Dws Manuale Dw008 en

DWS S.r.l. Via Lago di Levico, 3 36010 Zan (VI) ITALY Tel.
+39-0445-372323 Fax +39-0445-372191
STEREOLITHOGRAPHY MACHINE
Year of construction: 2011
Serial Number:
INSTRUCTION MANUAL FOR USE AND MAINTENANCE
DWS S.r.l. Via Lago di Levico, 3 36010 Zan (VI) ITALY Tel. +39-0445-372323 Fax +39-0445-372191 P.IVA - C.F. IT 03424670242
DWS S.r.l. Via Lago di Levico, 3 36010 Zan (VI) Italia

Tel. +39(0)445.372323 - Fax +39(0)445.372191 This manual is property of DWS Srl All rights reserved.
MACHINE DATA Machine type Model Serial DATA MACHINE No. Year of construction DIGITALWAX STEREOLITHOGRAPHY MACHINE DW008 2011
GENERAL INDEX
1 GENERAL INFORMATION.. 1.1 INTRODUCTION . 1.1.1 Importance of this manual ... 1.1.2 Persons concerned with this manual . 1.1.3 Information given in this manual . 1.1.4 Terminology IDENTIFICATION OF MACHINE AND MANUFACTURER ..... 1.2.1 Manufacturers details .. AFTER-SALES SERVICE . 6 6 6 6 6 7 7 8 8 9 9 9 10 11 13 13 14 14 15 16 16 16 17 18 18 18
1.2 1.3 2
MACHINE DESCRIPTION ... 2.1 MACHINE DESCRIPTION . 2.1.1 General ... 2.1.2 Nomenclature . 2.1.3 Safety devices 2.1.4 Control and work station .. 2.1.4.1 Control station .. 2.1.4.2 Laser supply unit .. 2.1.4.3 Work station .. TECHNICAL DATA TABLE ...
2.2 3 4
PRESCRIBED MACHINE USE ... SAFETY AND PREVENTION .. 4.1 4.2 4.3 PROFESSIONAL PROFILE OF PERSONNEL ASSIGNED TO MACHINE OPERATION . RESIDUAL RISKS .. SAFETY AND ACCIDENT- PREVENTION INSTRUCTIONS . 4.3.1 General instructions .. 4.3.1.1 Instructions for machine use ..
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4.4
4.3.1.2 Instructions for machine maintenance . Precautions for resin treatment ... General safety precautions .. Definitions and symbols used in this manual Safety signs fixed to the machine ... Noise ... Reference standards 4.3.7.1 Directives concerning machine safety .. 4.3.7.2 Directives concerning safety at the workplace 4.3.7.3 Directives concerning personal protection .. 4.3.7.4 Directives concerning environmental protection . 4.3.7.5 Safety standards .. SAFETY DEVICES . 4.4.1 Fixed guards .. 4.4.2 Movable guards . 4.4.3 <ON/OFF> button . 4.4.4 Power supply switch . 4.4.5 Power supply female plug 4.3.2 4.3.3 4.3.4 4.3.5 4.3.6 4.3.7
19 20 21 21 22 22 22 22 23 23 23 23 23 23 23 24 24 24 25 25 25 25 25 25 25 26 26 26 27 27 27 28 28 30 30 31 31 31 31 32 32 33 34 34 35 35 36 36 36 37
LIFTING, TRANSPORT AND STORAGE . 5.1 5.2 5.3 5.4 GENERAL INSTRUCTIONS . MACHINE LIFTING . 5.2.1 Lifting the packed machine .. 5.2.2 Lifting the unpacked machine . TRANSPORT ... STORAGE
ISTRUCTIONS FOR MACHINE INSTALLATION .. 6.1 6.2 6.3 GENERAL INSTRUCTIONS . CHARACTERISTICS OF INSTALLATION SITE MACHINE POSITIONING AND CONNECTIONS . 6.3.1 Machine positioning .. 6.3.2 Hardware connection 6.3.3 Electrical connection . PRELIMINARY ACTIONS ...................................................................................................... RESIN TANK INTRODUCTION/EXTRACTION . BUILDING PLATFORM REMOVAL/FITTING
6.4 6.5 6.6 7
MACHINE SETTING FOR WORK .. 7.1 7.2 7.3 FOREWORD CHECKS ON PARAMETERS ... CHECKS ON SAFETY DEVICE OPERATION ..
MACHINE OPERATION AND MODEL TREATMENT 8.1 8.2 GENERAL INSTRUCTIONS . 8.1.1 Precautions for resin treatment ... MODELLING CYCLE AND EXTRACTION OF THE MODEL .. 8.2.1 Filling the resin tank and preparing for modelling 8.2.2 Machine starting. 8.2.3 Model forming process . 8.2.3.1 How to start forming 8.2.3.2 Data transfer from the computer ... 8.2.3.3 How to stop forming and extracting the model TREATMENT OF THE RESIN .................................................
8.3
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8.4
8.3.1 Life of the resin.. 8.3.2 Cleaning of the resin tank and removal of the resin unused.. 8.3.3 Use and maintenance of the resin tank.. TREATMENT OF THE MODEL AFTER CONSTRUCTION 8.4.1 Cleaning a model before the secondary solidification . 8.4.2 Model removal
38 39 42 44 44 44 45 45 45 46 46 47 47 48 48 48 48 48 48 49 49 49 49 50 50 50 51 51 51 51 52 53 55 56 56 59 64 64 64 65 66 69 69 69 69 69 70 70 70 70 72 73
CLEANING AND MAINTENANCE . 9.1 9.2 9.3 9.4 GENERAL INSTRUCTIONS . CLEANING THE MACHINE .. 9.2.1 Operating methods 9.2.2 Summary of cleaning operations MAINTENANCE .. FAULT-FINDING .
10
ADDITIONAL INSTRUCTIONS .. 10.1 10.2 10.3 10.4 10.5 GENERAL INSTRUCTIONS . INFORMATION ON MACHINE DISMANTLING ALTERATIONS SALE . HOW TO ORDER SPARE PARTS ..
11
ENCLOSURES .. 11.1 RESIN SAFETY PRECAUTIONS................... 11.1.1 First aid measures ...................... 11.1.2 Fire-fighting measures... 11.1.3 Measures in case of resin accidental spillage .. 11.1.4 Handling and storage 11.1.5 Checking personal exposure/protection 11.2 DIGITALWAX 008 CONTROLLER .. 11.2.1 Introduction.. 11.2.2 Installation 11.2.2.1 System requirement. 11.2.2.2 DigitalWax 008 Controller installation and connection to the machine 11.2.2.3 Software installation for USB hardware protection key (Sentinel) 11.2.2.4 Connection between PC and DigitalWax 008.. 11.2.2.5 Setup of the pc for DigitalWax 008. 11.2.2.5.1 Procedure for Windows XP 11.2.2.5.2 Procedure for Windows Vista/Seven 11.2.3 Controls description... 11.2.3.1 Introduction.... 11.2.3.2 Controls of DigitalWax Controller... 11.2.3.3 Machine controls... 11.2.4 Procedure for the zero setting of the machine.. 11.3 DIGITALWAX FILE GENERATOR .. 11.3.1 Introduction.. 11.3.2 Installation 11.3.2.1 System requirement. 11.3.2.2 DigitalWax File Generator installation... 11.3.3 DigitalWax File Generator Controls. 11.3.4 Visualization of a .MKR file.. 11.3.5 Useful advice.. 11.3.6 How to create the .MKR file.. 11.4 REPRODUCTION OF EC CONFORMITY DECLARATION 11.5 REPRODUCTION OF EC MARKING PLATE
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1
1.1 1.1.1
GENERAL INFORMATION
INTRODUCTION Importance of this manual The manufacturer reserves the right to update production and relevant manuals without being obliged to update previous production and manuals, apart from exceptional cases. This manual is an integral part of the machine (2006/42/EC, art. 5, par. 1). This manual is essential for machine use and maintenance. This manual must be kept until final machine demolition. Should it be lost or damaged, a new copy can be requested to DWS or the dealer. This manual must be kept close to the machine, in a safe place known to the personnel assigned and accessible only to these. It must be handled with care to prevent it from being damaged; it is forbidden to remove, rewrite or in any way alter the pages or their contents. This manual must be updated whenever updating documentation is provided. This manual must be handed over to the purchaser if the machine is sold to another user. This manual reflects the state of the art at the time the machine is marketed, and cannot be considered inadequate only because it is subsequently updated in the light of new experience. If alterations are made to the machine, the manual will be updated; in this case new updating documentation will be provided. It is the users duty to eliminate obsolete copies. We recommend you use original spare parts. A product information sheet for the resin is enclosed with this document. The manual about DigitalWax 008 Controller is enclosed. The wiring diagram is enclosed separately.
1.1.2
Persons concerned with this manual Personnel assigned to handling and transport Personnel assigned to installation Personnel assigned to operation (operators) Personnel assigned to maintenance Personnel assigned to final demolition.
1.1.3
Information given in this manual General safety instructions Description and technical data Appropriate and inappropriate machine use Machine handling and transport Preparation of the place of installation Installation and connection to power sources Preparation and operation Maintenance operations How to order spare parts Final demolition.
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1.1.4
Terminology The specific terms used in this manual are explained here. Resin stereolithography obtained by optic forming process A 3D model is divided into horizontal sections. The laser beam is projected onto the liquid resin, along the image of each section, to solidify it layer by layer. This process is repeated in sequence to build up the layers. This allows the machine to make a 3D resin model that is an exact reproduction of the CAD model it was made from. Secondary solidification Even though the model built by the machine is perfectly formed, it might need to be exposed to UV light to fully cure the resin. Forming data (NC data) The image data of the model to be produced is required by the machine in order to carry out the model forming process. (NC is the abbreviation of Numerical Control). MKR File format for DigitalWax 028. It includes all parameters for slicing, hatching and tool compensation. CAD Computer Aided Design Software that allows using the computer to draw. CAM Computer Aided Manufacturing A system that allows manufacturing automation by means of a computer. A CAM system generates NC data which are transmitted to machine tools and automatic industrial devices.
1.2
IDENTIFICATION OF MACHINE AND MANUFACTURER A metal plate (fig. 1), fixed to the back of the machine, bears the information required by the EC MARKING (CEI EN 60240-1:2006, point 16.4): - Manufacturers name and address - Agents name and address - Description of the machine - Kind of machine - Machine model - Serial number - Year of construction - Power supply, phase, maximum electrical load - Short-circuit nominal characteristics of the equipment It is forbidden to remove or replace the EC MARKING. DWS must be informed if the plate has been damaged or removed. For all types of technical identification and/or spare parts, please refer to the identification data given on the EC plate.
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1.2.1
Manufacturers details DWS S.r.l. Via Lago di Levico, 3 36010 Zan (VI) ITALIA Telefono: ++39.0445.372323 Telefax: ++39.0445.372191
DWS S.r.l. Via Lago di Levico, 3 36010 Zan (VI) ITALIA Telefono: +39(0)445.372323 Telefax: +39(0)445.372191 Macchina: Modello: Tipo: Matricola No.: Anno di costruzione: Tensione di alimentazione (V): 1110/230 V a.c. 50/60 Hz Fig.
Macchina per stereolitografia DIGITALWAX DW008
Fig. 1
1.3
AFTER-SALES SERVICE For any enquiry, request for assistance from technical personnel, and spare parts, the customer can contact DWS or the dealer from whom the machine was purchased.
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2.1 2.1.1
MACHINE DESCRIPTION
MACHINE DESCRIPTION General The stereolithography machine creates models of three-dimensional pieces in plastic material by means of a photosensitive resin formed using ultraviolet rays produced by a laser source. With this machine it is possible to pass from a geometrical-mathematical three-dimensional model produced by any 3D CAD system to a dimensionally perfect prototype within a few hours. The machine uses an extremely low-powered laser (class 3B) specifically produced for this application. The machine has three mobile axes which enable three-dimensional models to be created by moving the laser and building platform. These axes are: - X axis moves the laser unit transversally (to the left/right of the operator); - Y axis moves the laser unit longitudinally (forward/backward with respect to the operator); - Z axis (called lift) moves the building platform support vertically The geometrical and mathematical data of the model to be created are elaborated by the proprietary software of DigitalWax machine. The files for machine operation are generated by DigitalWax Controller. The software must be installed on a computer and the computer is connected with the machine by data transfer cable. The machine is connected with a 230V power supply socket by means of a cable having IEC plugs; the cables are supplied as standard. The machine is made up of the following parts: the resin tank, the laser movement unit and the building platform unit. The resin tank is fixed, located over the laser unit, and is transparent so as to allow the laser beam to pass through to solidify the resin. The solidified resin rises up and adheres to the building platform, for a measure corresponding to the thickness of the solidified layer. Then the process is repeated when another layer of resin solidifies, and so on.
Platform support
Building platform Fig. 2 Resin tank
Fig. 2
Liquid resin Laser head
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2.1.2
Nomenclature Reference to fig. 3 (external parts) 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) Access door to the forming area, with safety switch and interlocking device Extractable resin tank Luminous <ON/OFF> start/stop button (it supplies the auxiliary units with power) Red LED indicating <DOOR OPEN> Yellow LED indicating machine in <ERROR> or <EMERGENCY STOP> White LED indicating alive <LASER> (power on) EEC 22 plug for 230V 50 Hz power supply Ethernet plug for connection to the computer <I/0> power supply with line fuses Line fuses Adjustable feet.
4 1
5 6
13
Fig. 3
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Reference to fig. 4 (accessories supplied as standard and various parts) 1) Three-pole power supply cable, EEC22 female socket and EEC7 3-pin plug, 230 V a.c. 50 Hz 2) Network interface cable between computer and machine
Fig. 4
2.1.3
Safety devices These safety devices are described in a special chapter, Chap. 4.4 SAFETY DEVICES. Here follows a list of the main safety devices present on the machine (fig. 5): 1) Machines door with safety glass 2) Safety switch with interlocking device connected with the access door to the forming area. If the door is open, the machine does not work. Door opening with the machine in operation is inhibited by the locking device. 3) <ON/OFF> start/stop button (supplies auxiliary units with power). 4) General power supply switch .
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1 2
Fig. 5
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2.1.4
Control and work station A) The machine control station is in front of the computer (A fig. 6). B) The work station (from where to control processing, model unloading, machine preparation and resin loading) is in front of the machine. The control and the work station are usually very close.
Fig. 6
Fig. 6
2.1.4.1
Control station The machine is operated and controlled by a computer, which is interfaced by means of the appropriate cable. All the operating parameters, as well as starting and stopping the machine work cycle, are managed from the computer, using the DigitalWax 008 Controller software. For all machine functions, refer to the software users manual. Once the work cycle has been started, the machine works automatically without requiring any further action from the operator. After completing the model, the machine stops automatically. Control devices on the machine (fig. 7): - Luminous <ON/OFF> button: it starts and stops the machine (ref. 1) White <LASER> LED indicating laser in operation - power on - (the machine is carrying out a work cycle) (ref. 2) - Yellow LED indicating machine in <ERROR> (ref. 3) - Red <DOOR OPEN> LED indicating door open (ref. 4) - <I/0> power supply switch (ref. 5)
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3 4 4
Fig. 7
2.1.4.2
Laser supply unit All the laser and laser operating parameters are managed from the computer, by means of the DigitalWax 008 Controller. For all laser functions, refer to the software users manual. The laser can only work with the access door to the forming area (ref. 1 fig. 3) closed. If the door is open when the machine is supplied with power but not in operation, the LED (4 fig. 7) is switched on. The door has a safety switch with an interlocking device on the control circuit (which stops it from being opened when the machine is in operation. In the case where the door needs to be opened with the machine in operation (e.g. to check the model or add the resin), the work cycle must be interrupted and the interlocking switch excluded by means of the software menu controls; the machine will complete the solidification process under way and will stop at a preset point. This will make it possible to check the presence of the model, the processing stage, the resin level in the resin tank, etc. To restart the work cycle, close the door and activate the appropriate software controls.
2.1.4.3
Work station The operator can only access the forming area by opening the door located in the top part of the machine (1 fig. 3). The door can only be opened when the machine is stopped by means of the appropriate software control and the laser is deactivated.
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2.2
TECHNICAL DATA
GENERAL TECHNICAL CHARACTERISTICS Power supply voltage (PC) Power supply frequency (PC) Total machine mass Overall machine dimensions Width Depth Height Axis stroke X Y Z LASER CHARACTERISTICS Power developed in continuous wave operation (CW) Power developed in pulsed mode operation Wave length Class Electric current intensity at beginning of oscillation (average) Electric current intensity during operation (average) Working voltage (average) Radiation angle Working temperature INSTALLATION SITE CHARACTERISTICS Temperature during operation Humidity during operation V a.c. Hz kg mm mm mm mm mW mW nm mA
mA V
110/230 50 40 380 x 495 x 560 65 65 65 30 400/415 3B 90 85 4,6 8 22 30
Horizontal Vertical C
25 40
WARNING: When the machine is operating, the temperature and humidity must remain within the values indicated at all times. Laser power varies with the change of temperature in the environment. A change in temperature ranging from 1 and 4C can reduce laser efficiency. During machine operation, temperature changes must be minimised. WARNING: In order to prevent external vibrations from affecting the laser and model formation, install the machine at an adequate distance from any sources of vibration and on stable surfaces.
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PRESCRIBED MACHINE USE This stereolithography machine has been designed to create three-dimensional models of resin by solidification of a liquid photosensitive resin using ultraviolet rays produced by a laser source. Other types of processing and materials are not compatible with the machine characteristics. WARNING - It is compulsory to use only the type of resin envisaged and supplied by DWS or the authorised dealer (see the product information sheet enclosed with this document). - The use of resin from other suppliers creates problems with machine operation and model forming, as well as problems with or damage to the machine itself and its delicate parts. - The use of resin from other suppliers causes the warranty on the machine supplied by DWS to expire; moreover, it relieves DWS of all responsibility for damage or injuries caused by the machine to persons, things or the machine itself. Use the resin following the precautions and warnings given in this manual. Avoid any direct contact whatsoever with the skin and eyes.
4
4.1
SAFETY AND PREVENTION

PROFESSIONAL PROFILE OF PERSONNEL ASSIGNED TO MACHINE OPERATION WARNING The operator must have attended a training course held by DWS technicians after machine installation. Operator (assigned to machine operation) Specialised and suitably trained person, able to carry out the following with the machine operating under normal conditions: a) Using the software (ordinary use) installed on the interface computer b) Preparing the resin c) Filling and emptying the resin tank d) Removing the model from the building platform e) Cleaning and finally solidifying the model f) Replacing the resin g) Cleaning and preparing the machine. The operator must also be able to carry out simple ordinary maintenance jobs (cleaning, lubrication, etc.) and adjustments, as well as machine operation starting or restoring after a compulsory stop. Technician from DWS or from authorised DWS dealers Qualified technician made available by DWS to carry out operations which require specific qualifications and skills (programming, adjustments, extraordinary maintenance, replacement of broken or damaged components, etc.). Qualified worker Specialised and suitably trained person assigned to handle and lift loads, and able to use all lifting equipment in full observance of safety standards.
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4.2
RESIDUAL RISKS The machine does not present any residual risk whatsoever, on the condition that it is used according to the directions given in this manual and that no component is tampered with, especially the laser. Moreover legal requirements must be complied with as far as the use, stocking and disposal of waste, particularly special waste (resin) are concerned). RESIDUAL RISK - DANGER - Risk of injuries caused by crushing, entanglement and collision against the movable parts or between the movable and fixed parts of the machine. - Risk of injuries caused by the laser source. The only residual risk constantly present does not concern the machine directly but the product used to construct the model that is the resin, during handling. DANGER - Strictly avoid touching the resin directly with your hands. Wear protective gloves. - If the resin comes in contact with the skin, it could give rise to allergic dermatitis. - If the resin comes in contact with the eyes, rinse with plenty of water for about 15 minutes, then go straight to the hospital Emergency Department. The following inherent dangers are absent from the machine (reference UNI EN 12100): - mechanical dangers - electrical dangers - dangers due to high noise levels - dangers due to heat - dangers due to vibration - dangers due to radiation; a few examples are: dangers generated by direct or reflected laser beam dangers generated by ionising radiation dangers generated by collateral radiation (UV, microwaves, etc.) produced for example from impulse lights, electric discharge tubes, or power sources in RF; dangers generated by secondary radiation reflected by targets because of the effect of the beam (the wave length of the reflected radiation may be different from that of the beam). - dangers generated by materials and substances, such as: dangers due to products used in the machine (for example laser gases, laser dyes, solvents); dangers resulting from the interaction between the beam and material (for example fumes, particles, vapours, deposits), fire or explosion; dangers deriving from associated gases used to contribute to the laser-target interactions and from any fumes produced; these dangers include explosion, fire, toxic effects and rarefaction of oxygen. - dangers caused by failure to observe ergonomic principles during the machine design stage. The following dangers created by external factors (interferences) are absent on the machine. Installation conditions and the environment in which the machine operates may cause the machine to malfunction, thereby giving rise to dangerous conditions and/or making the intervention of a person inside the danger area necessary. Further environmental interferences include: - temperature - humidity - impact/external vibrations - vapours, dust or gas coming from the environment - electromagnetic disturbances or disturbances in radiofrequency
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4.3
interruption or oscillation of mains voltage insufficient compatibility or integrity of hardware/software.
SAFETY AND ACCIDENT-PREVENTION INSTRUCTIONS Failure to observe these instructions and the information given in chap. 9 CLEANING AND MAINTENANCE or any tampering with safety devices shall relieve DWS of any responsibility whatsoever in the case of accidents, damage or machine malfunction.
4.3.1
General instructions It is essential that the operator is fully acquainted with the way all the controls work before putting the machine into operation. Moreover, the operator must know how to carry out all the operations described in this manual, ensuring that he has properly understood the safety standards and how to apply them correctly during machine use and maintenance. Strictly observe all the information given in the following document and comply with general EEC and national safety and accident-prevention standards. The customer must inform DWS in the case where faults or malfunctions are found in accident-prevention systems, as well as any presumed danger. Refer to EEC and national/local laws for the disposal of resin and other toxic substances. Handle the resin and other products used on the machine with care. Do not dispose of them by pouring them into drains, but according to regulations set out by the legislation in force. The machine must only be used by operators who have taken part in the training provided by DWS technicians. It is forbidden to remove the safety devices and guards installed on the machine. Do not make any alterations to the machine for any reason whatsoever; in the case of malfunction due to any such alterations, DWS shall be relieved of all responsibility. Do not alter software parameters in order to achieve different performance to the one prescribed and programmed during design and testing. Temperature and humidity of the environment where the machine is installed must fall within prescribed parameters (see chap. 2.2 TECHNICAL DATA TABLE). The machine must only be used for the purpose it was designed for (see chap. 3 PRESCRIBED MACHINE USE). The operator must not carry out operations of his own initiative which do not fall within his competence. The operator is obliged to inform his superior of any problem or dangerous situation that may arise. The personnel must observe all the danger and caution signs fixed to the machine.
4.3.1.1
Instructions for machine use
In the case of dangerous situations (immediate or actual danger) stop the machine by means of the software, press the <ON/OFF> button (1 fig. 8) and disconnect the power supply by means of the <I/0> switch (2 fig. 8). If the outer part of the machine becomes very hot or smokes comes out of the slits, stop the machine immediately by means of the software, press the <ON/OFF> button (1 fig. 8) and disconnect the power supply by means of the <I/0> switch (2 fig. 8). Finally, also unplug the power supply plug (3 fig. 8). Do not place the machine near sources of heat or fire. Do not move the machine when it is operating. When the machine is in operation, do not cover it with covers or anything else, in order to allow the heat to be exchanged through the slits. For connection to the computer, only use the cable supplied as standard; if this is broken or damaged, request a new one from the machine manufacturer.
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Do not use damaged or ruined interface cables. Do not place weights on the cable, bend it or tamper with it. The area on which the machine stands must be kept clean and free of obstruction at all times. Every day, before starting the machine, check that all the control and safety devices are operating properly. It is forbidden to try and start the machine with the door open or not properly closed. Start the machine only after checking that there are no foreign bodies inside the forming chamber. Do not lean or put weight on the door when it is open. Do not place weights on the appliance. Do not disconnect the interface cable or the computer when the machine is in operation. Do not open the door when the machine is in operation. Take care not to damage or scratch the resin tank surface. Damage to the resin tank may jeopardise the successful outcome of the forming process. At the end of every work cycle, disconnect the power supply. Then proceed to clean the machine. When the machine is not used for a long time, disconnect the computer interface cable. Never use resins with characteristics which are different from those set out in the product information sheet, prescribed by the manufacturer and recommended by DWS. The information sheet is enclosed with this document.
2 1
Fig. 8
4.3.1.2
Instructions for machine maintenance To clean the machine, follow the instructions given in ch. 9 CLEANING AND MAINTENANCE Before carrying out cleaning and maintenance on the machine, the power supply must be disconnected by means of the <I/0> switch (2 fig. 8) and by unplugging the power supply (3 fig. 8). Do not use water jets or sprays to clean the machine. If the machine needs to be moved, disconnect all cables before. All cleaning, adjustment and maintenance operations and repairs carried out with the electric power supply turned on can cause serious and even fatal accidents to persons. All extraordinary maintenance operations (i.e. those that go beyond ordinary maintenance, which cannot be carried out by the operator) or repairs must be carried out by personnel qualified to perform these tasks, with a suitable professional level, who are perfectly trained. Every electrical operation must be carried out by a qualified technician using suitable instruments.
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4.3.2
During adjustment and maintenance operations or repairs, personnel not appointed to carry out such tasks must remain at a safe distance from the machine. After any adjustment and maintenance operations or repairs, the technician in charge must make sure that the work has been completed, the safety devices reactivated and protective guards refitted before the machine is started again. Make sure all the signs and plates on the machine are kept easily legible.
Precautions for resin treatment When using the resin, remember the following specific precautions. a) Warnings for resin use Handle the resin only after carefully reading the warnings which are printed on the label attached to the tin. Keep the resin away from sources of heat and fire.
CAUTION Do not move the resin under direct exposure to a source of ultraviolet rays such as direct sunlight, transmitted light or high/low pressure of the mercury vapour lamp. The resin will deteriorate or solidify if this precaution is not respected. b) Warning for resin storage The resin has to be kept closed inside its tin, in a dry and dark place and at a temperature between 5C and 30C. c) Safety warning Always wear protective gloves, goggles and a mask before handling the resin. Handle the resin only in places having adequate ventilation. Wash your hands carefully with plenty of warm water and neutral soap after handling the resin, even after wearing gloves. If resin comes in contact with the skin, immediately remove overalls and protective devices soiled by the product and wash with plenty of water. Once the product has been washed away, clean the skin using soap and water. If resin gets into the eyes, wash immediately with plenty of water for 15 minutes and go straight to the hospital Emergency Department. If resin is inhaled, immediately remove the casualty to a place where the air is clean, then go straight to the hospital Emergency Department. If resin is swallowed, do not induce vomiting. Wash the inside of the mouth with water. Get the casualty to drink 1-2 glasses of water or milk to dilute the product inside the stomach, then go straight to the hospital Emergency Department. Do not leave the resin within the reach of children.
DANGER Strictly avoid touching the resin directly with your hands. Wear protective gloves. If the resin comes in contact with the skin, it could give rise to allergic dermatitis. d) Caution about clothing If any resin adheres to clothing, it hardens and cannot be removed. We therefore recommend you wear an apron or work clothes. e) Caution when treating discarded resin Discarded resin must be hardened and disposed of as plastic waste. If disposal of discarded resin is not allowed, contact DWS or the dealer.
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4.3.3
General safety precautions 1) Do not tamper with protective guards and/or attempt to operate the machine with the forming chamber open. Danger of serious including fatal injuries. 2) Do not remove any protective guards or panels, do not alter them or render them inefficient. Danger of serious including fatal injuries. 3) Any operations or repairs to the electrical installations must be carried out by qualified personnel, with the power supply disconnected. Danger of death. 4) Ordinary and extraordinary maintenance must be carried out with the machine stationary and disconnected from the power supply. Danger of death. 5) The work station must be kept clean and tidy at all times. Clean away any resin deposits immediately. Danger of injury caused by tripping and loss of balance. 6) The resin container may only be loaded and unloaded by the machine operator. Danger of damage to the machine. 7) Handle the resin and other products used on the machine with care. Do not dispose of them by pouring down drains, but according to regulations laid down by the legislation in force. Danger of damage to or diseases of the skin and organs (eyes, mouth, throat, etc.) which may accidentally come in contact with the resin. Danger of harm to the environment.
4.3.4
Definitions and symbols used in this manual The following definitions are given in enclosure I point 1.1.1 of the 2006/42/EC Machine Directive: - Danger area: any area inside and/or in the proximity of the machine where the presence of an exposed person constitutes a risk for the health and safety of such person. - Exposed person: any person who is inside or partly inside a danger area. - Operator: person assigned to install, operate, adjust, clean, repair and transport the machine or carry out the maintenance on it. The following terms and their corresponding symbols are used in this manual. CAUTION, SIGN: Useful information Basic operations required for machine use Slight danger for machine safety WARNING, SIGN: Instructions on safe machine operation Advice for preventing damage Reference to safety directives DANGER, SIGN: Serious danger for - the operator - the machine - the environment DANGER, SIGN: Serious danger from electrically live components
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Compulsory use of
Gloves
Goggles
Mask
4.3.5
Safety signs fixed to the machine Special plates complying with the 92/58/EEC directive have been fixed to the machine in order to further improve the safety of operators. SYMBOL Read the instruction manual SYMBOL Danger: Laser appliance SYMBOL Danger of electric discharge
4.3.6
Noise The tests conducted have given the following results: - The equivalent continuous sound pressure level, weighted A (Lwa), work/operation/control station is equal to 59 dB (A). - The maximum instantaneous sound pressure level, weighted C (Lp), work/operation/control station does not exceed 63 Pa. at at the the
It is compulsory for the user and employer to respect legal requirements in terms of protection of operators against daily personal exposure to noise (in Italy Law by Decree no. 81/2008 and subsequent modifications), prescribing if necessary the use of personal protection devices (ear muffs, etc.) according to the overall sound pressure level in the work area. The overall sound pressure level depends on four main factors: 1) the sound pressure level emitted by the individual machine; 2) the sound pressure levels produced by other machines already installed in the work area; 3) the background sound pressure level from the environment; 4) the soundproofing and reverberating features of the building where the machine is installed. The daily personal exposure level represents an average level over time of the sound pressure level the operator is exposed to in the course of his working activity. A practical way of measuring this daily dose of noise, the equivalent average level, is by using a special integrating meter applied to the operator during a typical day of work. See regulations (in Italy Law by Decree no. 81/2008 and subsequent modifications) for the division of noise level into bands and relevant prescriptions of protection for operators. For personal noise protection devices, see the 89/686/EEC and 89/656/EEC directives. 4.3.7 4.3.7.1 Reference standards Directives concerning machine safety 2006/42/EC Directive known as Machine directive. 2006/95/EC Directive known as Low voltage directive. 2004/108/EC Directive known as Electromagnetic compatibility directive.
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4.3.7.2
Directives concerning safety at the workplace 98/24/EC Directive, 2003/10/EC and 88/642/EC Directives covering protection of workers against risks deriving from exposure to chemical, physical and biological agents during their work. 89/391/EC Directive regarding improvement in company safety and workers health, with the 89/654/EC and 2009/104/EC annexed Directives. 2004/37/EC Directive regarding the protection of workers against the risks deriving from exposure to carcinogenic agents during their work. 92/58/EC and 79/640/EC Directives concerning safety signs in the workplace.
4.3.7.3
Directives concerning personal protection 89/656/EEC and 89/686/EEC Directives concerning the use of personal protection devices.
4.3.7.4
Directives concerning environmental protection 75/442/EEC Directive concerning waste disposal. 78/319/EEC Directive concerning the disposal of toxic and noxious waste.
4.3.7.5
Safety standards The laser installed is classified as class 3B in compliance with standard IEC 60825-1.
4.4 4.4.1
SAFETY DEVICES Fixed guards The machine is enclosed within one steel plate casing (1 fig. 9), classified as a fixed guard (in accordance with regulations 2006/42/EC, annex I, point 1.4.2.1, UNI EN 12100, UNI EN 953). All the mechanical, electrical and electronic components, as well as the laser and the resin tank are housed in the enclosure. Access to the inside is partially allowed (only in the forming area) through an opening located in the top section of the enclosure, covered by a movable guard (door). DANGER It is not permitted to operate the machine without the fixed guards. Danger of serious injuries. DANGER Do not remove or alter any fixed safety guards. Danger of serious injuries.
4.4.2
Movable guards The access door to the forming chamber (2 fig. 9) can be classified as a movable guard since it is hinged at the back and has a safety switch with a guard locking device (3 fig. 9) (in accordance with regulations 2006/42/EC, Annex I, p. 1.4.2.2; UNI EN 12100). Opening of the access door with the machine in operation is prevented by the guard locking; opening can be controlled only by means of the appropriate software control which can be activated with the machine at a standstill and with the laser switched off only. DANGER Do not remove or alter the door or its safety devices. Danger of serious injuries.
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4.4.3
<ON/OFF> button A luminous <ON/OFF> button fitted to the front panel (5 fig. 9) is used to start/stop the machine. Avoid stopping machine operation by means of this button. Use the software. The machine cannot operate when the button is switched to <OFF>, even if connected to the power supply and the computer.
4.4.4
Power supply switch The <I/0> power supply switch (6 fig. 9) is fitted to the back of the machine, next to the socket. The switch must be positioned to <0> at the end of the work cycle, before carrying out any operations inside the machine, and each time the plug must be taken out of the power supply socket (7 fig. 9).
4.4.5
Power supply female plug The machine is intended to be electrically supplied by a plug/socket device. The plug is located on the back of the machine (7 fig. 9), next to the <I/0> switch. Before carrying out any operation on the machine, the plug must be taken out of the socket (7 fig. 9).
2 1
Fig. 9
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5
5.1
LIFTING, TRANSPORT AND STORAGE

GENERAL INSTRUCTIONS Before moving the machine, remove the resin, secure the laser and check the dimensions and weight of the machine (printed on the packing or see chap. 2.2 TECHNICAL DATA TABLE). Since the weight of the machine is 40 kg (unpacked), the lifting of the machine unpacked has to be done manually by 2 operators working at the same time. If the machine has to be moved more than ten metres on the premises, use a suitably-sized fork lift truck. Beware of the danger of crushing when the machine (packed or unpacked) is lowered to the ground.
5.2
MACHINE LIFTING Machine state: machine (packed or unpacked) positioned on the ground suitable for supporting the machine weight. Personnel assigned to the operation: 2 qualified workers Total weight of machine packed in a crate: kg 80 Total weight of the machine unpacked: kg 40
5.2.1
Lifting the packed machine a) To lift the packed machine, use a forklift truck of a suitable capacity. b) Move the machine to the desired area.
5.2.2
Lifting the unpacked machine a) To lift the unpacked machine, two workers must get hold of the machine from underneath. b) Bend the knees and keep the trunk in an upright position so as to avoid any serious injury to the lumbar area of the back. c) Then simultaneously rise to an erect position while lifting the machine. d) Finally move the machine to the desired area. Vibrations or jolts may damage or decrease laser performance.
5.3
TRANSPORT The packing (or the machine) is of such a size as to enable it to be transported by all means of goods transport. Furthermore, given its limited weight it does not involve any capacity problems. A small van, estate car or any space wagon is large enough to carry it. The packing (or the machine if unpacked) must be properly locked in position to avoid it turning over or creating danger for the driver and/or vehicle in the case of an emergency stop or other sudden manoeuvre.
5.4
STORAGE In the case where the machine remains in storage for a long time, we recommend first of all that the packing is not removed Make sure that the place where the machine is stored does not have excessive temperature ranges in order to prevent damage to the electrical components.
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Environmental values required for correct storage: Temperature: From +5 to +40C Relative humidity: from 30% to 80% without condensation Max. Altitude: 1000 m above sea level
Fig. 10
6
6.1
INSTRUCTIONS FOR MACHINE INSTALLATION

GENERAL INSTRUCTIONS During installation take the utmost care in order to ensure that no damage is caused to the machine, things and persons. Check on the TECHNICAL DATA TABLE (see chap. 2.2) that the characteristics given are the ones requested. Check the place of installation to identify the presence of any danger areas. The packing must be disposed of according to current laws and standards.
6.2
CHARACTERISTICS OF INSTALLATION SITE When choosing the place of installation, the following points should be taken into account: An air extractor should be fitted in the vicinity of the machine for resin smell to be extracted. The resin is not suitable for use in a hot, damp or cold environment. The resin tends to solidify on contact with sunlight or certain interior lights (with ultraviolet radiation). - Installation of the machine in the vicinity of sources of vibration must be strictly avoided. Vibrations or jolts may damage the laser or decrease its performance. - Provide a stable surface of suitable dimensions to stand the machine on (see chap. 2.2 TECHNICAL DATA TABLE) which must be perfectly level. - Provide good lighting (in accordance with standards in force), but not near a window or directly exposed to sunlight. - Interior light sources must not be directed towards the machine. - The machine must be placed at least 20 cm from the nearest wall in order to allow heat to be dispersed. -
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- The machine must not be positioned near heat sources (radiators, heaters, etc.) or near cold air generators (air conditioners). - Position the machine at a distance from the computer which is compatible with the length of the interface cable, usually about 1 metre. - Avoid positioning the machine in a particularly dusty environment. Environmental values required for correct machine operation: Temperature: from 22 to 30C with an average not higher than 28C over a 24 hour span Relative humidity: from 30% to 60% without condensation Max. Altitude: 1000 m above sea level 6.3 MACHINE POSITIONING AND CONNECTIONS Machine state: machine unpacked and positioned in the place of installation. Personnel assigned to the operation: No. 1 DWS Technician 6.3.1 Machine positioning - Position the machine on the surface prepared for it. 6.3.2 Hardware connection The machine can only operate when connected to a computer, which communicates with the machine by means of the DigitalWax Controller software supplied as standard. Connection is made by means of the cable supplied as standard. The instructions on computer operation should also be consulted. For the connection, proceed as follows: - Be sure that the machine and the computer are both disconnected from the power supply. - Connect the Ethernet crossover cable (3 fig. 11) to the socket (3M fig. 11) located on the back of the machine and the other end of the cable to the socket (3P fig. 11) located on the computer. No. 1 Operator
3 3P
3M Fig. 11
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DANGER - Electrical installation and connections must be made by qualified personnel. Danger of fatal electric discharges. - When the communication cable between the machine and computer is connected or disconnected, make sure the mains power supply to both devices is switched off. If the cable is connected or disconnected with the power supply on, the device could break down due to excessive electrical voltage or a current overload. 6.3.3 Electrical connection The power mains of the building must have an efficient earthing system in accordance with the electrical standards in force in the country: this comes within the purchasers responsibility. Check that the mains power supply voltage and frequency correspond to those given on the technical data plate. The machine is supplied with power by means of a three-pole plug, which is plugged into the EEC22 socket of the cable provided. For connection, proceed as follows: 1. Make sure that the switch <I/0> (1 fig. 11) on the back of the machine is positioned to <0>. 2. Connect the EEC22 cable socket to the plug (2 fig. 12) located next to the <I/0> switch. 3. Connect the EEC7 cable plug to a socket of the power mains of the building. DANGER - WARNING - Electrical installation and connections must be made by qualified personnel. Danger of fatal electric discharges. - Earthing of the device is compulsory. If the plug is not properly connected to earth, the risk of static electricity or shocks exists and this could damage the laser. Moreover, the device may malfunction. - Check that the computer has been correctly earthed. If not, errors in device operation could occur due to electrical disturbances. Also, check that there is continuity of current between the computer and device sockets. 6.4 PRELIMINARY ACTIONS Machine state: machine on the work bench prepared for it (table or specific support) in the place of installation, properly connected. Personnel assigned to the operation: No. 1 DWS Technician No. 1 Operator
In order to obtain a precise model, the resin must be spread evenly on the bottom of the resin tank, which must be perfectly horizontal. To obtain perfect levelling, adjust the machine supporting feet as necessary. Take care not to damage or scratch the surface of the inside of the resin tank. Damage to the surfaces in contact with the resin may jeopardise the successful outcome of the forming process. If its present, remove the film under the resin tank.
a) Switch on the machine by positioning the back switch to <I> and pushing the <ON/OFF> button (1 fig. 12). The button will light up. b) Start the computer and run DigitalWax Controller software c) By the software, start up the connection and open the door.
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d) Switch the machine off by pushing the <ON/OFF> button and positioning the back switch (2 fig. 12) to <0>. e) Turn the locking knobs (3 fig. 12) and extract the resin tank (4 fig. 12). If there is a film under the resin tank, remove it. f) By a spirit level (5 fig. 12), check the parallelism of the machine both on X axis and Y axis. If necessary, use a spanner to adjust the nuts of the supporting feet (6 fig. 12) until the machine is perfectly level. g) Re-insert the resin tank and turn the locking knobs (3 fig. 12).
2 1
Fig. 12
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6.5
RESIN TANK INTRODUCTION/EXTRACTION Machine state: machine installed. Personnel assigned to the operation: 1 Operator The resin needed for modelling must be poured into the resin tank; proceed in the following way: a) When the machine is on, open the DigitalWax Controller and Open the door to access the modelling chamber. b) Switch off the machine by turning the <I/0> switch to <0>. c) Slacken the threaded knobs (3 fig. 12) and take out the resin tank (4 fig. 12). d) Check that the inside of the resin tank is perfectly clean; if necessary, take the resin tank out and clean it with a cloth and pure (not denatured) alcohol. e) Now the resin can be poured. WARNING - Do not expose the resin to direct light. This way the resin does not harden or deteriorate. When the resin tank is inserted in the appropriate compartment, take care not to spill or drop the resin. - In the case where any resin is spilt or dropped, immediately clean with a paper towel or something similar. - Do not leave alcohol inside the resin tank as it could damage the silicone.
6.6
BUILDING PLATFORM REMOVAL/FITTING To remove/fit the building platform on the support of the Z-axis carriage, proceed in the following way: a) Open the door to access the modelling chamber. b) Switch off the machine by turning the <I/0> switch to <0>. c) Unscrew the threaded locking knob (1 fig. 13). d) Grip the handle (2 fig. 13) to withdraw the building platform from the support e) Remove the model, if present, and always accurately clean the surface of the building platform; if necessary, clean with a cloth and alcohol. f) Still holding the handle , position the building platform on the support. g) Secure the building platform by screwing the threaded locking knob (1 fig. 13). h) Close the door of the modelling chamber.
1 Fig. 13 2
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7
7.1
MACHINE SETTING FOR WORK

FOREWORD Before starting the machine after installation, some checks and controls are required which must be carried out by a technician from DWS or another qualified technician from the dealer. It is essential that the customers technician who will be in charge of the machine (operator) is present during these operations. These checks, in fact, must be repeated during the preventive maintenance stage, see chap. 9 CLEANING AND MAINTENANCE.
Machine state: machine installed. Personnel assigned to the operation: No. 1 DWS Technician No. 1 Operator
7.2
CHECKS ON PARAMETERS Check all the parameters set by the Manufacturer; particularly check the zero point of the Z axis, which means that the building platform must perfectly rest on the bottom of the resin tank. This check must be carried out each time the machine is moved. Please contact DWS at info@dwssystems.com
7.3
CHECKS ON SAFETY DEVICE OPERATION a) When the machine is in operation, check that the access door to the forming chamber (1 fig. 14) is locked and cannot be opened. b) Check that, when the <ON/OFF> button (2 fig. 14) on the front panel is pressed during operation, the machine stops
Fig. 14
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MACHINE OPERATION AND MODEL TREATMENT

Machine state: machine installed, checked and ready for use. Personnel assigned to the operation: 1 Operator Personal protection devices to be used when handling the resin: Gloves Goggles Mask
8.1
GENERAL INSTRUCTIONS In the case of dangerous situations (immediate or actual danger) stop the machine by means of the software and disconnect the power supply by means of the <ON/OFF> button (1 fig. 15) and the <I/0>switch on the back of the machine (2 fig. 15). If the outer part of the machine becomes very hot or smoke comes out of the slits, stop the machine immediately by means of the software, press the <ON/OFF> button (1 fig. 15) and disconnect the power supply by means of the <I/0> switch (2 fig. 15). Finally, also unplug the power supply plug (3 fig. 15). Do not place the machine near sources of heat or fire. Do not move the machine when it is operating. When the machine is in operation, do not cover it with covers or anything else, in order to allow the heat to be exchanged through the slits. For connection to the computer, only use the cable supplied as standard; if this is broken or damaged, request a new one from the machine manufacturer. Do not use damaged or ruined interface cables. Do not place weights on the cable, bend it or tamper with it. The area on which the machine stands must be kept clean and free of obstruction at all times. Every day, before starting the machine, check that all the control and safety devices are operating properly. It is forbidden to try and start the machine with the door open or not properly closed. Start the machine only after checking that there are no foreign bodies inside the forming chamber. Do not lean or put weight on the door when it is open. Do not place weights on the appliance. Do not disconnect the interface cable or the computer when the machine is in operation. Do not open the door when the machine is in operation. Take care not to damage or scratch the resin tank surface. Damage to the resin tank may jeopardise the successful outcome of the forming process. At the end of every work cycle, disconnect the power supply. Then proceed to remove the model and clean the building platform. When the machine is not used for a long time, disconnect the computer interface cable. Never use resins with characteristics which are different from those set out in the product information sheet, prescribed by the manufacturer and recommended by DWS.
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Fig. 15
8.1.1
Precautions for resin treatment When using the resin, remember the following specific precautions. a) Warnings for resin handling Handle the resin only after carefully reading the warnings which are printed on the label attached to the tin. This resin is a liquid polymer having a slightly unpleasant smell, which can be noticed when the machine door is opened. This resin is an inflammable compound: keep it away from sources of heat and fire. b) Caution when opening the resin tin and moving the resin from the tin to the container in the machine The resin liquid is only minimally protected from ultraviolet rays when being moved from the open tin to the container in the machine. WARNING Do not move the resin under direct exposure to a source of ultraviolet rays such as direct sunlight. The resin will deteriorate or solidify if this precaution is not followed. c) Caution when replacing the resin When the resin is kept at a low temperature, pieces of crystal may be formed inside of it which would jeopardise its quality. Before using the resin, leave it at ambient temperature for about two hours and shake well before use. Avoid adding new resin to old one. Replace all the resin when it gets old. Replacement intervals for the resin vary depending on the conditions of use.
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d) Safety warning Handle the resin only in places having adequate ventilation. Wash your hands carefully with plenty of warm water and neutral soap after handling the resin, even after wearing gloves. If resin comes in contact with the skin, immediately remove overalls and protective devices soiled by the product and wash with plenty of water. Once the product has been washed away, clean the skin using soap and water. If resin gets into the eyes, wash immediately with plenty of water for 15 minutes and go straight to the hospital Emergency Department. If resin is inhaled, immediately remove the casualty to a place where the air is clean, then go straight to the hospital Emergency Department. If resin is swallowed, do not induce vomiting. Wash the inside of the mouth with water. Get the casualty to drink 1-2 glasses of water or milk to dilute the product inside the stomach, then go straight to the hospital Emergency Department. Do not leave the resin within the reach of children. DANGER Strictly avoid touching the resin directly with your hands. Wear protective gloves. If the resin comes in contact with the skin, it could give rise to allergic dermatitis. e) Caution about clothing If any resin adheres to clothing, it hardens and cannot be removed. We therefore recommend you wear an apron or work clothes. Caution when treating discarded resin Discarded resin must be hardened and disposed of as plastic waste. If disposal of discarded resin is not allowed, contact DWS or the dealer.
f)
8.2 8.2.1
MODELLING CYCLE AND EXTRACTION OF THE MODEL Filling the resin tank and preparing for modelling Machine state: switched on and connected WARNING - Take care not to damage or scratch the surface on the inside of the resin tank. Damage to the internal surfaces may jeopardise the successful outcome of the forming process. - Make sure that no direct light reaches the inside of the machine, which could cause the resin to solidify in the resin tank and damage the machine. - Check that the building platform is clean. a) b) c) d) e) Open the door (1 fig. 16) to gain access to the modelling chamber. Switch off the machine by pushing the ON/OFF button (2 fig. 16). Unscrew the threaded knob (3 fig. 16) that locks the building platform. Take out the building platform (4 fig. 16). Take out the models, if there are some, and always check that the building platform is perfectly clean; if necessary, clean it wih a cloth and alcohol. f) Re-insert the building platform into its housing and lock the threaded knob. g) Unlock the locking knobs of the resin tank (5 fig. 16). h) Take out the resin tank completely i) Check that the inside of the resin tank is perfectly clean; if necessary, clean with a cloth and alcohol (not denatured). j) Pour the resin into the resin tank, until it reaches a height of 4-5 mm (corresponding to 100 g approx.). Nevertheless, in general we suggest you to pour a slightly greater quantity of resin than the quantity you think sufficient for your work (7 fig. 16). k) Reinsert the resin tank, lock it by turning the locking knobs and close the door.
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1 2
6 7
Fig. 16
8.2.2
Machine starting a) b) c) d) e) f) Position the <I/0> switch to <I> (1 fig. 17). Start the machine by pressing the <ON/OFF> button (2 fig. 17); the button must light up. Start the computer and the DigitalWax 008 Controller (see manual enclosed) By means of the software, lower the building platform down to the zero point of the Z axis. Check that the <DOOR OPEN> LED (3 fig. 17) and the <ERROR> LED (4 fig. 17) are switched off. Now the machine is ready to be set at work.
8.2.3
Model forming process The forming process occurs as follows: - Once started the forming process, the machine moves the Z axis downwards bringing the building platform to plunge in the resin and leaving a thickness between the silicone film of the resin tank and the building platform equivalent to the slicing value that was set during the creation of file. - The laser directed from below (more precisely from the bottom of the resin tank) solidifies a layer of resin equal to the value set (from hundredths to tenths of a millimetre). - The building platform is raised according to the thickness of each layer and, layer by layer, a remarkably precise model is formed, even models with several undercuts. - When the forming process is complete, with the building platform raised, the model obtained is extracted together with the building platform.
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8.2.3.1
How to start forming By using the DigitalWax Controller software, set the parameters required to start the forming process (see manual enclosed). Check the following points: a) Make sure that the door of the forming chamber is closed properly. When the door of the forming chamber is open, the <DOOR OPEN> LED (3 fig. 17) is lit and the laser cannot work. b) When the laser is working, the <LASER> LED (5 fig. 17) is lit.
3 4 1
2 Fig. 17
8.2.3.2
Data transfer from the computer After the forming data have been sent to the computer, the machine starts the stereolithography cycle. During the forming process, the door (1 fig. 18) to the forming chamber must be left closed. If the user tries to open the door to the forming chamber, the guard locking device on the safety switch prevents the manoeuvre. Model forming can be interrupted for check.
8.2.3.3
How to stop forming and extracting the model Once the forming process is finished, the DigitalWax Controller software signals the end of the working cycle and the machine stops. At that moment, the operator can extract the building platform and the models formed on it. DANGER Wear protective gloves, goggles and a mask to avoid any direct contact with the resin. Gloves Goggles Mask
WARNING - Ensure that no light gets into the forming chamber.
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Take care not to allow the resin to drip onto the machine. If this happens, clean thoroughly and immediately using paper tissues and alcohol before the drops solidify. Otherwise these could cause the machine to break down.
a) Open the door (1 fig. 18) to access the modelling chamber. b) Switch off the machine by pushing the ON/OFF button (2 fig. 18). The light of the button has to go out. c) Unscrew the knob (4 fig. 18). d) Extract the building platform by gripping its handle (5 fig. 18). f) Close the door. If the machine is not going to be used for some time, empty the resin tank, clean it well and unplug the power supply cable from the socket.
4 Fig. 18 5
8.3
TREATMENT OF THE RESIN At the end of the stereolithography cycle, there is always a certain quantity of resin left over. If another forming cycle is to be carried out straight away, simply add the quantity of resin needed to reach the required quantity. Otherwise, proceed to eliminate the resin left and to clean the resin tank. Follow the explanations given below. a) Take out the resin tank completely (fig. 19). b) Empty the resin tank completely. c) Clean the resin tank well using a clean cloth with some alcohol. d) Insert the resin tank into its compartment.
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Fig. 19
8.3.1
Life of the resin The life of the resin is variable and depends on three essential factors: 1. Humidity 2. Temperature 3. Light absorbed; a. Shelf life When left inside its bottle as supplied by DWS, the resin can maintain its characteristics unaltered for 12 months only if stored in a suitable environment with a stable temperature between 10C and 25C. b. Duration of the resin inside the machine: When the resin is poured into the resin tank, it comes directly in contact with sunlight or artificial light which degrade its physical/chemical characteristics. For this reason we recommend you to store the resin in an environment poor in lighting and protected from changes of temperature. The average life of the resin inside the resin tank is about 30 days, then there is an remarkable decrease of performance both in the solidification process and in the quality of the model surface. The deterioration of the resin is evident if you observe its colour when it is liquid: if the resin is fresh and in good conditions the colour is nearly transparent, while at the end of its life the colour becomes yellow/orange and we recommend you to replace it with new resin. c. Elimination of deteriorated resin: When the resin becomes unusable, we advice to pour it in a plastic cup and let it solidify in the sunlight as long as it becomes completely hard and so it is possible to dispose of it together with the plastic waste, according to the laws in force in your own country. CAUTION The resin tank surface can be easily damaged. If this happens, the model can show defects. Take care not to scratch the bottom of the resin tank during cleaning operations. DANGER Wear protective gloves, goggles and a mask to avoid any direct contact with the resin and the alcohol used to wash the resin tank. Gloves Goggles Mask
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8.3.2
Cleaning of the resin tank and removal of the resin unused 1. Remove the resin tank from the machine as shown in fig. 19. Lay it on a clean surface covered with a clean cloth to avoid resin spots. Prepare the following tools (fig. A) Latex gloves A soft spatula made of silicone or teflon A funnel with filter A glass for the resin A glass where to pour the alcohol used for washing Some alcohol inside a spray Absorbing paper
Fig. A
2. Put the funnel inside the glass (fig. B)
Fig. B
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3. Wear the gloves and, using the soft spatula, pour the resin inside the funnel. Move the spatula from the top to the bottom of the resin tank, in order to remove the more resin as possible. (fig. C) Once the resin is poured inside the funnel, wait for some minutes, as long as it is completely filtered. Put the glass with resin far from direct light and heat.
Fig. C
4. Wash the resin tank by spraying some alcohol in order to melt any resin which could be left inside the resin tank. Use the spatula to remove the resin-alcohol mixture (Fig. D). Remove the alcoholresin mixture by the spatula and pour it into a plastic cup. Move the spatula on the whole surface of the resin tank as long as it becomes dry. Repeat the washing by spraying some new alcohol on the internal surface and, again, pour the alcohol in the plastic cup.
WARNING Carry out this job under an exhauster, in order not to breath the alcohol and the vapours generated during its evaporation.
Gloves
Goggles
Mask
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Fig. D
5. By a clean and soft cloth or absorbing paper, dry the edges of the resin tank dirty with resin fig. E).
Fig. E
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Now the resin tank is clean inside. You need to clean the lower side as well, in order to be sure to remove any grease spot that could hamper the laser beam. Lay it on a clean table and using a clean cloth or some absorbing paper dampened with alcohol, clean the whole surface (Fig. F).
Fig. F
8.3.3
Use and maintenance of the resin tank The resin tank is a fundamental part of the machine which has to be handled with the maximum care. It is composed by a methacrylate frame with a proper silicone coat on the bottom poured at DWS factory. The conditions of this silicone coat as well as those of the resin tank can deeply affect the result of the modelling process, thats why the utmost care is recommended. Carry out each operation scrupulously otherwise the resin tank could be damaged a. Cleaning the resin tank - Use clean and soft clothes or absorbing paper for each cleaning operation. - Use ethyl alcohol only. Do not use benzene, solvents or other chemicals which could damage the silicone coat or the resin tank. - To clean the resin tank and remove the resin use only soft spatulas made of Teflon or silicone. - We strongly recommend you not use any pointed or cutting tool during the maintenance and the clearing operations, since they could damage the resin tank irreparably. In fact, the use of improper tools can cause the silicone to break: the resin could enter between the silicone and the methacrylate and the forming process could not take place. - Be careful to the lower surface as well, it has to be properly cleaned with a cloth dampened with alcohol, since other kinds of detergent can make the surface opaque and hamper the passage of the laser beam. b. How to use the resin tank - When using a new resin tank, remove the protection packing being careful not to scratch it with pointed tools or with the nails. - Lay the resin tank on a clean table, putting a sheet of paper or a clean cloth under the building platform in order not to damage or scratch it.
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Be sure that there are neither dust nor grease spots on both sides. If necessary, clean the resin tank with some alcohol and absorbing paper as explained at point a. Let the resin tank dry perfectly from alcohol and insert it inside the machine as explained at paragraph 6.4 Preliminary operations. Pour the resin and wait for some time, so that it is spread uniformly on the whole surface of the resin tank. Now a new modelling cycle can start.
c. Maintenance - The resin tank does not need any particular maintenance, but you need to be careful not to scratch it or touch the lower part with your hands, in order not to leave greasy spots. - If you need to empty it from the resin to check the zero setting or to filter the resin, use the spatula supplied together with the machine as standard or a soft spatula to remove the resin and pour it inside a suitable cup, as explained at par. 8.3.2 fig. C. - Wash the resin tank by spraying some alcohol in order to melt any resin which could be left inside the resin tank. Use the spatula to remove the resin-alcohol mixture (Fig. D, par. 8.3.2). - In case after a modelling cycle there are some resin residues which could be hardened on the silicone coat of the resin tank, pour some alcohol inside the resin tank and, using a soft spatula, gently press each side of the residue so that the alcohol goes under as long as you can remove it. d. Life of a resin tank The life of a resin tank is variable. The only method to check the status is the observation of the transparency of the silicone coat. The transparency is a fundamental aspect to allow the laser beam go through the resin tank and solidify the resin to create the model. A worn out resin tank has a opaque surface correspondent to the working area. This is due to the laser which makes the silicone opaque going through it (Fig. G).
Fig. G
If the resin tank is transparent but the surface is wrinkled, that means the silicone was damaged and some resin has infiltrated between the resin tank and the silicone coat. The passage of the laser beam is hampered and as a consequence the building of the piece is not possible: you have to substitute the resin tank.
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8.4 8.4.1
TREATMENT OF THE MODEL AFTER CONSTRUCTION Cleaning a model before the secondary solidification The object which has just been created is not fully solidified yet. To complete solidification, proceed as described below. All the operations described here below must be carried out without exposing the object to direct light (especially sunlight). 1. Example of a model with a solid structure - If the model presents a compact structure, you can remove it from the building platform using a spatula or a scraper, then plunge it into a cup with some alcohol. - Dip the cup with the model inside a ultrasound washing machine, being careful that the water does not come I contact with the alcohol inside the cup. - Wash the model for some minutes, than remove them from the alcohol and carefully dry by compressed air, being careful not to use a too strong, direct air jet which could damage the resin piece. - Complete the secondary solidification. 2. Example of a model with a fragile structure - If the model is rather big and its structure is fragile, you can leave it secured to the building platform and spray some alcohol directly in order to eliminate the surplus resin which is still on its surface. - If necessary, wash it many times. In fact, it is necessary to eliminate all the surplus liquid resin which is left on the surface of the model when it is still wet, because if this resin get dried, it can obstruct the holes or damage the model. - Complete the secondary solidification.
8.4.2
Model removal To remove the object from the building platform, the following equipment is required: a) clippers b) a small stainless steel spatula c) jewellers tools d) a coping saw Only after the operations described above you can leave the model in sunlight or under a UV lamp for some time to complete the secondary solidification (5 to 15 minutes, it depends on its size. In sunlight the process is longer). DANGER - Do not touch the model directly with your hands. - Use adequate safety protection devices, such as gloves and goggles. - Take care not to breath in resin dust, wear a protective mask. Gloves Goggles Mask
The procedure for removing the model from the building platform is described below : a) Use the clippers or a similar instrument to cut the supports of the object after secondary solidification. b) Remove the supports left on the building platform by means of a small stainless steel spatula. c) Thoroughly clean the building platform and the spatula with alcohol. Take care not to damage the building platform with the spatula.
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9
9.1
CLEANING AND MAINTENANCE

GENERAL INSTRUCTIONS Before carrying out cleaning and maintenance on the machine, the power supply must be disconnected by means of the <I/0> switch (1 fig. 20) and by unplugging the power supply (2 fig. 20). Do not use water jets or sprays to clean the machine. If the machine needs to be moved, also disconnect the computer interface cable (3 fig. 20). All cleaning, adjustment and maintenance operations and repairs carried out with the electric power supply turned on can cause serious and even fatal accidents to persons. All extraordinary maintenance operations (i.e. those that go beyond ordinary maintenance, which cannot be carried out by the operator) or repairs must be carried out by personnel qualified to perform these tasks, with a suitable professional level, who are perfectly trained. Every electrical operation must be carried out by a qualified technician using suitable instruments. During adjustment and maintenance operations or repairs, personnel not appointed to carry out such tasks must remain at a safe distance from the machine. After any adjustment and maintenance operations or repairs, the technician in charge must make sure that the work has been completed, the safety devices reactivated and protective guards refitted before the machine is started again. - Make sure all the signs and plates on the machine are kept easily legible.
3 1 2
Fig. 20
9.2
CLEANING THE MACHINE Before carrying out cleaning and maintenance on the machine, the power supply must be disconnected by means of the switch <I/0> (1 fig. 20) and by unplugging the power supply (2 fig. 20). Machine state: machine not operating. Personnel assigned to the operation: 1 Operator DANGER When cleaning the different parts of the machine that went into contact with the resin it is compulsory to wear the recommended IPE. Gloves Goggles Mask
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Cleaning the machine is essential to maintain its performance and identify any problems, breakages or loosening of parts. MATERIAL REQUIRED 1) alcohol 2) cloths or paper tissues 3) paper 4) swab 9.2.1 Operating methods a) Resin tank Remove the resin tank according to the instructions given in chap. 6.5 RESIN TANK INTRODUCTION/EXTRACTION. Clean the resin tank with alcohol, taking care not to scratch or damage the resin tank.
b) Building platform (after each stereolithography cycle) Remove the building platform as indicated in chap. 6.6 BUILDING PLATFORM REMOVAL/FITTING. Clean the building platform with alcohol and eliminate the resin which has become stuck using a stainless steel spatula. WARNING A dirty building platform could cause problems to model forming. c) Cleaning drops of resin sprayed inside the machine (when necessary) It may happen that sprays of resin adheres to the inside of the machine while it is working. At the end of every work cycle, check if any drops of resin have got stuck to the walls of the machine. If necessary, clean immediately with a tissue slightly dipped in alcohol.
9.2.2
Summary of cleaning operations PARTS TO BE CLEANED Building platform, any drops or residues of resin. Controls, machine enclosure.
FREQUENCY OF OPERATION Daily or whenever used Weekly PARTS TO BE CLEANED Resin tank
CLEANING METHOD Clean with alcohol using clean cloths and/or paper tissues. If there are any deposits, remove them with alcohol and a plastic spatula. Building platform Clean with alcohol using clean cloths and/or paper tissues. If there are any deposits, scrape them off with a steel spatula. Glass protection for scan head Clean with cleaning product for glasses. Metal plate parts Use a cloth dipped in alcohol and wipe with a dry cloth. Mechanical parts Use a cloth dipped in alcohol, wipe with a dry cloth and dry with a compressed air jet. Electrical controls Clean with a soft dry cloth. Electrical parts Clean using a vacuum cleaner. Micro switches Clean carefully using a soft cloth. MATERIALS AND SUBSTANCES NOT TO BE USED Do not use chemicals, solvents or toxic non-biodegradable products, as prescribed by standards in force.
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9.3
MAINTENANCE This machine requires minimum but careful and accurate maintenance in order to keep its original precision features unaltered over time and to avoid corrosion. For this purpose it is recommended to perform any operations by DWS technicians or by staff trained from DWS.
9.4
FAULT-FINDING
PROBLEM The machine does not respond to computer command.
CAUSE Power supply cable not connected sockets/plugs not inserted correctly. Switch in <OFF> position.
or
REMEDY Check and connect the cable correctly. Position the switch to <ON>. Position the button to <ON>. Check and connect the cable correctly. Close any useless open process. If necessary, re-start the PC. Pour an adequate quantity of resin into the resin tank. Check the file.
ON/OFF> start/stop button in <OFF> position. Interface cable not connected or connectors not inserted correctly. There are many open processes and the machine cannot detect the inputs correctly Model forming not take place. does No resin in the resin tank. The design of the model is not correct in its structure (e.g., the supports are not enough or their dimension is not correct) Laser beam not irradiated.
Check that the <LASER> LED is switched on when the machine is in operation. Position the building platform correctly. Check the zero setting. Check the temperature of the resin and the temperature of the room. The resin can be solidified in the resin tank. Substitute it. Keep a constant room temperature and substitute the resin.
The building platform was not at the same level as the resin tank when the stereolithography cycle was started. The resin has solidified in the resin tank. The resin was not at the right temperature for the modelling cycle. The inside of the forming chamber has been exposed to light too long. The temperature in the installation site has largely exceeded 30C.
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10
10.1
ADDITIONAL INSTRUCTIONS
GENERAL INSTRUCTIONS Strictly observe all the information given in the following document and comply with general EEC and national accident-prevention standards. - Always use the personal protection devices provided for by the EEC 89/686 and EEC 89/656 directives; furthermore, follow all the instructions given in this manual. - The operator must not carry out operations of his own initiative which do not fall within his competence. - During disabling, dismantling or disposal operations, unauthorised persons must keep away from the machine and the working area. - The floor around the machine must be clean and free of obstruction.
10.2
INFORMATION ON MACHINE DISMANTLING At the end of its working life, the machine can be dismantled and disposed of. In this case, the operation must be carried out in accordance with local legislation concerning the disposal of scrap, as well as that provided for by European laws on environmental protection (see chap. 4.3.7.4 DIRECTIVES CONCERNING ENVIRONMENTAL PROTECTION). Machine state: machine not operating with switch positioned to <0> and power supply plug unplugged from socket. Personnel assigned to the operation: 1 Operator a) DISMANTLING: follow the instructions given in chap. 6 in reverse order. b) HANDLING AND TRANSPORT: follow the instructions given in chap. 5 in reverse order.
10.3
ALTERATIONS Any alterations or additions made to the machine will be supplied with updating information or provided with a new instruction manual.
10.4
SALE Should the machine be sold, the purchaser is entitled to be informed of any work or repairs made, as well as to be trained on machine use and maintenance; moreover all the documentation and the conformity declaration must be handed over to the new owner. HOW TO ORDER SPARE PARTS To order spare parts, state the following: - Machine type - Model - Serial number - Year of construction
10.5
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11
11.1
ENCLOSURES
RESIN SAFETY PRECAUTIONS DANGER The compound is irritating for eyes and skin. The compound can cause sensitisation on contact with the skin. The compound is flammable
11.1.1
First Aid measures General indications In the case of an accident, consult a doctor, providing the information given on the label and on this information sheet. Remember that in the case of an injury, First Aid must be provided by trained personnel to avoid further complications for the casualty. Remember that drugs must only be administered and medical equipment only be used under the control of healthcare staff. If the casualty has fainted, do not attempt to make him/her drink or administer drugs orally. b) In the case of inhalation In the case of inhalation, take the following First Aid measures: move the casualty away from the contaminated area to a warm and ventilated place, cover with a blanket, remove tight clothing (collar, belt, etc.) which may hinder breathing and consult a doctor. If necessary, practise artificial respiration and call an ambulance immediately (in case of apnoea) or apply inhalation of oxygen (in case of dyspnoea). c) In the case of accidental contact with the eyes In the case of accidental contact with the eyes, rinse carefully with water for at least 15 minutes, and consult a doctor or go the hospital Emergency Department. d) In the case of accidental contact with the skin Move the casualty away from the contaminated area and remove contaminated clothing. In the case of accidental contact with the skin, remove the resin from the skin using a paper towel, carefully wash the area involved with soap and water for a long time, and consult a doctor or go to the hospital Emergency Department. e) In the case of ingestion Do not induce vomiting. Carefully rinse the mouth out with water without swallowing. Then go straight to the hospital Emergency Department. a)
11.1.2
Fire-fighting measures a) Appropriate means and measures for extinguishing fire In the case of a fire or involvement of the compound in a fire, use the following procedures and means for extinguishing the fire: - immediately interrupt all sources of heat or substances feeding the flames; - use water, powder, foam or carbon dioxide to extinguish the fire. b) Protective equipment for fire fighters Provide fire fighters with the following protective equipment: overall flame-resistant body suit, helmet with visor or hood with shield, heat-proof gloves, heat-proof boots, breathing apparatus or gas mask, and mask with filter for organic vapours. Prohibit the access of persons not involved in putting out the fire to the whole area around the fire. In the case of extensive fire, move all movable containers to a safe place immediately.
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11.1.3
Measures in case of resin accidental spillage a) Individual precautions In case of accidental spillage of the compound, use the following personal protection means: protective goggles, visor, gloves, suitable boots and aprons. If the resin become solid, its no more dangerous. There no need of protection precautions to handle the solidified material.
b) Protection of the environment In case of accidental spillage: - Remove sources of heat or power of the flame, sparks or electricity. - Avoid or reduce dispersal of the material into the soil or environment to a minimum. - Collect contaminated waters or soil into appropriate containers and send for suitable decontamination treatment. Use shovels and other tools which do not cause combustion to collect the resin. c) Procedures for containing and cleaning up the spillage Contain and absorb the spilt liquid using inert absorbent materials (earth, sand,..). 11.1.4 Handling and storage a) Handling the resin During handling, use the means of protection given in point and paragraph 11.1.3.3 of the present form and the following procedures: handle with caution, avoid projecting the product and avoid contact with the skin or eyes. Do not eat, drink or smoke in the nearness of the preparation.
b) Storing the resin When storing the compound, remember the following precautions: All the electrical equipment in the storing place must be explosion-proof and have adequate earthing. Keep in mind the chemical and physical properties of the compound in order to prevent possible interactions with other products and keep the containers hermetically sealed. Store in a cool dark place, and avoid exposure to direct sunlight. Do not store in a place where there are organic oxides or peroxides. Keep the bottle close at: temperature 10-20 C and humidity 60%RH. 11.1.5 Checking personal exposure/protection General precautions to be adopted Use the product according to the indications given in this information sheet, paying particular attention to the indications given in point 11.1.4 (a). Use the means of personal protection given in points c, d, e. Use the product away from heat sources or sparks and in an adequately ventilated environment. b) Concentration limits in working and biological environments According to the data available, the compound does not contain substances having exposure limits. c) Protection of the hands During handling, protect the hands with gloves made of waterproof material which is resistant to contact with chemicals, such as for example Polyurethane (PU), Polyvinyl Chloride (PVC), Latex, Acrylic Nitrile. d) Protection of the eyes Protect the eyes with safety goggles during handling. e) Protection of the skin Wear overalls with long sleeves, preferably made of polyester, when handling the product. a)
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11.2 11.2.1
DIGITALWAX 008 CONTROLLER Introduction
Fig.23: Main form of the DigitalWax Controller
DigitalWax Controller is an application developed exclusively for the DigitalWax machines. It allows the following operations: 11.2.2 11.2.2.1 to get the connection from the PC to the machine via Ethernet connection; to set the machine parameters (working speed, zero...); to start the machine; to check the working process; to make a pause during the work; to make an emergency stop;
Installation System requirement The DigitalWax Controller requires the following minimum system properties: 256 Mb of RAM; 6 Mb of free space; System: Windows 2000/Xp with Service Pack 2; Processor Pentium4 or higher or AMD 2000 or higher;
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11.2.2.2
DigitalWax 008 Controller installation and connection to the machine To install the software, follow these steps: a) Insert the CD-ROM given together with the machine; b) close all the open applications; c) just click Start in Windows, select Computer Resource; d) select the CD-ROM; e) If the Setup procedure does not start automatically: - open the CD-ROM and double click on 'DWCtrl - click on setup.exe' to install the software; the following window will appear:
Select the destination folder by confirming the current position or choosing a new destination:
Confirm next step pressing Install
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Now the pc will complete the installation.
11.2.2.3
Software installation for USB hardware protection key (Sentinel Protection Software) In order to ensure the best working of all software installed on the machine, you need to install the Sentinel Protection software. - Select the file: Sentinel Protection Installer 7.exe from the CD-Rom. - Do not insert the USB Hardware key before the end of the installation. - The following window will appear and the installation will start:
- Select Next; in the following window you will be required to accept the contract in order to continue with the installation.
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- Select Custom and press again Next.
- In the following window deselect the buttons marked with a red X pressing the button on the left side of the entries and select the X that disables them.
- Continue with the installation pressing Next.
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- Press Yes to enable the software to install the USB hardware key. - Now it is possible to insert the key and use the software. 11.2.2.4 Connection between PC and DigitalWax 008 In order to allow the connection between the machine and the PC , we must adapt some parameters. Follow this guise step by step: Required components: Ethernet cross cable and power cord 1. Connect the Ethernet cable, received with machine, to the socket placed behind the machine:
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2. Connect the Ethernet cable to the socket placed on your desktop or laptop:
3. Connect the power cord to the machine and switch ON the general button placed behind the machine and the main button in front of the machine. If everything is working correctly, it should become green. 11.2.2.5 11.2.2.5.1 Setup of the pc for DigitalWax 008 Procedure for Windows XP 1. Press Start and select Control panel, then click on the icon Network Connections
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2. Double click on the Ethernet connection that is active and select properties on the new window that appears.
3. On the new window appeared, double click on internet protocol(TCP/IP), in the next window select use the following IP address and insert the value as below, then click OK and close every window.
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4. Open the control panel and select windows firewall, then turn it OFF.
5. Open the Control panel and select System, then select hardware and Device manager
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6. Find the Network adapter and open it, then remove any flag from the energy saver option on the power management as below.
11.2.2.5.2
Procedure for Windows Vista/Seven 1. Right click on the Ethernet icon on the left side of the screen and select Network and sharing center
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2. Select view status
3. Now click on Properties, remove the flag on Internet protocol Version 6(Arrow A) and double click on Internet protocol Version 4 (Arrow B).
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4. Select Use the following IP address and insert value as below, then click ok and close every window.
5. Open the control panel and select Windows firewall, then click on change setting
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6. Turn off the firewall.
7. Open the Control panel and select System, then select Device manager
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8. Find the network adapter and select it
9. Disable the energy saver as below from the power management
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11.2.3 11.2.3.1
Controls description Introduction The Digital Wax controller is the main software that allow to manage the machine, load files, control system status and create models.
11.2.3.2
Controls of DigitalWax Controller This is the main window of the DigitalWax controller
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11.2.3.3
Machine controls Open door: This function allows you to open the door and enter into the working area for the standard maintenance; the door will be closed automatically. Home: Start the reset process for X, Y and Z axes. Open file: Load MKR file. Execute file: After the loading process, it is possible to start the process with this button. Simulation: When you enable this option, it is possible to start a virtual process and control on the display if everything is working correctly. Set zero: Necessary option to set the zero level. Please see the user manual for further information. Parameters: Into this window you can modify some parameters about the building process. Please modify them after complete knowledge about the machine. o Speed M3/M4 Working speed X and Y axis, std. value 4000 (mm\100); o OffsetZ Movement space for Z axis after every layer built, std. value 700 (mm\100); o NumFirstLayers Number of first layers produced with slow speed to increase adherence to the platform, std. value 4; o SpeedFirstLayers Speed of first layers, std. value between 120 and 200 (mm\100) to increase the adherence to the platform. Pause When you press this button, the machine will complete the layer, then the building platform will be moved up till the top of the Z axis, the door will be opened automatically and now you will be able to control the building process. During the first layers, the waiting time before enabling this option can be longer due to slow building speed. When the Z axis reaches the upper point, the program will unlock the door. It is possible to press "Continue" to restart the job from the previous point. Do not remove the platform from the machine! Restart the job: This function is enabled when, after an electric cut off, the machine and the computer are switched off. Once you restart the computer this button will be enabled. Press it to restart the job from the last layer built, do not touch the building platform to avoid problems to the model. Control panel: Building size and process situation: Layer = Layer built / Layer to do Speed = Working speed Time = time since the beginning X = Size X axis Y = Size Y axis Z min = height of the first layer (must be the same of the layer thickness selected) Z max = Maximum height
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11.2.4
Procedure for the ZERO setting of the machine: 1. Push the button Option/Set Zero (Fig. 26).
Fig. 26
2. Prepare two sheets of paper, one kit of Allen spanners and one 7 mm setscrew wrench.
Fig. 27
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3. Slightly loosen the 3 nuts that fix the zero, marked in red. It is necessary to raise them for some millimetres to release the platform.
Fig. 28
4. Raise the 4 Allen screws, marked in yellow, using a 2mm Allen spanner, to bring the zero to a neutral level and tighten the central knob for fastening. 5. Put 2 sheets of paper inside the resin tank under the platform, the first one will touch the silicone coat, the other one will help us feel the pressure of the drawer. 6. Move the Z axis with the software Digital Wax Controller using the shafts UP and DOWN to bring it near to the resin tank. Insert in the window some decreasing values, in order not to lower the building platform too much and risk to damage the resin tank. 7. When the building platform is almost touching the sheets of paper, insert a value of movement equal to 0,1/0,2 mm. Every time the platform is lowered downwards, move the sheet of paper that is in contact with the building platform and check which one of the corners of the building platform is pressing mostly on the resin tank.
Fig. 29
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8. If one edge is blocked by the building platform, screw one of the Allen screw, marked in yellow, corresponding to the blocked edge: this will raise the drawer in the same point. 9. When we adjust the Allen screws for regulation, we create a tension on the building platform. To eliminate it, loosen and tighten again the central knob after every regulation of the Allen screws. 10. Check again the pressure on the sheet of paper and if necessary screw one of the other Allen screws and go back to point 8. 11. If the sheet of paper can move freely, lower the platform again with steps of 0,1 mm. Check again that the pressure on the sheet of paper is uniform on all corners. If necessary adjust the pressure working on the Allen screws. 12. At the end of the zero setting, the sheet should be pressed uniformly on all the corners of the building platform but you should be able to move it as well, pulling it with a certain strength. 13. Now insert in the window the value equivalent to the thickness of the two sheets of paper. Usually a normal sheet measure 0,1 mm, so insert 0,2 mm. Go down pushing the button DOWN and push OK to save the zero.
Fig. 30
When the zero is set, it is not important if the Z axis is moved (for example to pour the resin into the resin tank) because the zero point is saved. For more information about the system zero setting, check the system instruction manual.
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11.3 11.3.1
DIGITALWAX FILE GENERATOR Introduction
Fig. 31 Main Form of DigitalWax File Generator
The DigitalWax File Generator is an application developed to create the laser path. It allows the following operations: - to choose the *.prm or slc file; - to set hatching; - to choose the name of the destination file *.mkr; - to show the laser track when it is generated; - to show the laser track of a specified *.mkr file; 11.3.2 11.3.2.1 Installation System requirement The DigitalWax File Generator program requires the following system minimum properties: 256 Mb of RAM; 15 Mb of free space; Operating System: Windows 2000/Me/Xp/Vista/Seven; DigitalWax File Generator installation To install the program, follow these steps: 1) Insert the given CD-ROM in the CD-ROM reader of the PC; 2) close all the open applications; 3) If the Autorun software does not start: - Select Computer Resource-->select the CD-ROM reader; - in the CD-ROM double click on 'DW File Gen setup.exe' to install the program; - follow the messages and complete the installation;
11.3.2.2
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11.3.3
DigitalWax File Generator Controls The program allows you to generate the laser path of a specified object. When we start the program we can select the name of the *.prm or *.slc file. After choosing it, select the hatching value than you need to use, take note that it is related to the resin that you will use. Then choose the name and the folder of the *.MKR file (the folder can differ from the *.prm file). When all the setting operations are terminated just click Elaborate Data and the program starts to elaborate the file. The program checks all the layer of the file before creating the track, it could take some minutes (it depends by file dimension and PC configuration). In Every moment is possible to stop the elaboration using Stop button.
11.3.4
Visualization of a *.MKR File In the lower part of the main form you can select a generic *.MKR file and visualize the laser track and building estimation time. The Check it button starts the elaboration.
11.3.5
Useful advice There are some rules to follow to ensure a good performance of the program. In case you need to reinstall the program or to install a new version of it, it is necessary to remove the old version. One important thing about the *.prm file is that this file has to be in the same folder of the layers generated by 'STL Autoedit'. How to create the MKR file: Select the cad files to produce, using your cad software, place them into a working area equal to our platform: 65*65mm. Pay attention: not to overlap models; place them perfectly adherent to the base of the platform in Z axis;
11.3.6
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The center of the platform corresponds to the center of X-Y virtual axes. The files must be placed at zero level on the Z axis. There is no quantity limit, but you have to consider the total building time. The models must be supported and the distance between one and the other must be enough to remove them easily. Once that your models are ready you can save the platform as an STL file or export it as an SLC file, it depends on the cad software that you are using. For STL files proceed using STL autoedit or other software that allow to slice the model; save as SLC or PRM. For SLC files open the DWFileGenerator and import the SLC file, select the hatching value related to the resin that you will use and save the file as MKR.
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11.4
REPRODUCTION OF EC CONFORMITY DECLARATION
EC CONFORMITY DECLARATION
(in accordance with 2006/42/EC Machine directive, Enclosure II point A)
The undersigned Manufacturer
DWS s.r.l. Via Lago di Levico, 3 36010 Zan (VI) Italia

declares under its own responsibility that the following machine
Name Model Type Serial No. Year of construction
STEREOLITHOGRAPHY MACHINE DIGITALWAX DW008 2011
complies with the legislative prescriptions which transpose the following Directives: 2006/42/EC machine Directive, 2006/95/EC Low Voltage Directive, 2004/108/EC Electromagnetic Compatibility Directive.
HARMONISED STANDARDS APPLIED

UNI EN 12100 (Safety of machinery General design principles Risk evaluation and risk reduction) CEI EN 60204-1 (General rules for machinery electrical equipment) The company also declares, as provided for in enclosure V to the 98/37/EC Directive, that: - the EC symbol marking has been applied to the machine; - the technical booklet was constituted by the person in charge of the technical department and it is available to the Competent Bodies at the Manufacturers head office. Zan (date) RENATO MADDALENA (name and surname) 01/03/1956 (date of birth) GOVERNING DIRECTOR (position of signatory)
DWS S.r.l.
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11.5
REPRODUCTION OF EC MARKING PLATE
DWS S.r.l. Via Lago di Levico, 3 36010 Zan (VI) ITALIA Telefono: +39(0)445.372323 Telefax: +39(0)445.372191 Macchina: Modello: Tipo: Matricola No.: Anno di costruzione: 2011 110/230 V a.c. 50/60 Hz Tensione di alimentazione (V):
Macchina per stereolitografia DIGITALWAX DW008
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DWS S.r.l. Via Lago di Levico, 3 36010 Zan (VI) ITALY Tel.

+39-0445-372323 Fax +39-0445-372191

Year of construction: 2011

INSTRUCTION MANUAL FOR USE AND MAINTENANCE

DWS S.r.l. Via Lago di Levico, 3 36010 Zan (VI) Italia

6.4 6.5 6.6 7

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Macchina per stereolitografia DIGITALWAX DW008

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Building platform Fig. 2 Resin tank

Liquid resin Laser head

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110/230 50 40 380 x 495 x 560 65 65 65 30 400/415 3B 90 85 4,6 8 22 30

SAFETY AND PREVENTION

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interruption or oscillation of mains voltage insufficient compatibility or integrity of hardware/software.

Instructions for machine use

Ver. 3.0 - 2011

Ver. 3.0 - 2011

Ver. 3.0 - 2011

LIFTING, TRANSPORT AND STORAGE

INSTRUCTIONS FOR MACHINE INSTALLATION

Ver. 3.0 - 2011

Ver. 3.0 - 2011

Ver. 3.0 - 2011

MACHINE SETTING FOR WORK

MACHINE OPERATION AND MODEL TREATMENT

Ver. 3.0 - 2011

Ver. 3.0 - 2011

WARNING - Ensure that no light gets into the forming chamber.

Ver. 3.0 - 2011

Ver. 3.0 - 2011

2. Put the funnel inside the glass (fig. B)

Ver. 3.0 - 2011

Ver. 3.0 - 2011

Ver. 3.0 - 2011

CLEANING AND MAINTENANCE

Ver. 3.0 - 2011

PROBLEM The machine does not respond to computer command.

Ver. 3.0 - 2011

Ver. 3.0 - 2011

DIGITALWAX 008 CONTROLLER Introduction

Fig.23: Main form of the DigitalWax Controller

Confirm next step pressing Install

Ver. 3.0 - 2011

Now the pc will complete the installation.

- Select Custom and press again Next.

- Continue with the installation pressing Next.

Ver. 3.0 - 2011

Ver. 3.0 - 2011

Ver. 3.0 - 2011

2. Select view status

Ver. 3.0 - 2011

6. Turn off the firewall.

Ver. 3.0 - 2011

8. Find the network adapter and select it

9. Disable the energy saver as below from the power management

Ver. 3.0 - 2011

Ver. 3.0 - 2011

Ver. 3.0 - 2011