Window Baffle Plug into the top of the chamber see illustration 6 With the handle facing towards you fully insert the print cake cyl...

Page 46: ...sing the print cake open the outer and inner print chamber doors 11 Slide the Print Cake Tray underneath the cylinder as shown and latch the tray with the pull pins on the cylinder Align cart with print chamber Slide tray and cylinder onto cart 12 If the print cake is light enough it can be moved manually to the MQC System Otherwise use the Part Transfer Cart 13 Move and align the cart to the prin...

Page 47: ...line of the parts with a spatula and brush Ensure the sifter is running then brush unsintered print cake powder into the sifter When you can easily grasp a part carefully lift it Gently brush off the parts and place them on the breakout area of the MQC Sys tem Part Finishing After Breakout NOTE Consult your Material Guide for full details on part finishing After breakout remove and dispose of any ...

Page 48: ...e user to choose the mode of material handling for the MQC System Full Cycle will allow the MQC System and printer to control all material handling in fully automatic mode Local Cycle is the same as Full Cycle except that all printer powder requests are ignored by the MQC Choose Stop Cycle to turn material handling off Operational mode Run Full cycle Run Local Cycle Stop Cycle Main Control Operati...

Page 49: ...K Rotate knob to highlight and select press knob to return to previous menu Rotate the knob to switch between items Press and hold the knob down to return to Main Staus screen MQC System Main Status Screen The Main Control screen allows the user to Displays the current operational mode and other status information Shows amount of powder in MQC bins Kg and Liters and the amount of powder re quired ...

Page 50: ...obe The amount of powder required in the Fresh and Reclaimed bins to start a blend will vary based on the current refresh percentage MQC Main Control Screen The Main Control Screen allows the user to Navigate to the Operational Mode screen Load Fresh Powder into the system To do this the user must first scan the material RFID tag on the lid of the material container across the RFID reader on the f...

Page 51: ...ally recirculate the powder in the fresh and blended bins Local Cycle will allow the MQC System to operate the same way as Full Cycle mode except that all printer requests for powder are ignored by the MQC Stop Cycle prevents the MQC from blending powder recirculating powder in Fresh and Reclaimed bins or responding to printer requests for powder User should select Stop Cycle to Load Fresh Powder ...

Page 52: ...owder containers you must close and lock the Fresh Bin doors between each container 6 When finished with loading powder into the Fresh Bin return MQC to Full Cycle mode to blend powder or continue in Stop mode if you wish to change Replenish percentage or make any other changes to the setup parameters To change Replenish percentage 1 Quickly press and release knob to display the following screen 2...

Page 53: ...tion selection cursor 6 Push knob to change cursor from Select to Change mode and rotate to change value 7 Push knob again to go back to Select mode 8 Continue to rotate until the selection is adjacent to the OK and push knob again this will save your changes ...

Page 54: ... Cool by temp time Cool time min Cool temp Reset material data System Shutdown Diagnostics Material tracking Fresh bin diag Used bin diag Blend bin diag Sifter diag Generic I O diag Material Tracking Matl Name Matl density Min Fr Bl Max Fr Bl MaxRecircPeriod Used bin diagnostics This allows you to view status details of the components that comprise the handling of used material in the system See U...

Page 55: ...not Gate valve open closed Indicates if the gate valve for the blended material bin is opened or closed Transport level full not full Indicates whether or not the transporter for the blended material is full or not Fluidizing air on off Indicates whether or not the air responsible for fluidizing Fresh bin diag L door closed open R door closed open Doors unlocked locked Pwdr level full not full Gat...

Page 56: ...luid air on off Tport air on off Pinch S U bin closed open Pinch S Drum closed open Cycle start active inactive Cycle stop active inactive Shaker on off Pressure Generic I O diag Estop active inactive 24V Relay on off Red light on off Amber light on off Green light on off Logo backlight on off N2 supply v open closed N2 blanket v open closed PC1 temp PC2 temp DO temp PS temp ble for transporting t...

Page 57: ...ny procedures that are not covered in this section or that you are not fully trained and qualified to perform MAINTENANCE KIT With each ProX 500 3D Systems provides a maintenance kit for routine maintenance procedures Many of the tools you need for these procedures can be found in this kit PRINT CHAMBER MAINTENANCE Replacing Light Bulbs in the Process Chamber There are two light bulbs located on t...

Page 58: ...Use a non ignition vacuum cleaner 7 Clean the door with the tack cloth and vacuum the door and the window If necessary clean the window with ethanol or glass cleaner NOTE Use only soft cloths or paper towels and non abrasive cleaners on the inside of the print chamber window to avoid damaging the coating that prevents the laser beam from escaping during the print process 8 There are pull pins on t...

Page 59: ...urn the heater assemblies to their print position 18 Clean the laser window See the section Cleaning the Laser Window on page 59 Cleaning the Laser Window The laser beam passes through the laser window into the print chamber It is very important that all impurities are kept off the laser window Impurities can be burned onto the laser window decreasing the laser power available at the print bed Cle...

Page 60: ... Side of lens that needs to be cleaned Remove lid and set to the side Cover with lens tissue Remove and clean O Ring Replace into baffle assembly Turn the assembly over Remove lens and set on work table Set the lens aside on the work table This will be the side of the O ring that will need to be cleaned the most However both sides will be cleaned in this procedure 5 Remove the O ring and wipe it c...

Page 61: ...of the acetone pull it off gently to avoid streaking Discard the tissue Apply acetone to lens Gently wipe lens dry Replace lens Replace top ring and fasten with 2 5mm allen wrench Ensure O Ring is visible and lens is flush with housing Soak up excess acetone with lens tissue 17 Apply a small amount of acetone to the lens again 18 Fold up a lens tissue lengthwise to wipe the acetone off with 19 Gen...

Page 62: ...with the tip of the wet swab and rotating the swab 3 Use a dry swab to dry the IR sensor head by gently touching the IR sensor head with the tip of the dry swab and rotating the swab Cleaning the Black Body A clean black body will have a dark matte finish It is important to inspect the black body at least 3 times a week or after 40 hours of print time and clean if needed Powder deposit on a black ...

Page 63: ...Hepa Filter Exhaust Processing Module Filters Tools and Supplies Tack cloth New filters Non Ignition vacuum cleaner The exhaust processing module filters gas moving through the print chamber You access these filters from the back of the printer by loosening the thumb screws and removing the panel To clean or replace the filters Air Processing Module Active Charcoal Filter Particulate Filter 1 Open...

Page 64: ... of the enclosure Electrical Enclosure Filter 2 Stage Hepa Filter Also located at rear of MQC System 2 Stage Hepa Filter Hepa Filter Sock Filter Electrical Enclosure Filter Tools and Supplies Tack cloth New filters Non Ignition vacuum cleaner Replacing Electrical Enclosure Filter Air moving through the electrical cabinet is filtered from both sides of the cabinet You access these filters by loosen...

Page 65: ...as a fluid capacity of 5 liters 1 3 gallons It requires a mixture of one pint of OptiShield p n 110362 00 to one gallon of distilled water p n 9208 30021 Refer to the OEM documentation for detailed instructions Tank Lid Circulating Fluid Fill Liquid Level Air vent filter replacement Drain filter replacement Fluid replacement Cleaning the Chiller Air Vent and Changing the Air Vent Filter If the fin...

Page 66: ...s En cas du changement de la machine pas consenti sur par nous la déclaration perdra sa validité Description of the machine La description de la machine Machine type Usiner le type Serial Number Year of Manufacture Numéro de série Année de Fabrication Applicable EC Directives Les Directives applicables de CE Applicable Harmonized EC Standards Les Normes de CET Harmonisé applicables Manufactured in...

Page 67: ...3D Systems Inc 333 Three D Systems Circle Rock Hill SC 29730 www 3dsystems com 2015 3D Systems Inc All rights reserved pn 134012 00 Rev C ...

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