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ht500:manual [2016/03/22 14:28] Markus Bürgener [Electronic chamber] picture renewed |
ht500:manual [2016/05/12 11:20] Markus Bürgener [Filament supply] graphic quality improved |
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</WRAP> | </WRAP> | ||
</WRAP> | </WRAP> | ||
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- | ===== EU declaration of conformity ===== | ||
- | Valid {{:reprap-industrial-v1:ec-declaration-of-conformity.pdf|EU declaration of conformity}} for reference. | ||
===== Personnel safety and device reliability ===== | ===== Personnel safety and device reliability ===== | ||
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==== Injury risks ==== | ==== Injury risks ==== | ||
- | Some hazards are design related and cannot be avoided by mere constructive measures. To avoid injuries it is necessary that the operator is aware of such situations and takes adequate care. The owner has to make sure that the safety precautions are observed.\\ | + | Some hazards are design related and cannot be avoided by mere constructive measures. To avoid injuries it is necessary that the operator is aware of such situations and takes adequate care. It is the owners responsibility to ensure that every user of the 3D Printer is informed about risks and preventions and that the safety precautions are observed. Access to this manual must be provided at all times.\\ |
- | The safety advices given in the following are meant to protect the operator of the HT500. It is the owner's responsibility to ensure that anybody working with or on the 3D Printer is familiar with this chapter and observes the given information.\\ | + | The safety advice given in the following is meant to protect the operator of the HT500.\\ |
=== Electrical safety === | === Electrical safety === | ||
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=== Hot surfaces === | === Hot surfaces === | ||
Outer surfaces of the HT500 are adequately isolated and do not exceed temperatures of +40°C (104°F). They are safe to the touch at any time.\\ | Outer surfaces of the HT500 are adequately isolated and do not exceed temperatures of +40°C (104°F). They are safe to the touch at any time.\\ | ||
- | Inside the build chamber, the heating elements generate the necessary ambient temperature for warp-free printing. Depending on the processed material, surfaces inside the build chamber can **reach temperatures up to +70°C (158°F)**.\\ | + | Inside the build chamber, the heating elements generate the necessary ambient temperature for warp-free printing.\\ Depending on the processed material, surfaces inside the build chamber can **reach temperatures up to +70°C (158°F)**.\\ |
The print table is heated separately, also to minimize warpage. It can **reach temperatures up to 130°C (266°F)**.\\ | The print table is heated separately, also to minimize warpage. It can **reach temperatures up to 130°C (266°F)**.\\ | ||
- | The extruder nozzles are heated to melt the filament strands and may **exceed temperatures of 300°C (572°F)**.\\ | + | The extruder nozzles are heated to melt the filament strands and may reach **temperatures of 500°C (932°F)**.\\ |
- | Do not open the build chamber during or immediately after completion of a print job. The print table heating shuts down after finishing a print and cools down to chamber temperature. **Always wait** at least 10 minutes before removing the printed object. This is also to avoid stress cracks due to sudden temperature drop.\\ | + | \\ |
- | If, for reasons of avoiding damage (e.g. collisions), it becomes necessary to interrupt the printing process and to open the build chamber before the cool down time has passed, **wear adequate protective gloves** when touching any interior. | + | Touching heated components may lead to grade 1 burning injuries, in case of the nozzles of grade 2 of limited size.\\ |
+ | \\ | ||
+ | To avoid burning injuries: | ||
+ | * **Do not open** the build chamber during or immediately after completion of a print job. | ||
+ | * **Always switch off** the preheating and wait until the print bed temperature indicated on the touchscreen has dropped below 50°C (122°F) before removing the print bed. This is also to avoid stress cracks due to sudden temperature drop. | ||
+ | * Some tasks require handling at operating temperature (e.g. changing the nozzle tip). **Wear adequate protective gloves** when handling hot components. | ||
+ | * Observe the procedures and waiting times stated in this manual. | ||
=== Coolant === | === Coolant === | ||
For proper operation the HT500 is equipped with a closed loop low-maintenance cooling system that needs little interference. The circuit is filled with coolant type //Innovatek Protect IP ready-to-use//.\\ | For proper operation the HT500 is equipped with a closed loop low-maintenance cooling system that needs little interference. The circuit is filled with coolant type //Innovatek Protect IP ready-to-use//.\\ | ||
If it is necessary to perform works on the cooling system, such as refilling coolant or exchanging defective hoses, avoid direct skin or eye contact. Always wear **adequate protective gloves** that are resistant to chemical substances (e.g. PVC, NBR).\\ | If it is necessary to perform works on the cooling system, such as refilling coolant or exchanging defective hoses, avoid direct skin or eye contact. Always wear **adequate protective gloves** that are resistant to chemical substances (e.g. PVC, NBR).\\ | ||
- | Observe the information provided in the manufacturer's safety data sheet. | + | Observe the information provided in the {{:ht500:eg_safetydatasheet_innovatekprotect_eng.pdf|manufacturer's safety data sheet}}.\\ |
Additional information concerning the cooling system and required maintenance can be found in the [[service-guide#cooling-water-pump|Service Guide]].\\ | Additional information concerning the cooling system and required maintenance can be found in the [[service-guide#cooling-water-pump|Service Guide]].\\ | ||
+ | === Noise === | ||
+ | The HT500 3D Printer is build to be operated in a professional environment such as workshops and laboratories. It is not suited for the operation in an office. During print jobs, it does not exceed 60dB(A), which is considered "unauspicious" for long-term exposure.\\ | ||
+ | Special noise protection equipment is not required. | ||
+ | |||
+ | === Fumes === | ||
+ | Molten plastics may emit unpleasantly smelling fumes. The HT500 3D Printer is equipped with an activated charcoal filter element to reduce such fumes. It is mainly to reduce smells and **does not** protect from toxic fumes that evaporate from overheated plastics. Such fumes can be **perilous**.\\ | ||
+ | It is vitally important not to exceed the temperature limits stated for a printed [[knowledge-base#materials|material]]. Overheating is indicated by discoloration and coking. | ||
==== Emergency stop ==== | ==== Emergency stop ==== | ||
You will find a red **Emergency STOP** button in the top-right corner of the touchscreen. In case of any unexpected performance of the 3D Printer, press this button to immediately stop any mechanical movement in the build chamber and to shut down all heater elements.\\ | You will find a red **Emergency STOP** button in the top-right corner of the touchscreen. In case of any unexpected performance of the 3D Printer, press this button to immediately stop any mechanical movement in the build chamber and to shut down all heater elements.\\ | ||
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====== Structural and functional description ====== | ====== Structural and functional description ====== | ||
+ | The following paragraphs name and explain all components of the HT500 to give you an exact overview. The terms are used consistently throughout this manual and will help you identifying any part you may wish to find or [[http://kuehlingkuehling.de/shop|order as a spare part]]. | ||
+ | |||
+ | ===== Functional principle ===== | ||
+ | <WRAP group> | ||
+ | <WRAP half column> | ||
+ | The HT500 3D Printer uses the **F**used **F**ilament **F**abrication (FFF) process to build up workpieces in subsequent layers of 0.10 to 0.60mm thickness. The plastic filament is heated in the nozzle to its melting temperature and continuously conveyed by a cogwheel. The molten plastic is pressed through the bore of the nozzle tip and onto the heated print bed. After each layer the print bed is lowered by the preset layer height and the next layer is applied. The heat of the newly applied plastic ensures an adequate binding of the layers.\\ | ||
+ | \\ | ||
+ | All temperatures and movement commands are provided by the GCODE, a file format previously generated with a "slicing" software. This file contains all information for a single print job and is uploaded to the 3D Printer via the [[operation#the-web-interface|web interface]]. All Kühling&Kühling 3D Printers are built to operate best with [[http://slic3r.org|Slic3r]], an OpenSource Software designed for professional 3D printing.\\ | ||
+ | \\ | ||
+ | After the workpiece has been finished the user can leave it in the heated build chamber to slowly cool down thus reducing shrinkage and internal tensions, or he can immediately remove it and start the next print job. | ||
+ | The layered building process enables the user to create even complex forms that otherwise could not be realized. | ||
+ | </WRAP> | ||
+ | |||
+ | <WRAP half column> | ||
+ | [{{:ht500:fff_principle_manual.png?400|The layer-by-layer build-up of random geometries becomes possible with FFF-3D Printers.}}] | ||
+ | </WRAP> | ||
+ | </WRAP> | ||
+ | |||
+ | |||
+ | ===== Hardware components ===== | ||
<WRAP group> | <WRAP group> | ||
<WRAP half column> | <WRAP half column> | ||
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| 2 | [[#Electronic chamber|Electronic chamber]] | | | 2 | [[#Electronic chamber|Electronic chamber]] | | ||
| 3 | [[#Touchscreen|Touchscreen]] | | | 3 | [[#Touchscreen|Touchscreen]] | | ||
+ | <WRAP clear/> | ||
- | The following paragraphs name and explain all components of the HT500 to give you an exact overview. The terms are used consistently throughout this manual and will help you identifying any part you may wish to find or order as a spare part.\\ \\ | + | The HT500 is built on an aluminum framework covered with acrylic panels. Its main functional sections are the upper [[#Build chamber|build chamber]] and the lower [[#Electronic chamber|electronic chamber]]. The build chamber is covered with translucent plates to provide insight during production. It contains all mechanical components, the [[#air-filter|air filter]]. At the back cover, the [[#Filament supply|filament supply]] is installed.\\ \\ The lower is covered with opaque sheets and contains the electronic components and the mains adapter. All connections and the power switches are located here and the [[#Touchscreen|touchscreen]] for operation is mounted at the front cover.\\ \\ All covers are fixed to the frame with M4x20 hexagon socket screws and hammerhead nuts, thus being easy [[ht500:service-guide#opening-the-electronic-chamber|to remove]] and making all around access possible to all parts if required. |
- | The HT500 is built on an alloy framework and is mainly divided into two chambers. The upper [[#Build chamber|build chamber]] is covered with acrylic glass plates to provide insight during production. It contains all mechanical components. At the back cover, the [[#Filament supply|filament supply]] is installed.\\ \\ The lower [[#Electronic chamber|electronic chamber]] is covered with opaque plastic plates and contains the electronic components and the mains adapter. All connections and the power switches are located here and the [[#Touchscreen|touchscreen]] for operation is mounted at the front cover.\\ \\ All covers are fixed to the frame with M4x20 hexagon socket screws and hammerhead nuts, thus being easy [[ht500:service-guide#opening-the-electronic-chamber|to remove]] and making all around access possible to all parts if required. | + | |
</WRAP> | </WRAP> | ||
<WRAP half column> | <WRAP half column> | ||
- | [{{:reprap-industrial-v1:desc_bc_overview_1.png?400|General overview of the HT500 3D Printer.}}] | + | [{{:ht500:desc_main_1.png?400|General overview of the HT500 3D Printer.}}] |
</WRAP> | </WRAP> | ||
</WRAP> | </WRAP> | ||
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</WRAP> | </WRAP> | ||
- | ===== Build chamber ===== | + | ==== Build chamber ==== |
<WRAP group> | <WRAP group> | ||
<WRAP half column> | <WRAP half column> | ||
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<WRAP half column> | <WRAP half column> | ||
- | [{{:reprap-industrial-v1:desc_filamentfeedunit.png?400|Filament supply}}] | + | [{{:ht500:desc_filamentfeedunit.png?400|Filament supply}}] |
- | [{{:reprap-industrial-v1:desc_filamentfeedunit_dustsponge.png?400|Filament inlet with limit switch and dust wiping sponge.}}] | + | [{{:ht500:desc_filamentfeedunit_dustsponge.png?400|Filament inlet with limit switch and dust wiping sponge.}}] |
</WRAP> | </WRAP> | ||
</WRAP> | </WRAP> | ||
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|<100% 5% 95%>| | |<100% 5% 95%>| | ||
^ No. ^ Description ^ | ^ No. ^ Description ^ | ||
- | | 1 | [[http://doku.radds.org/en/|RADDS]] v1.5 3D Printer Controller | | + | | 1 | [[http://doku.radds.org/en/|RADDS]] v1.5 3D Printer Driver Shield | |
- | | 2 | [[http://www.udoo.org/|UDOO]] Single Board Mini PC | | + | | 2 | [[http://www.udoo.org/|UDOO Quad]] Single Board Mini PC | |
- | | 3 | 2.4 V power supply for internal clock | | + | | 3 | 3V power supply for internal real-time clock | |
- | | 4 | solid state relays on cooling substructure | | + | | 4 | Solid State Relays on cooling substructure | |
+ | | 5 | 12V(DC) Mains Adapter | | ||
<WRAP clear></WRAP> | <WRAP clear></WRAP> | ||
- | All control elements are installed in the electronic chamber together with the 12 V(DC) mains adapter and the cooling unit.\\ | + | All control elements are installed in the electronic chamber together with the 12V(DC) mains adapter and the cooling unit.\\ |
The chamber is completely covered with white acrylic sheets fastened to the aluminum frame with hexagon socket screws and hammerhead nuts.\\ | The chamber is completely covered with white acrylic sheets fastened to the aluminum frame with hexagon socket screws and hammerhead nuts.\\ | ||
- | The RADDS 3D Printer Controller controls all processes of the printing process, i.e. the drives, the heating resistors, heating fans and the temperature sensors. Exchangeable hardware components are the stepper motor drivers.\\ | + | The RADDS 3D Printer Driver Shield in conjunction with the SAM3X microcontroller on the UDOO board controls all processes of the printing process, i.e. the drives, the heating resistors, heating fans and the temperature sensors. Exchangeable hardware components are the stepper motor drivers.\\ |
- | The UDOO Single Board Mini PC provides the GUI of the [[#Touchscreen|touchscreen]] and the ethernet connection and processes the G-codes of the slicing software.\\ | + | The UDOO Quad Single Board Mini PC provides the GUI of the [[#Touchscreen|touchscreen]] and the ethernet connection and processes the G-codes of the slicing software.\\ |
Slots in the bottom cover provide an air inlet for the cooling unit.\\ | Slots in the bottom cover provide an air inlet for the cooling unit.\\ | ||
- | When the 3D Printer is switched off the internal clock of the Mini PC is fed by two external batteries so that the time signal is not lost. | + | When the 3D Printer is switched off the internal real-time clock of the Mini PC is fed by two external batteries so that the system's time signal is not lost. |
The solid state relays switch the four heating resistors of the [[#Build chamber|build chamber]] heating and the heating resistor of the [[#Print table and print bed|print table]].\\ | The solid state relays switch the four heating resistors of the [[#Build chamber|build chamber]] heating and the heating resistor of the [[#Print table and print bed|print table]].\\ | ||
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<WRAP half column> | <WRAP half column> | ||
- | [{{:ht500:desc_ht500-overviewelectroniccomponentes.png?400|Inside view of the electronic chamber (left side).}}] | + | [{{:ht500:desc_ht-500_overviewelectronicchamberleft.png?400|Inside view of the electronic chamber (left side).}}] |
</WRAP> | </WRAP> | ||
</WRAP> | </WRAP> | ||
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|<100% 5% 95%>| | |<100% 5% 95%>| | ||
^ No. ^ Description ^ | ^ No. ^ Description ^ | ||
- | | 5 | Mains adapter | | ||
| 6 | Cooling unit radiator | | | 6 | Cooling unit radiator | | ||
| 7 | Cooling unit pump | | | 7 | Cooling unit pump | | ||
<WRAP clear></WRAP> | <WRAP clear></WRAP> | ||
- | The cooling unit consists of a pump with water reservoir, a radiator and the closed loop coolant circuit, which is filled with Innovatek Protect IP ready-to-use. The coolant is pumped in a circle past the [[#Motors|motors]] and the [[#Extruder head components|extruder nozzles]] where it absorbs heat and is then cooled down by the radiator. The pump starts/stops automatically when the build chamber is switched on and off.\\ How to judge if [[service-guide#cooling-water-pump|refilling of coolant]] is necessary and the necessary steps are described in the Service guide. | + | The cooling unit consists of a pump with water reservoir, a radiator and the closed loop coolant circuit filled with an electronic cooling liquid. It is automatically switched on and off when the build chamber is activated/deactivated. |
+ | |||
+ | The coolant is pumped in a circle past the [[#Motors|motors]] and the [[#Extruder head components|extruder nozzles]] where it absorbs heat which is then emitted via the radiator.\\ | ||
+ | |||
+ | Check the coolant level [[service-guide#monthly-150-operating-hours|monthly]] and if required, refill as described in the [[ht500:service-guide|Service Guide]]. | ||
</WRAP> | </WRAP> | ||
<WRAP half column> | <WRAP half column> | ||
- | [{{:ht500:desc_ht-500_overviewelectronicchamberleft.png?400|Inside view of the electronic chamber (right side).}}] | + | [{{:ht500:desc_ht500_overviewelectronicchamberright.png?400|Inside view of the electronic chamber (right side).}}] |
</WRAP> | </WRAP> | ||
</WRAP> | </WRAP> | ||
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| 11 | Main switch | | | 11 | Main switch | | ||
| 12 | RJ45 ethernet plug | | | 12 | RJ45 ethernet plug | | ||
- | | 13 | 230 V supply cable with Schuko plug | | + | | 13 | 230V supply cable with Schuko plug | |
<WRAP clear></WRAP> | <WRAP clear></WRAP> | ||
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|<100% 5% 95%>| | |<100% 5% 95%>| | ||
^ No. ^ Description ^ | ^ No. ^ Description ^ | ||
- | | 14 | Touchscreen user interface (GUI) | | + | | 14 | 10" TFT high-resolution touchscreen with Graphical User Interface (GUI) | |
| 15 | Wake button | | | 15 | Wake button | | ||
<WRAP clear></WRAP> | <WRAP clear></WRAP> | ||
- | The wake button at the front panel provides a wake-up function and indicates the general operating status of the 3D Printer. It is equipped with a light ring that is illuminated while operational and dims after the 3D Printer has been shut down. Press the button to restart the 3D Printer from standby. | + | The wake button at the front panel provides a wake-up function and indicates the general operating status of the 3D Printer. It is equipped with a light ring that is illuminated while operational and dims after the 3D Printer has been shut down. Press the button to restart the 3D Printer from standby.\\ |
+ | |||
+ | All 3D Printer [[operation]] is carried out via the Graphical User Interface at the [[#touchscreen-operation|touchscreen]]. | ||
</WRAP> | </WRAP> | ||
<WRAP half column> | <WRAP half column> | ||
- | [{{:reprap-industrial-v1:desc_overviewelectronicchamberfront.png?400|Touchscreen user interface and wake button at the front cover.}}] | + | [{{:ht500:desc_ht500_electronicchamberfront.png?400|Touchscreen user interface and wake button at the front cover.}}] |
</WRAP> | </WRAP> | ||
</WRAP> | </WRAP> | ||
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All operation of the HT500 is carried out via the **RepRapOnRails** operating software which provides status messages and control functions that can be chosen by simply tapping the respective buttons. | All operation of the HT500 is carried out via the **RepRapOnRails** operating software which provides status messages and control functions that can be chosen by simply tapping the respective buttons. | ||
- | Find detailed explanations of functions and operating procedures in the [[:reprap-industrial-v1:Software version v1.1.0 - Operation and commissioning|Operating manual]]. | + | Find detailed explanations of functions and operating procedures in the [[:ht500:operation|Operating Manual]]. |
In case you experience any trouble, please refer to the [[service-guide|Service guide]] and [[ht500:Troubleshooting|Troubleshooting]]. If you cannot solve a problem with the information given there, you are always welcome to [[http://kuehlingkuehling.de/imprint/|contact us]] personally. We are trying to improve these information constantly and will be grateful for your help when you encounter any previously undescribed faults or problems. | In case you experience any trouble, please refer to the [[service-guide|Service guide]] and [[ht500:Troubleshooting|Troubleshooting]]. If you cannot solve a problem with the information given there, you are always welcome to [[http://kuehlingkuehling.de/imprint/|contact us]] personally. We are trying to improve these information constantly and will be grateful for your help when you encounter any previously undescribed faults or problems. | ||
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The transport box is made of unfinished plywood and may hold splinters and sharp edges that can cause cutting injuries. | The transport box is made of unfinished plywood and may hold splinters and sharp edges that can cause cutting injuries. | ||
* Take care when removing the transport packaging and wear protective gloves. | * Take care when removing the transport packaging and wear protective gloves. | ||
+ | </WRAP> | ||
+ | |||
+ | |||
+ | <WRAP note> | ||
+ | NOTE | ||
+ | |||
+ | If the 3D Printer has a temperature below 16°C (e.g. directly after delivery in cold weather) there is a danger of air humidity condensing on sensitive electronic components. This can lead to severe damages due to short circuiting during commissioning.\\ Therefore, it is necessary to thoroughly let the 3D Printer warm up to ambient temperature for at least 12 hrs. at its operating place **prior** to commissioning.\\ Regard the [[technical-data#td-ac|ambient conditions]] required for operation. | ||
</WRAP> | </WRAP> | ||
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===== Initial commissioning ===== | ===== Initial commissioning ===== | ||
- | After set-up has been completed the further commissioning of the HT500 takes place at the web-interface and the touchscreen as described in the [[ht500:operation#Initial commissioning|Operating Manual]]. | + | After set-up has been completed the further commissioning of the HT500 takes place at the [[operation#the-web-interface|web interface]] and the touchscreen as described in the [[ht500:operation#initial-commissioning|Operating Manual]]. |
====== Decommissioning ====== | ====== Decommissioning ====== | ||
Decommissioning may be necessary on two occasions: the temporary decommissioning if the 3D Printer will just be out of operation for a limited time (e.g. moving) or the permanent decommissioning if the 3D Printer has expired its lifetime and will be scrapped. | Decommissioning may be necessary on two occasions: the temporary decommissioning if the 3D Printer will just be out of operation for a limited time (e.g. moving) or the permanent decommissioning if the 3D Printer has expired its lifetime and will be scrapped. | ||
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<WRAP group> | <WRAP group> | ||
<WRAP half column> | <WRAP half column> | ||
- | * Take the HT500 out of operation as described [[#Decommissioning for transport and storage|above]]. | + | * Take the HT500 out of operation as described [[#temporary-decommissioning|above]]. |
* Drain the cooling system and collect the coolant. Dispose of the coolant according to your local guidelines and the manufacturer's data sheet. | * Drain the cooling system and collect the coolant. Dispose of the coolant according to your local guidelines and the manufacturer's data sheet. | ||
* Disassemble all components according to their recyclablility and dispose of them adequately and lawfully. | * Disassemble all components according to their recyclablility and dispose of them adequately and lawfully. | ||
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<WRAP group> | <WRAP group> | ||
<WRAP half column> | <WRAP half column> | ||
- | The HT500 3D Printer features a low-maintenance design, thus regular maintenance is not required during normal operation. [[service-guide#cleaning-recommendation|Regular cleaning]] will mostly suffice to keep your 3D Printer running satisfactorily. In case of faults, refer to the [[Troubleshooting|troubleshooting guide]] and the [[service-guide|Service Guide]] where most problems known to us and according remedies are lodged. | + | The HT500 3D Printer features a low-maintenance design, thus intensive maintenance time is not required during normal operation. Nonetheless regard the [[service-guide#maintenance-intervals|maintenance intervals]] stated in the [[service-guide|Service Guide]].\\ |
+ | |||
+ | Apart from this, [[service-guide#cleaning-recommendation|regular cleaning]] will mostly suffice to keep your 3D Printer running satisfactorily.\\ | ||
+ | |||
+ | In case of faults, refer to the [[Troubleshooting|Troubleshooting Guide]] and the [[service-guide|Service Guide]] where most problems known to us and according remedies are lodged. | ||
</WRAP> | </WRAP> | ||