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HT500 - Manual

The Kühling&Kühling HT500 3D Printer

General

Welcome to the HT500 3D Printer operating manual of the Kühling&Kühling GmbH (in the following
referred to as Kühling&Kühling).
The HT500 3D Printer (in the following referred to as HT500 or 3D Printer) is a fully automatic stand-
alone device for Fused-Filament-Fabrication (FFF) in a lab or commercial environment.
Any information needed for

installing and commissioning

,

operating

,

troubleshooting

,

maintenance

and repair

of the 3D Printer are described in the following paragraphs and the accompanying sites.

This user's manual must be read thoroughly as it is meant to provide the operator with all information
needed to operate the HT500 safely and reasonably. Please always provide access to the website for

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Summary of Contents for HT500

Page 1: ...tand alone device for Fused Filament Fabrication FFF in a lab or commercial environment Any information needed for installing and commissioning operating troubleshooting maintenance and repair of the 3D Printer are described in the following paragraphs and the accompanying sites This user s manual must be read thoroughly as it is meant to provide the operator with all information needed to operate...

Page 2: ...rear side of the HT500 you ﬁnd all information to precisely identify your 3D Printer Serial number Date of manufacturing Hardware Revision You will also ﬁnd the valid hardware revision in the Setup menu on the touchscreen Type plate on the rear side Software versions Operating sofware RepRapOnRails Version v1 3 x Operating manual Intended use The HT500 3D Printer has been designed and built for pr...

Page 3: ...rescribed maintenance work Operation in an explosive atmosphere Warranty terms The general terms and conditions of Kühling Kühling GmbH apply The customer is familiar with these terms latest on the day of signing the purchase contract The warranty terms and the liability period can be found in the contract documents and in the order conﬁrmation Warranty claims and liability are voided in one or mo...

Page 4: ...ng it up and connecting the power supply The 3D Printer is delivered in a wooden transport box on a palette It is advisable to leave the HT500 packed and on the palette until moving it to its ﬁnal installation site for commissioning At the installation site unpack the HT500 according to the information in the accompanying Quick Start Guide Dispose of the packaging in accordance with the local wast...

Page 5: ...ets only The storage ambient conditions for the HT500 and its components are stated in the data sheet For recommissioning after lengthy periods of storage follow the information given in initial commissioning Environment recycling and disposal When used as intended the HT500 presents no environmental danger However the internal cooling works with a coolant that can be environmentally dangerous whe...

Page 6: ...ous situations is increased by Using the HT500 for other applications than the intended Inappropriate usage of the 3D Printer Operating the 3D Printer in a non safe state or under improper conditions Insuﬃcient attention lax handling or intensive soiling Therefore Use the HT500 for its intended use only The HT500 must be in goor working order and in a safe state at any time Check the apparatus pri...

Page 7: ...parts immediately Do not setup and operate the 3D Printer in a humid environment 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 Inside the build chamber the heating elements generate the necessary ambient temperature for warp free printing Depending on the processed material surfaces inside the bu...

Page 8: ...T500 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 material Overheating is indicated by discoloration and coking Emergency stop You will ﬁnd a r...

Page 9: ...of components can lead to loss of production due to property damage therefore we strongly recommend following the information given in this manual Extruder nozzles The brazen extruder nozzles are sensitive to heat treatment and mechanical strain If the nozzles or extruder barrels are clogged by congealed material reheating during the normal production ﬂow is utterly suﬃcient to clear them in most ...

Page 10: ... All Kühling Kühling 3D Printers are built to operate best with 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 creat...

Page 11: ...nd looking inside the build chamber This is the reference view for all other directions L Left Left side of the 3D Printer referred to the frontal view R Right Right side of the 3D Printer referred to the frontal view B Back Backside of the 3D Printer referred to the frontal view All movement directions of the axes are deﬁned throughout this manual as follows Tag Called Movement direction X X posi...

Page 12: ...ctrical motors are installed at their working point and equipped with a water cooling system The extruder head moves on an H frame tooth belt driven by two separate stepper motors in X and Y direction The print table is lifted and lowered in Z direction by a spindle drive For regulating the temperature inside the build chamber two heating resistors in separate housings heat the air which then is c...

Page 13: ...ever release function 5 Spring tensioning screw M4x20 6 Idler spring 7 Filament feed hose 8 Cooling hoses The extruder head is mounted to the traverse of the H frame and moves horizontally in X and Y direction with useful operating ranges of X 200 mm and Y 185 mm It contains the ﬁlament drive gears forwarding the ﬁlament strands and the hot ends which melt and dose the material onto the print tabl...

Page 14: ...e To improve the thermal control of the melting process the hot end mount is connected to the cooling system ensuring an even temperature distribution in a well deﬁned area of the nozzles so that there is a preheating zone and a melting zone Extruder head components The nozzle is exchangeable to provide diﬀerent bore diameters for diﬀerent materials layer thicknesses or print speed Ex factory the ...

Page 15: ...ich panel with a silicone rubber heating pad that provides temperatures of up to 130 C providing an even temperature distribution and ensuring optimal adhesion throughout the printing process Print table and print bed fastened with four bulldog clamps No Description 5 Set screws of the spring mounted 3 point leveling support It rests on three springs lockable with set screws for an even and accura...

Page 16: ...or a special treatment with tape or glue PEI is highly resistant to a lot of solvents which makes it a suitable subsurface for a lot of materials since removing residues and refurbishing for the next print becomes quite easy Find more information about the custom made Kühling Kühling PEI print bed Operating and handling are described in the Operating manual Cleaning and care can be found in the Se...

Page 17: ...position is the reference value for all relative movement of the extruder head and the print bed Hall eﬀect sensor and magnet of the X axis Hall eﬀect sensor and magnet of the Y axis Hall eﬀect sensor and magnet of the Z axis Thermistors measure the relevant temperatures for the printing process i e the print bed temperature and the build chamber temperature All thermistors deliver their input sig...

Page 18: ...er of 2 85 mm with a tolerance of 0 1 mm More information about ﬁlament and materials can be found in the material section and the print preparation section of the Knowledgebase Two separate strands can be fed from the outside to the extruder head One ﬁlament spool can be positioned on each spool carrier a stop collar prevents them from falling down due to their rotation The end of the ﬁlament str...

Page 19: ...rd Mini PC 3 3V power supply for internal real time clock 4 Solid State Relays on cooling substructure 5 12V DC Mains Adapter 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 RADDS 3D Pr...

Page 20: ...y switched on and oﬀ when the build chamber is activated deactivated The coolant is pumped in a circle past the motors and the extruder nozzles where it absorbs heat which is then emitted via the radiator Check the coolant level monthly and if required reﬁll as described in the Service Guide Inside view of the electronic chamber right side No Description 8 Type plate 9 Cooling unit radiator grill ...

Page 21: ... 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 Touchscreen user interface and wake button at the front cover Touchscreen operation Operating the HT500 is designed to be comfortable and intuitive Therefore a high resolution 10 TFT t...

Page 22: ...t operation of the HT500 The currently installed version of the operating software is displayed on the right hand side of Setup menu together with additional system information RepRapOnRails software version displayed in the Setup menu Setup and Installation Use a lifting carriage to bring the HT500 on its transport pallet as near to its setup site as possible Before setting up the HT500 remove th...

Page 23: ...o ensure free air circulation at the ventilation grill in the back cover At the front a free space of 1 250mm is recommended to allow easy operation with open chamber doors To easily access the touchscreen in a sitting or standing position the height of the setup table should not undercut 780mm A 230V power source must be within the range of the connection cable Necessary free space around the HT5...

Page 24: ...er and remove the wooden cover plate and the air cushion foil Set aside and store all parts of the transport packaging for later use e g moving or shipping the 3D Printer The wooden box and the lid are fastened to the pallet with tensioning straps The 3D Printer is padded with air cushion foil and a wooden cover plate and strapped to the pallet with tensioning straps INFO Find detailed information...

Page 25: ... the print table Connections After setting the apparatus up it must be connected to the power supply and the data network Set the power supply main switch at the back of the 3D Printer to 0 OFF 1 Unpack the supply cable and connect it to the mains plug at the backside 2 Connect the Schuko plug to a 230 V socket 3 Connect the HT500 to your data network by plugging the network cable into the RJ45 et...

Page 26: ...he mains cable and the network cable Store them together with the 3D Printer e g ﬁxed with adhesive tape inside the build chamber Protect the print table surface and the touchscreen with a cardboard pad against scratching Secure the extruder head the print table and the build chamber doors with strapping tape tape against moving see Transport Position the 3D Printer on a transport pallet and cover...

Page 27: ...ted in the Service Guide Apart from this regular cleaning will mostly suﬃce to keep your 3D Printer running satisfactorily In case of faults refer to the Troubleshooting Guide and the Service Guide where most problems known to us and according remedies are lodged INFO If you encounter and or solve problems nowhere to be found in the troubleshooting guide you are welcome to inform us and we will gl...

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