PERFACTORY Rapid Prototyping System Troubleshooting Guide PERFACTORY Machine Envisiontec GmbH Elbestraße 10 D-46768 Marl Germany Phone:+49 2365 915460 Email:support@envisiontec.de
Disclaimer This troubleshooting allows the customer to quickly solve problems with the PERFACTORY machine. The contents of this documentation is meant to provide people such as industrial designers, technical draftsmen, dental laboratory technicians, architects and model-makers - people involved in the making of and working with models - with speedy information about solving problems with the PERFACTORY machine. Please carefully read this troobleshooting manual. Keep this short instruction manual alongside your workstation for all eventualities. Envisiontec 1 offers a one year limited warranty from date of Purchase unless longer warranty periods are required by Law in the country of installation. Envisiontec warranties that the PERFACTORY System sold and all accessories with it are free from defects. Envisiontec s responsibility is limited to repairs or replacement of defective parts at our discretion. Envisiontec makes no warranties which extend beyond the descriptions contained in this Guide. The User assumes all risks and liability for results obtained by the user or implementation of the instructions described herein, whether used singly or in combination with other designs or products derived or resulting from the software licensed to the user by Envisiontec hereunder will not infringe the claims of domestic or foreign patents. Except for the negligence of Envisiontec, its agents, representatives or employees, user shall protect, indemnify and save harmless Envisiontec of and from any loss, cost, damage or expense arising from any claim that is in any way associated with the operation of the PERFACTORY system as described in this guide. Envisiontec shall not be liable for any special or consequential damages. Data presented in examples do not necessarily reflect the actual test results and should not be used as operating criteria. 1. Envisiontec does not accept any further warranty claims or modified warranty limitations. 2-12 Troubleshooting Guide Preliminary Issue 4/2004
UNDER NO CIRUMSTANCES THE MACHINE EMERGENCY BUTTON WILL BE PRESSED PRIOR TO MANUALLY SHUTING DOWN THE PROJECTOR IN THE PERFACTORY SYSTEM!! SEVERE DAMAGE WILL OCCUR IF THE PROJECTOR IS ABRUPTLY SHUT DOWN WITHOUT PROPER COOLING DOWN!! 3-12
Software (Situation Code: s.1) The Computer with the Perfactory Direct software module cannot connect to the Perfactory machine via Ethernet. 1. Look at you network parameters of your PC/ network IP address of the Perfactory should only differ in the last digit. Make sure that the selected IP adress is ONLY for the Perfactory and no other computer in the network has the same. Also, both IP addresses are using the exact gateway submask (ie: 255.255.255.0). The subnet mask numbers should match exactly. 2. Ensure you are using the correct cable to connect the machine: a) Use at least a type Cat 5 cable which is double screened. b) Check that you are using a cross over cable if it is a direct connection between the computer and the Perfactory, or a patch network cable if the Perfactory is on a network. c) The cable length should be smaller than 10 m. 3. Check to make sure that the correct cable use is not defective and fully snaps into the socket at the computer and the Perfactory PC. 4. Try to use the ping command to see the Perfactory machine from the Pre-processing computer: a) Go to "Start" at you windows system (Bottom lefthand corner) b) Select "programs" c) Select "accessories" d) Select "command prompt" e) In the text box type the following at the prompt "ping <ip address of Perfactory machine>" f) After entering the command the PC will try and contact the machine directly. If the response is "destination host unreachable" the test has failed. A positive response will result in the following text appearing "reply from <ip address>: Bytes=32" 5. Make sure that you rebooted the Perfactory or the pre-processing computer after you entered a new IP address or a Submask for the changes to take effect. Software (Situation Code: s.2) The Perfactory machine is connected to the PC under "Perfactory Direct", but when we "add job", I can see the job on Perfactory Direct, but when I push the orange start button on the machine keypad, the message " NO JOB FOUND" appears. Go to Network settings. Do not make any changes to the IP address or the submask. Push Enter when prompted to reboot the system, and try sending the job again. 4-12 Troubleshooting Guide Preliminary Issue 4/2004
Projection Unit (Situation Code: p.1) After installing a new light bulb, it is not possible to achieve the brightness level which could achieved if the previous light bulb is re-installed. 1. Remove the light bulb and look through the hole at the yellow filter to see if there is a problem with the glass filter such as cracking or milky spot at the entry point of the light. If yes, please contact your local service provider to change that glass filter. 2. If you go to projector brightness and adjust the level from minimum of zero to a maximum of 200, then the power measured should also change, other wise increase the lamp power by 10% and try again in 5 minutes, then you should see a change in the power when adjusting the brightness. If you do not see a change, then the pc-board is defective. Please contact your local service provider to change the board. Projection Unit (Situation Code: p.2) After installing a new light bulb the projector will not ignite. Please check with Envisiontec that the projector has been updated with the new hardware to eliminate any ignition problems. Projection Unit (Situation Code: p.3) The projector runs for a few minutes then shutting down. 1. The projector is over heating because one of the two fans on the projector has failed. This is most likely to occur if the fan that is responsible for cooling the bulb fails. Please contact your local service provider to change the fans. 2. The temperature sensor for the projector is defective. Please contact your local service provider to change the sensor. Projection Unit (Situation Code: p.4) After installing a new light bulb no build process will done properly and constantly on the Perfactory machine. 1. Check to make sure that the light bulb is properly installed, that is the nuts on both screws are all the way to the back of the thread prior to screwing into the projector. 2. Check to see that the if you go to projection brightness, the power after the projector is on for more than 20 minutes you have less than 10 mw in power fluctuation at the samebrightness level. 3. Check to make sure that when you choose check "Gray Mask", and let it sit for more than ten minutes check for any kind of flickering. In all cases change light bulb. 5-12
Projection Unit (Situation Code: p.5) The projected image is only a diffuse round circle as. 1. Check if you have removed the cover of the lens of the projection unit. 2. Check if the lens is assembled correctly at the projection unit. 3. Adjust the focus (ONLY Mini and Standard System!). Projection Unit (Situation Code: p.6) The projection unit is working, the lamp is on but I cannot see an image. 1. Check if the black velvet is covering the lens of the projection unit. 2. Check if the cap of the lens is removed. Projection Unit (Situation Code: p.7) The projection system is running but the lamp will not ignite. 1. Check if the lamp is assembled correctly. Please make sure, that the front-black cover for the light bulb is properly installed so that the two threaded screws are properly adjusted and pressing the two safety switches to allow for ignition. 2. Check if the lamp is not or not correctly mounted. 3. Check if the lamp is defective. 4. Please check with Envisiontec that the projector has been updated with the new hardware to eliminate any ignition problems. Projection Unit (Situation Code: p.8) The lamp/image is flickering. 1. Lamp is too old, take a new one. 2. The projector brightness is too small. Adjust it to a higher level. Projection Unit (Situation Code: p.9) Projected image is not sharp. 1. Image is out of focus. Using motorised zoom/focus to re-adjust the focus (ONLY Standard). 2. Lens is not assembled correctly in the projection unit (ONLY Multilens). Projection Unit (Situation Code: p.10) Time out message after starting projector. 1. Check if black main power switch is positioned correctly at I. 2. Use black main power switch to turn the projector off and on. Start projector manually. 6-12 Troubleshooting Guide Preliminary Issue 4/2004
Projection Unit (Situation Code: p.11) The projection brightness is too dark. 1. Remove the light bulb and look through the hole at the yellow filter to see if there is a problem with the glass filter such as cracking or milky spot at the entry point of the light. If yes, please contact your local service provider to change that glass filter. 2. If you go to projector brightness and adjust the level from minimum of zero to a maximum of 200, then the power measured should also change, other wise increase the lamp power by 10% and try again in 5 minutes, then you should see a change in the power when adjusting the brightness. If you do not see a change, then the pc-board is defective. Please contact your local service provider to change the board. 3. Lamp is too old. Change lamp. 4. Cover glass between projection unit and polymer basement is polluted. 5. Projection unit is polluted. If yes, please contact your local service provider to clean the projection unit. Projection Unit (Situation Code: p.12) Re-calibration of the Gray Mask will not improve the homogeneity of the brightness. 1. Ensure that you position the sensor centric to every projected point. 2. Check if the projected points are too small. If yes, then the wrong lens is used (ONLY Multilens). 3. The electrodes of the lamp are shifted extremly from each other. If yes, change lamp. 4. The measured brightness should be stable before you confirm the values. 5. If the measured brightness is not stable check if the output is stable. 7-12
Machine Handling (Situation Code: m.1) There is a small box that is always ON at the front of the build envelope during the build process, and I cannot read what it says (Can read the box on standard machine "LAMP"). How do I get rid of it? All machines with firmware prior to version 823 will not reset the lamp hours on the projector. Please contact your local service provider to Install latest firmware. Machine Handling (Situation Code: m.2) The machine hangs up during the build process, and I cannot do anything except push the emergency button and shut down and restart the job from the beginning. If the machine is still powered up and the projector illuminated press the power button on the projector to turn off the bulb without damage. Then turn off the power with the emergency stop button! 1. Check if the machine can connected by doing a reconnect with "Perfactory Direct". If not contact your local service provider. 2. Check if there was a power cut/loss during the build. 3. Connect a keyboard to the embedded PC of Perfactory machine. Machine Handling (Situation Code: m.3) Upon machine power up, the machine will not start the procedure of finding reference point by moving the platform to the home switch, and moving the tilting mechanism down, then up. Check that the machines hood is closed properly. Machine Handling (Situation Code: m.4) Cannot turn on the machine. 1. Check if the emergency stop button is not pressed. 2. Check if the main power fuse on the Perfactory is not defective. 3. Check if the power cable is plugged correctly and is not defective. 4. Check the power supply. 5. Check if the voltage needed by the Perfactory machine (look at the type plate) is the same your power supply will give. Machine Handling (Situation Code: m.5) The size of the projected image is not correct. 1. Select correct lens in menu (ONLY Multilens). Select correct build envelope size (ONLY Standard). 2. Wrong lens was assembled at the projection unit. 3. Check if the properties of the lens are set correctly. If not re-calibrate these properties. 4. Please contact your local service provider with serial number of the Perfactory machine and the projection unit. 8-12 Troubleshooting Guide Preliminary Issue 4/2004
Machine Handling (Situation Code: m.6) The weight of the balance is not correct. Weight sensor is not functioning properly. Calibrate the weight sensor. Machine Handling (Situation Code: m.7) AutoFill mechanism is not working. 1. Enable AutoFill function in the menu. 2. No material cartridge is mounted cartridge on the hook of the balance arm. 3. The cap of the cartridge is not removed. 4. The stopper up to the bottom of the cartridge is not open. 5. The weight sensor or fill sensor need calibration. Machine Handling (Situation Code: m.8) Filling height is wrong. 1. Check if you use the polymer basements with the black dot. 2. Check if the machine is correctly leveled using the integrated spirit level. 9-12
Building Process (Situation Code: b.1) Could not build any parts completely. 1. Check if gray mask average power is above Critical energy of the material used, if not calibrate 2. Check if the offset is set correctly. If not set the offset correctly. 3. Check that the tilting mechanism is working properly (e.g. no resin on two front and two back screws). If not, please contact your local service provider 4. Check the gray mask for any flickering after 10 minutes of "Show Gray Mask", replace bulb if problem persists, replace projector 5. Check to make sure that your exposure parameters and layer thickness correspond to each other. 6. Check if enough material is available to build the parts. 7. Check if lamp is on after build process. To check that disable automatic shut down after build process. If lamp is off check color mode of the LED at the projection unit: a) If LED is constantly red the lamp is too old. Use new lamp. b) If LED is blinking red-yellow there was a temperature problem. Ensure that room temperature is not too high. Check, that exhaust pipe has no leak. 8. Finally check the machine power during the build to see if there is any variation in the power. Building Process (Situation Code: b.2) Parts will not stick at the building plate. 1. Check if gray mask average power is above Critical energy of the material used, if not calibrate 2. Check if the offset is set correctly. If not set the offset again. 3. Check that the polymer basement and the building plate are coplanar. 4. Check that the tilting mechanism is working properly (e.g. no resin on two front and two back screws). 5. Check the gray mask for any flickering after 10 minutes of "Show Gray Mask", replace bulb if problem persists. 6. Check that your exposure parameters and layer thickness correspond to each other. 7. Check that you are using the proper exposure time for the resin you are curing at the slice thickness you have chosen. 8. Check the settings for the waiting time before 10-12 Troubleshooting Guide Preliminary Issue 4/2004
leveling. Ensure that this value is not to small. 9. Check the material batch number and contact Envisiontec. 10. Check that the building plate is clean. 11. Check that the polymer basement is not damaged. 12. Check the machine power during the build to see if there is any variation in the power. 11-12
Part Quality (Situation Code: q.1) The small holes seem to be closing during the build process. 1. Check to make sure that you are using the proper exposure time for the resin you are curing at the slice thickness you have chosen. 2. Check the projector focus to confirm that the projector is focused to the maximum using the auto focus on the MINI, or by raising or lowering the projector on the MINI systems. In case of the mini systems, please enter the correct new envelope size for the focus image in the "material" and "machine" files under "Perfactory RP" in the Perfactory Software Suite. Part Quality (Situation Code: q.2) There is a lot of jelling in the basement and on some areas of the part even though my offset is correct and the basement and the material are new. 1. Check that the tilting mechanism is working properly (e.g. no resin on two front and two back screws). If not, please contact your local service provider. 2. Check if the offset is set correctly. If not set the offset correctly. 3. Check material batch number and contact Envisiontec. Part Quality (Situation Code: q.3) Bigger details at the base of the built part. Burn-in layers used to build model layers. The longer exposure time will create thicker structures. Do not use Burn-in layers as model layers. Part Quality (Situation Code: q.4) Built part at the base strong and at the top soft. Lamp is old and changes its brightness behave during build process. Use new lamp. Part Quality (Situation Code: q.5) Built part is soft. 1. Lamp is old and changes its brightness behave during build process. Use new lamp. 2. Light intensity is too small. Increase light intensity. 12-12 Troubleshooting Guide Preliminary Issue 4/2004