Renishaw RenAM 500Q Original Instructions Manual
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Renishaw RenAM 500Q Original Instructions Manual

Renishaw RenAM 500Q Original Instructions Manual

Additive manufacturing system
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User guide
H-5800-3693-03-C
RenAM 500Q/S
additive manufacturing system
ORIGINAL INSTRUCTIONS

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Summary of Contents for Renishaw RenAM 500Q

  • Page 1 User guide H-5800-3693-03-C RenAM 500Q/S additive manufacturing system ORIGINAL INSTRUCTIONS...
  • Page 2 © 2018–2021 Renishaw plc. All rights reserved. This document may not be copied or reproduced in whole or in part, or transferred to any other media or language by any means, without the prior written permission of Renishaw. Renishaw plc. Registered in England and Wales.

  • Page 3: Table Of Contents

    RenAM 500Q/S user guide Contents Chapter 1 – Before you begin Introduction ..............1-1 Disclaimer .
  • Page 4 Contents H-5800-3693 Chapter 4 – Safety Introduction ..............4-1 General safety information .
  • Page 5 RenAM 500Q/S standard build plates ........6-4...
  • Page 6 RenAM 500Q/S main isolating switch ........
  • Page 7 RenAM 500Q/S user guide 7.35 Hopper trolley (RenAM 500Q/S excluding Flex) ....... . .7-29 7.36 Beacon light .............7-30 Chapter 8 –...
  • Page 8 AB-005 – RenAM 500Q/S system – Power up........
  • Page 9 PB-010 – RenAM 500Q/S system – Power down ....... .9-82...
  • Page 10 PM-002 – RenAM 500Q/S system – Clean ........11-2 PM-003 – RenAM 500Q/S safety devices – Check .......11-3 PM-004 –...
  • Page 11 RenAM 500Q/S user guide PM-010 – Powder flasks and large safe change filters – Check .....11-7 PM-010-01 – Powder flasks.........11-7 PM-010-02 – Large safe change filters .
  • Page 12 Contents H-5800-3693 This page is intentionally left blank. Issue 03-C...

  • Page 13: Chapter 1 - Before You Begin

    RenAM 500Q/S user guide Chapter 1 – Before you begin Introduction This chapter contains the disclaimers, trade marks, warranty and changes to equipment statements that form part of the standard Renishaw terms and conditions. Issue 03-C...

  • Page 14: Disclaimer

    Unless you and Renishaw have agreed and signed a separate written agreement, the equipment and/or software are sold subject to the Renishaw Standard Terms and Conditions supplied with such equipment and/or software, or available on request from your local Renishaw office. Renishaw warrants its equipment and software for a limited period (as set out in the Standard Terms and Conditions), provided that they are installed and used exactly as defined in associated Renishaw documentation. You should consult these Standard Terms and Conditions to find out the full details of your warranty.

  • Page 15: Patents

    RenAM 500Q/S user guide Patents Features of the RenAM 500Q/S additive manufacturing system, and other similar systems, are the subject of one or more of the following patents and/or patent applications: CA 2016102970 EP 2331232 JP 2018-523015 US 10335901 WO2014/125258...

  • Page 16: Battery Safety

    Lithium metal batteries are classified as dangerous goods for transportation and require labelling and packaging in accordance with the dangerous goods regulations before being offered for transportation. To reduce the risk of shipment delays, should you need to return this product to Renishaw for any reason, do not return any batteries. 1.7.1 Disposal of batteries The use of this symbol on the batteries, packaging or accompanying documents indicates that used batteries should not be mixed with general household waste.

  • Page 17: Declaration Of Conformity

    RenAM 500Q/S user guide Declaration of conformity Renishaw plc hereby declares that the RenAM 500Q/S is in compliance with the essential requirements and other relevant provisions of • the applicable EU directives • the relevant statutory instruments under UK law The full text of the declaration of conformity is available at: www.renishaw.com...

  • Page 18: Control Of Pollution, Applicable In The People's Republic Of China

    Chapter 1: Before you begin H-5800-3693 1.11 Control of pollution, applicable in the People's Republic of China Renishaw have prepared a table in accordance with the provisions of SJ/T 11364. This is available on request from Renishaw. 1.12 China RoHS For more information on China RoHS, visit: www.renishaw.com...

  • Page 19: Chapter 2 - Scope Of Supply

    RenAM 500Q/S user guide Chapter 2 – Scope of supply Introduction The following chapter describes the items of equipment supplied with the RenAM 500Q/S system as standard, and the equipment available as options. Issue 03-C...

  • Page 20: Standard Equipment (Renam 500Q/S Excluding Flex)

    Chapter 2: Scope of supply H-5800-3693 Standard equipment (RenAM 500Q/S excluding Flex) The following equipment and services are supplied as standard when you purchase a RenAM 500Q/S system from Renishaw. • Renishaw RenAM 500Quad/Single, referred to as 'RenAM 500Q/S', additive manufacturing system •...

  • Page 21: Required Accessories

    • Bead blast unit • Additional powder/overflow flasks – complete with isolating valves • Hopper trolley (RenAM 500Q/S excluding Flex) • Suitable mobile safety steps / step stool – strongly recommended for RenAM 500Q/S Flex (a specification can be supplied upon request) • SCF50 lifting bracket (Renishaw part no. A-6521-3607) • SCF50 wall-mounted bracket (Renishaw part no. A-6521-2111) • 10 L cyclone/overflow flask kit, complete with isolating valves •...
  • Page 22 Chapter 2: Scope of supply H-5800-3693 This page is intentionally left blank. Issue 03-C...

  • Page 23: Chapter 3 - Introduction

    Chapter 3 – Introduction Introduction RenAM 500 systems can be configured with one (single – S) laser, or four (quad – Q) lasers, and with recirculating or total loss (Flex) powder systems. The aim of this chapter is to begin to describe the RenAM 500Q/S additive manufacturing system and to explain some of the terms, language, related documents, safety information and text structure used within this User guide. Issue 03-C...

  • Page 24: Model Configurations

    If in doubt about the particular requirements of the Renishaw RenAM 500Q/S system for a specific material, please contact Renishaw for advice and guidance.

  • Page 25: Definitions

    An operator who is trained to change material parameters, fault-find and change material types Service A Renishaw Service engineer or Renishaw trained person who is qualified and engineer experienced to the highest level in repairing the RenAM 500Q/S system Equipment...

  • Page 26: Abbreviations

    Programmable Logic Controller Personal Protective Equipment Parts Per Million Present Value RenAM 500Q/S RenAM 500 platform, including quad and single laser system and including the Flex model, unless otherwise stated. RenAM 500Q/S RenAM 500 platform, including quad and single laser systems, but not including the (excluding Flex) Flex model.

  • Page 27: Safety Information In This User Guide

    A Note will be in sentence case medium text. Training schedule Renishaw provides a basic level of training to operate the RenAM 500Q/S system safely. Renishaw also offers extended training courses for operators and process engineers. Please refer to this User guide (Renishaw part no. H-5800-3693), the RenAM 500Q/S Installation guide (Renishaw part no. H-5800-3692)

  • Page 28: Contact Details

    RenAMP revision number, select the "Function" button, circled in the upper left corner (Figure 2) and then "About". For the PLC and PC revision, select the "System information" button, circled in the lower left corner (Figure 2). The "System information" button is available for Technician and Service level login. Additional support can be sought by contacting your local Renishaw office. See: www.renishaw.com/contact Issue 03-C...
  • Page 29 RenAM 500Q/S user guide Figure 1 System build information Issue 03-C...
  • Page 30 Chapter 3: Introduction H-5800-3693 Figure 2 Software welcome screen Issue 03-C...

  • Page 31: Chapter 4 - Safety

    RenAM 500Q/S user guide Chapter 4 – Safety Introduction The RenAM 500Q/S is safe to use when operated correctly. This aim of this chapter is to describe the general, personal, powder and system safety recommendations to enable you to operate the system safely.

  • Page 32: General Safety Information

    Chapter 4: Safety H-5800-3693 General safety information 4.1.1 Introduction The RenAM 500Q/S has been designed with safety in mind and has a number of in-built safety features. However, there are risks involved, but with sufficient planning and careful management these can be mitigated. RenAM 500Q/S safety features: • Sealed argon environment for processing. •...

  • Page 33: Basic Safety Measures

    This MUST be provided before receipt of your RenAM 500Q/S system. Should you require it, a Renishaw representative can help you work through this checklist in order to ensure that there are no problems when receiving, installing, and operating the machine and ancillary equipment. As Renishaw guidance is specific to the equipment supplied, it is a prerequisite that the...

  • Page 34: Explosion Prevention Document

    Renishaw recommends that you develop and maintain an explosion prevention document in accordance with the applicable local legislation in the geographic area where the RenAM 500Q/S is located. In the absence of applicable local legislation, Renishaw recommends that you refer to the applicable DSEAR (ATEX 137) or NFPA standard (NFPA 484) and develop your explosion prevention document in accordance with one of these standards.

  • Page 35: Normal Operation

    Records of the above activities should to be made. Contact Renishaw if you need advice or assistance. 4.1.10 Electro-magnetic compatibility Note: The RenAM 500Q/S laser melting system is industrial in design and not intended for use at any time in a residential environment or to be powered from the public low-voltage mains.

  • Page 36: Personal Safety

    RenAM 500Q/S Flex only: A Renishaw universal lifter is included as standard equipment upon purchase of a RenAM 500Q/S Flex for moving heavy items, such as the large safe change filters and full powder flasks. This equipment is also required for ergonomically difficult tasks such as the installation and removal of the feed hopper during material change.

  • Page 37: Laser Safety Precautions

    Normal system maintenance can be undertaken without risking exposure to laser light. Under no circumstances will it be necessary for maintenance to be undertaken with laser covers removed. The RenAM 500Q/S has a Class 4 laser enclosed in a Class 1 system; do not defeat or override safety interlocks.

  • Page 38: Training

    Renishaw approved training program. Training is included in the scope of supply of the Renishaw RenAM 500Q/S, unless the user indicates that no training is required, for instance where a local Renishaw approved trainer already exists.

  • Page 39: Improper Use

    The use of non-approved or highly toxic metal powders and other hazardous substances not approved by Renishaw. For system servicing purposes, Renishaw requires full knowledge of all the materials that have been used in the system in order to protect our staff.
  • Page 40 WARNING: DO NOT ALLOW THE METALLIC POWDER OR WASTE PRODUCTS TO FORM A DUST CLOUD. WARNING: NEVER EAT, DRINK OR SMOKE IN THE VICINITY OF THE RENISHAW AM SYSTEM OR COMPONENTS PRODUCED BY THE PROCESS THAT HAVE NOT BEEN PROPERLY CLEANED.

  • Page 41: Toxicity And Personnel Exposure

    RenAM 500Q/S user guide 4.2.9 Toxicity and personnel exposure Some metal powders may be harmful to health. This can only be ascertained by consulting the Safety data sheets and once again going through the risk assessment procedure and taking note of the guidance and procedures.

  • Page 42: Thermal Hazards

    4.2.10 Thermal hazards If work is to be carried out on the RenAM 500Q/S, the equipment must be isolated and a period of time should be allowed for hot parts of the equipment to cool. Care must also be taken if unplanned work is to be carried out.

  • Page 43: Powder Safety

    WARNING: ENSURE YOU ARE WEARING THE CORRECT PPE: ESD SAFETY FOOTWEAR, EYE PROTECTION, FULL FACE RESPIRATOR (TO EN143 TYPE P3 + A1), PROTECTIVE GLOVES AND FULL-LENGTH CLOTHING. Note: Renishaw recommends that full-length clothing is made from non-static-generating fabric such as cotton (avoid wool and synthetic fabrics). Avoid turn-ups or pockets that may trap powder. Refer to NFPA 484 for details.
  • Page 44 WARNING: RENISHAW RECOMMENDS FITTING SUPPLEMENTARY BONDING BETWEEN THE ATEX VACUUM CLEANER AND THE OBJECT BEING VACUUMED (BUILD PLATE, BENCH TOP OR AM SYSTEM). RENISHAW OR RUWAC CAN PROVIDE A SUPPLEMENTARY BONDING LEAD (RUWAC PART NUMBER 59803 FOR NA7). WARNING: A ROUTINE INSPECTION, TESTING AND MAINTENANCE PROGRAM INCLUDING TESTING OF ELECTRICAL CONTINUITY (BONDING BETWEEN PIECES OF EQUIPMENT) AND EARTHING/GROUNDING (RESISTANCE TO GROUND) SHOULD BE IMPLEMENTED.

  • Page 45: Handling Of Metal Powders

    • Where multiple powder types are used in the same facility, Renishaw strongly recommends labelling and colour coding powder flasks and other equipment to identify the powder type. In addition, robust procedures to ensure powder type segregation should be implemented.

  • Page 46: Combustibility

    Chapter 4: Safety H-5800-3693 4.3.3.1 Combustibility The fire triangle (Figure 4) demonstrates the three prerequisites for a fire. All elements and molecules that react with oxygen are combustible and are a source of fuel. Most metals in solid form are not normally considered a fire risk due to their poorly mixed fuel-to-air ratio. Metal powders will burn readily if subjected to a high ignition temperature. Fuel Figure 4 Fire triangle 4.3.3.2 Explosivity An explosion is caused by rapid burning –...

  • Page 47: Safe Disposal Of Waste Products

    Alternatively, waste, and waste powder, can be vacuumed up using an ATEX vacuum cleaner, as supplied by Renishaw. NEVER use any other type of vacuum cleaner. • Filters must be immersed in water, then stored immersed in water in a ventilated drum in a well- ventilated area.

  • Page 48: Handling And Processing

    Chapter 4: Safety H-5800-3693 4.3.5 Handling and processing • Avoid contact of metal powders with potential ignition sources (for example flames or sparks). • Spills – see Section 4.3.7 "Spills". • Ensure that any vacuuming of powder is kept to a minimum quantity – ideally only vacuum what cannot easily be collected by brushing. Brushing must only be done with non-sparking tools and avoiding the creation of a dust cloud, see Section 4.3.7 "Spills".

  • Page 49: Metal Powder Safety Checklist

    RenAM 500Q/S user guide 4.3.8 Metal powder safety checklist • Have you informed your insurance provider of the powder on site and process being used? • Have you read and understood the metal powder's physical and chemical properties and the associated hazards from the supplied Safety data sheet and other product information? •...

  • Page 50: Hazards Due To Fire Or Explosion

    Chapter 4: Safety H-5800-3693 • Are employees appropriately trained on workplace hazards? • Are written procedures in place which address safety issues to be considered during maintenance and repair activities in metal powder storage or processing areas? • Is there a written procedure for metal powder shipping that meets international standards? •...

  • Page 51: Identifiable Ignition Sources

    RenAM 500Q/S user guide 4.3.10 Identifiable ignition sources All potential ignition sources should be listed in accordance with BS EN 1127-1:2011: • Hot surfaces. • Flames and hot gases, including hot particles. • Mechanically generated sparks. • Electrical apparatus. •...

  • Page 52: Hydrogen Gas

    WARNING: WATER-BASED FIRE EXTINGUISHERS AND SPRINKLER SYSTEMS MAY ALSO PROVIDE A SOURCE OF WATER, AND HYDROGEN, IN SOME CASES. REFER TO NFPA 484. 4.3.12 Safety data sheets Safety data sheets can be found on the Renishaw website, www.renishaw.com/amdatasheets In addition to metal powder, the information for fluids and additives used within Renishaw equipment such as Hydra-Sol MAG vacuum cleaner additive and Nalco chiller fluid can be found here.

  • Page 53: Metal Condensate

    RenAM 500Q/S user guide 4.3.13 Metal condensate NOTE: Processes requiring removal of components for clean-down or service can lead to localised exothermic reactions. These rare events are expected and should not cause alarm. Some processes may instruct the closure or opening of valves etc. to ensure the reaction remains localised. Any risks can be further mitigated by maintaining a high standard of cleanliness of the machine and the working environment.

  • Page 54: System Safety

    Mechanical door lock Operator touch screen control panel Service mode switch "Emergency Stop" button Glovebox door magnetic switch "Reset" button Hazard zone 1: work/maintenance area Build chamber door magnetic switch Figure 6 RenAM 500Q/S front view – safety functions 4-24 Issue 03-C...

  • Page 55: Renam 500Q/S Rear View - Safety Functions

    RenAM 500Q/S user guide 4.4.1.2 RenAM 500Q/S rear view – safety functions Hazard zone 1: work/maintenance area Hazard zone 2: electrical control cabinet Electrical isolator Figure 7 RenAM 500Q/S rear view – safety functions Issue 03-C 4-25...

  • Page 56: Renam 500Q/S Top View - Safety Functions

    H-5800-3693 4.4.1.3 RenAM 500Q/S top view – safety functions Rear Front Lockable door Lockable door Hazard zone 2: electrical control cabinet Lockable door Hazard zone 1: work/maintenance area Figure 8 RenAM 500Q/S top view – safety functions 4-26 Issue 03-C...

  • Page 57: Safety Signs And Laser Safety Labels

    4.4.2.1 Safety signs A number of safety signs are fixed to the RenAM 500Q/S. The safety sign and location are described in the table below. Replacement safety signs can be ordered from Renishaw. Safety sign Description and location...
  • Page 58 Chapter 4: Safety H-5800-3693 Safety sign Description and location WARNING: HIGH VOLTAGES PRESENT WARNING: ISOLATE MACHINE BEFORE OPENING Two × two stickers, on the front electrical cupboard door, next to the two security locks. WARNING AVERTISSEMENT ISOLER LA MACHINE ISOLATE MACHINE Two ×...
  • Page 59 RenAM 500Q/S user guide Safety sign Description and location DANGER 400V WARNING THIS EQUIPMENT MUST BE EARTHED HIGH LEAKAGE CURRENT LEAKAGE CURRENT >100mA EARTH CONNECTION One label on the left-hand side of the system at low level where ESSENTIAL BEFORE...

  • Page 60: Laser Safety Labels

    4.4.2.2 Laser safety labels In order to comply with international standards, the Renishaw RenAM 500Q/S carries various laser safety labels regarding the emission of laser light. These labels form part of the safety information and it is recommended that users regularly check the condition and presence of the labels in the locations shown in the following images.
  • Page 61 RenAM 500Q/S user guide The laser safety labels and location are described in the following table. Replacement laser safety labels can be ordered from Renishaw. Laser label Description and location Laser 1 classification label. LASER Laser 1. IEC 60825-1:2014. EN 60825-1:2014. IEC 60825-1:2014 EN 60825-1:2014 Fitted to the nameplate on the rear of the system.
  • Page 62 Chapter 4: Safety H-5800-3693 Laser label Description and location Class 4 classification label. DANGER - CLASS 4 VISIBLE AND INVISIBLE LASER RADIATION WHEN DANGER - CLASS 4 VISIBLE AND OPEN. AVOID EYE OR SKIN EXPOSURE DANGER – CLASS 4 VISIBLE AND INVISIBLE LASER INVISIBLE LASER RADIATION WHEN TO DIRECT OR SCATTERED RADIATION.

  • Page 63: Transport And System Relocation

    4.4.3 Transport and system relocation If your RenAM 500Q/S system is to be moved to an alternative production facility or resold, Renishaw is happy to assist and advise. With this in mind, please inform us at your earliest convenience. Caution: The transportation of the RenAM 500Q/S should only be carried out following the advice and recommendations of Renishaw plc.

  • Page 64: Hazards Due To Unexpected Malfunctions

    WARNING: SERIOUS INJURY MAY RESULT FROM UNEXPECTED SYSTEM MOVEMENT. 4.4.6 RenAM 500Q/S ergonomics Note: Space in the build chamber is limited, especially for two-handed working. To reach some areas of the build chamber, you may need to adopt an awkward body position. Minimise the time you spend in awkward body positions and take a break if you feel discomfort.

  • Page 65: Gas Safety

    EXOTHERMICALLY. When the RenAM 500Q/S is in use, a small amount of inert gas is emitted from the two gas outlets located on the top of the system. DO NOT connect the two gas outlets to any form of extraction system and DO NOT obstruct the two gas outlets.
  • Page 66 Chapter 4: Safety H-5800-3693 This page is intentionally left blank. 4-36 Issue 03-C...

  • Page 67: Chapter 5 - Overview

    RenAM 500Q/S user guide Chapter 5 – Overview Introduction This chapter contains images of the RenAM 500Q/S system and gives an overview of the user accessible system features. Issue 03-C...

  • Page 68: Renam 500Q/S Front View

    Glovebox door locks Air vent Build chamber viewing window Security lock Top door Plinth (covering combined castor and adjustable jacking feet) Top door handle with interlock Combined castor and adjustable jacking feet LED strip light (behind plinth) × 5 Figure 1 RenAM 500Q/S front view Issue 03-C...

  • Page 69: Renam 500Q/S Rear View

    Air vent Air vents Main isolating switch Rear centre equipment cupboard door System nameplate Plinth (covering combined castor and Air vent adjustable jacking feet) Security lock Rear left-hand electrical cupboard door Security lock Security lock Figure 2 RenAM 500Q/S rear view Issue 03-C...

  • Page 70: Renam 500Q/S Right-Hand End View

    Air vents Main isolating switch "Emergency Stop" button Air vent Air vents External services label System external connections (electrical power, secondary earth, Ethernet, chiller data cable, argon inlet, coolant inlet and coolant outlet) Figure 3 RenAM 500Q/S right-hand end view Issue 03-C...

  • Page 71: Renam 500Q/S (Excluding Flex) Front View With Powder Fill And Large Safe Change Filter

    RenAM 500Q/S user guide RenAM 500Q/S (excluding Flex) front view with powder fill and large safe change filter door open Powder fill and large safe change filter left- Load hopper filling point hand door open (shown removed) Large safe change filter lower isolation Ultrasonic sieve system valves Powder system isolation valves Large safe change filter number 1 (left- hand) and large safe change filter number Powder metering screw feeder 2 (right-hand) Load hopper level load cells...

  • Page 72: Renam 500Q/S (Flex Only) Front View With Overflow And Large Safe Change Filter Door

    RenAM 500Q/S (Flex only) front view with overflow and large safe change filter door open Powder loading arm Powder overflow isolation valves Feed hopper (small size shown) Powder overflow flask (10 L flask shown) Beacon tower Figure 5 RenAM 500Q/S Flex front view with overflow and large safe change filter door open Issue 03-C...

  • Page 73: Open

    RenAM 500Q/S rear view with rear right-hand cupboard door open Solenoid valves Cyclone separator isolation valves Solenoid valves Flow switch (RenAM 500Q/S excluding Flex) Vacuum pump Right-hand manifold Vacuum pump oil level viewing window Cyclone separator collection flask Cyclone separator (lower section) Powder recirculation pump (RenAM 500Q/S excluding Flex) Figure 6 RenAM 500Q/S rear view with rear right-hand cupboard door open Issue 03-C...

  • Page 74: Renam 500Q/S Plan View

    Service access – front right-hand Operator access – rear right-hand electrical cupboard door cupboard door Operator access – top and bottom doors Service/Technician access – rear centre equipment cupboard door Figure 7 RenAM 500Q/S plan view Issue 03-C...

  • Page 75: Chapter 6 - System Specification

    Chapter 6 – System specification Introduction This chapter describes the specification of the RenAM 500Q/S system. It contains information relating to the physical size of the system, electrical supply, weight and noise emissions. It also contains the specification for the build plates.

  • Page 76: Renam 500Q/S System Specification

    H-5800-3693 RenAM 500Q/S system specification Technical specifications may change from time to time. Renishaw reserves the right to change any technical specification at any time. Any specification not listed in the table below is available upon request; see Section 3.8, "Contact details", for the contact details of your local Renishaw office.
  • Page 77 RenAM 500Q/S user guide System fill/purge consumption < 1 200 L (43 ft³) Argon quality (greatest permissible impurities) 20 ppm or better (99.998% pure) Continuous noise level ≤ 70 dB Maximum noise level (temporary) ≤ 71 dB Laser power Q (quad) 4 × 500 W S (single) 1 × 500 W Laser focus diameter 80 μm (3 μin) Laser focusing Dynamic Maximum scanning and positioning speed 10 m/s (32.8 ft/s)

  • Page 78: Build Plate Specification

    Chapter 6: System specification H-5800-3693 Build plate specification To regrind or remanufacture RenAM 500Q/S build plates, please see the following drawings: 6.2.1 RenAM 500Q/S standard build plates 6.2.1.1 Standard build plate – mild steel Uncontrolled issue for reference only Figure 1 Standard build plate – mild steel...

  • Page 79: Standard Build Plate - Titanium

    RenAM 500Q/S user guide 6.2.1.2 Standard build plate – titanium Uncontrolled issue for reference only Figure 2 Standard build plate – titanium Issue 03-C...

  • Page 80: Standard Build Plate - Aluminium

    Chapter 6: System specification H-5800-3693 6.2.1.3 Standard build plate – aluminium Uncontrolled issue for reference only Figure 3 Standard build plate – aluminium Issue 03-C...

  • Page 81: Standard Build Plate - Stainless Steel

    RenAM 500Q/S user guide 6.2.1.4 Standard build plate – stainless steel Uncontrolled issue for reference only Figure 4 Standard build plate – stainless steel Issue 03-C...

  • Page 82: Standard Build Plate - Full Build Titanium

    Chapter 6: System specification H-5800-3693 6.2.1.5 Standard build plate – full build titanium Uncontrolled issue for reference only Figure 5 Standard build plate – full build titanium Issue 03-C...

  • Page 83: Standard Build Plate - Long Life Stainless Steel

    RenAM 500Q/S user guide 6.2.1.6 Standard build plate – long life stainless steel Uncontrolled issue for reference only Figure 6 Standard build plate – long life stainless steel Issue 03-C...

  • Page 84: Standard Build Plate - Full Build Stainless Steel

    Chapter 6: System specification H-5800-3693 6.2.1.7 Standard build plate – full build stainless steel Uncontrolled issue for reference only Figure 7 Standard build plate – full build stainless steel 6-10 Issue 03-C...

  • Page 85: Standard Build Plate - Long Life Aluminium

    RenAM 500Q/S user guide 6.2.1.8 Standard build plate – long life aluminium Uncontrolled issue for reference only Figure 8 Standard build plate – long life aluminium Issue 03-C 6-11...

  • Page 86: Standard Build Plate - Full Build Aluminium

    Chapter 6: System specification H-5800-3693 6.2.1.9 Standard build plate – full build aluminium Uncontrolled issue for reference only Figure 9 Standard build plate – full build aluminium 6-12 Issue 03-C...

  • Page 87: Standard Build Plate - Long Life Mild Steel

    RenAM 500Q/S user guide 6.2.1.10 Standard build plate – long life mild steel Uncontrolled issue for reference only Figure 10 Standard build plate – long life mild steel Issue 03-C 6-13...

  • Page 88: Standard Build Plate - Long Life Titanium

    Chapter 6: System specification H-5800-3693 6.2.1.11 Standard build plate – long life titanium Uncontrolled issue for reference only Figure 11 Standard build plate – long life titanium 6-14 Issue 03-C...

  • Page 89: Standard Build Plate - Full Build Mild Steel

    RenAM 500Q/S user guide 6.2.1.12 Standard build plate – full build mild steel Uncontrolled issue for reference only Figure 12 Standard build plate – full build mild steel Issue 03-C 6-15...
  • Page 90 Chapter 6: System specification H-5800-3693 This page is intentionally left blank. 6-16 Issue 03-C...

  • Page 91: Chapter 7 - Functional Description

    RenAM 500Q/S user guide Chapter 7 – Functional description Introduction The aim of this chapter is to describe the RenAM 500Q/S system, its major systems and sub-systems, and how they combine to create homogeneous solid metal components directly from 3D CAD data.

  • Page 92: Renam 500Q/S Main Isolating Switch

    H-5800-3693 RenAM 500Q/S main isolating switch The equipment main isolating switch is located on the rear left-hand side of the RenAM 500Q/S cabinet. Raising the switch to the "On" position (Figure 1 – left) energises the system electrical circuits. The controller and the main computer will then begin their start-up routines. Moving the switch down to the "Off"...

  • Page 93: Operator Touch Screen Control Panel

    The additive manufacturing build process is controlled from a 480 mm capacitive touch screen control panel built into the front of the RenAM 500Q/S cabinet (Figure 3). It incorporates a user privilege access system. The level of access will depend on the individual operator's unique log-in code (up to a maximum of six alphanumeric characters).

  • Page 94: Programmable Logic Controller

    The build and process control software runs on the main computer (Figure 5), which is located within the RenAM 500Q/S electrical cabinet. In normal use there are no input or output devices for human intervention. The main computer is a Windows-based PC and starts up as soon as it receives power from the main isolating switch.

  • Page 95: System Software

    Operator – Level 1 – enables the user to operate the RenAM 500Q/S system, including carrying out build preparation, post-build and occasional tasks • Technician – Level 2 – enables the user to carry out more advanced tasks on the RenAM 500Q/S system, including basic fault-finding and maintenance •...

  • Page 96: Laser

    RenAM 500Q/S cabinet (Figure 7). The laser system includes one or four 500  W lasers which have been specifically designed and engineered for this application. The lasers are 500 W ytterbium fibre type, with dynamic focusing carried out in the optical module. Further information about the lasers can be obtained from Renishaw upon request. Located above the lasers is the laser power supply. Figure 7 Four PRISM lasers with laser output and cooling connections Chiller Renishaw recommends that an SMC Pneumatics chiller, model number HRSH090-AF-40, is used with the RenAM 500Q/S system (Figure 8). The chiller maintains a stable temperature for the laser and...

  • Page 97: Lens Protection Window

    The top door of the RenAM 500Q/S features a viewing window and a protective insert (Figure 10). This meets the standard ANSI Z136.1 – 2007 and is specified to protect the user against scattered laser radiation for the wavelength used in RenAM 500Q/S. The viewing window is located in the top door and in this application permits a Class 1 laser specification to be achieved. Figure 10 Build chamber viewing window...

  • Page 98: Powder Recirculation System (Renam 500Q/S Excluding Flex)

    Chapter 7: Functional description H-5800-3693 7.11 Powder recirculation system (RenAM 500Q/S excluding Flex) RenAM 500Q/S (excluding Flex) features an on-board powder sieving and recirculation system. The main components of this system are the load hopper, dosing silo, powder level detection system, ultrasonic sieve, oversize powder storage (for removal of waste), cyclone separator and powder recirculation pump. 7.12 Load hopper (RenAM 500Q/S excluding Flex) The load hopper is located at waist height, behind the left-hand door (Figure 11). To add new powder, a standard powder flask is attached to the load hopper isolation valve on the load hopper filling point. The...

  • Page 99: Feed Hopper (Renam 500Q/S Flex Only)

    Figure 12 RenAM 500Q/S Flex feed hopper as fitted There are three available sizes of RenAM 500Q/S Flex feed hopper: small, medium and large. The table on the following page indicates the maximum available volume, and an approximate total mass of powder that can be added to each hopper for Renishaw supplied materials.

  • Page 100: Dosing Silo (Renam 500Q/S Excluding Flex)

    Height from floor to top KF flange on the hopper. Space to allow filling from powder flask will also be required. Height from floor to top of 1.7 L powder flask fitted to hopper (341 mm from flask base to top of flange clamp). 7.14 Dosing silo (RenAM 500Q/S excluding Flex) There are level sensors located in the dosing silo (Figure 13). They accurately sense the level of powder to ensure the dosing silo is at the optimum level.

  • Page 101: Dosing Silo (Renam 500Q/S Flex Only)

    Note: If the low-level sensor behaviour is set to allow the build to continue without pause, it is possible for a build to fail due to running out of powder. This setting should only be used if the user is confident that the remaining powder in the silo will be sufficient to finish the build. 7.16 Renishaw ultrasonic sieve (RenAM 500Q/S excluding Flex) The Renishaw ultrasonic sieve (Figure 14) features a powder metering screw that controls the rate at which powder is fed through to the ultrasonic sieve. Alongside all the used material returned from the build process, all powder loaded into the load hopper is fed through the ultrasonic sieve before being transported to the dosing silo.

  • Page 102: Pneumatic Transfer (Renam 500Q/S Excluding Flex)

    Powder in the dosing silo is then precisely fed into the build process by Renishaw's proven powder dosing system. The oversize powder is transferred into a powder receiver ready to be removed when required.

  • Page 103: Powder Delivery

    RenAM 500Q/S user guide 7.18 Powder delivery The powder delivery mechanism is situated inside the chamber and dispenses a dose of metal powder on to the rear edge of the build chamber process plate. The mechanism can be configured to vary the amount of powder dosed. The percentage dosage can be entered using the "Operator touch screen control panel", see Chapter 9, "Operation", for details.

  • Page 104: Overflow Flasks (Renam 500Q/S Flex Only)

    Chapter 7: Functional description H-5800-3693 7.20 Overflow flasks (RenAM 500Q/S Flex only) Two 1.7 L (Figure 17) or 10 L flasks located in the front left-hand door are used to store any excess material deposited during the build process or during de-build operations. Stainless steel pipework between the flask and the build chamber houses a capacitive sensor used to alert the user or pause the build when the overflow is full and requires emptying.

  • Page 105: Powder Loading Arm (Renam 500Q/S Flex Only)

    Located on the top of the machine, on the right-hand roof panel, the powder loading arm (Figure 18) is used to aid the user in loading powder into the RenAM 500Q/S Flex feed hopper. The arm rotates out over the front and back of the machine to reduce the reach required for loading a flask, then rotates and lowers into position to connect the KF flange from the flask to the feed hopper.

  • Page 106: Gas Circuit

    Chapter 7: Functional description H-5800-3693 7.22 Gas circuit Gas enters the build chamber from the top and lower right-hand sides of the build chamber (Figure 19). It creates a flow of gas directed across the build plate from right to left. The finest metal powder and nanoparticles (known as condensate) produced during the build process are collected and directed to a port on the lower left-hand side of the build chamber which is connected via a cyclone separator to the two large safe change filters. The two large safe change filters are located and accessed through the left-hand door of the system cabinet. The large safe change filters are replaced when indicated on the touch screen control panel.

  • Page 107: Build Plate

    IPA. Depending upon the application, a build plate thicker than standard may be required, to ensure the internal stress in the part is adequately resisted. This is typically only when very large and particularly dense parts are being built. If in doubt, contact Renishaw. See Section 6.2, "Build plate specification", for build plate specifications.

  • Page 108: Heating/Temperature Control

    Chapter 7: Functional description H-5800-3693 7.24 Heating/temperature control There is a heater built into the elevator table which can be used to heat soak the build plate. The temperature can be set in degrees on the thermostat (170 °C (338 °F) max) via the touch screen control panel. The material parameters file supplied with the Renishaw metal powder you have purchased will give you the specific temperature to be used for heat soak, if heat soak is required. 7.25 Large safe change filter (LSCF50) The RenAM 500Q/S system features a recirculating gas flow across the build area, flowing from right to left. The rate of flow can be altered from the touch screen control panel. The finest metal powder and nanoparticles that are emitted from the build process are carried by the flow of gas and captured in one of the two large safe change filters housed in an aluminium cylinder located behind the left-hand door of the cabinet (Figure 21). The filtered inert gas is then recirculated through the system to maintain an extremely...
  • Page 109 RenAM 500Q/S user guide When indicated by the filter graphic on the touch screen control panel, the large safe change filter assembly must be removed from the RenAM 500Q/S and the filter made inert by filling it with water. The filter assembly is then disassembled and the used filter placed in a ventilated drum containing water. When processing aluminium, a 5% solution of Hydra-Sol-MAG additive (part no. P-LU08-0004) must be added to the water in the filter storage drum. See Chapter 9, "Operation", for full details. Note: RenAM 500Q/S large safe change filters (LSCF50) feature 50 mm (2 in) KF flanges and are NOT interchangeable with filters from AM 250, AM 250/400, AM 400 or RenAM 500M. The RenAMP software automatically controls the rate at which the changeover from a dirty to a clean safe change filter occurs – this function is called switching type. Switching type helps to negate any sudden pressure or gas flow fluctuations caused by suddenly switching from a dirty to a clean filter. Both clean filters are automatically preconditioned by exposing them to the finest metal powder and nanoparticles at the start of the build. One of the filters is then automatically isolated from the gas flow and the pre- conditioned filter held in an inert argon gas atmosphere until it is required by the build. Switching type is particularly useful when running long builds where dirty safe change filters may need to be swapped out periodically for clean filters without waiting for the airflow to reduce to a level where it must be changed, for example near the end of a shift.

  • Page 110: Oxygen Monitoring Sensors

    • RenAM 500Q/S Flex only: Material Change – Operators/technicians trained in the material change process can access the following: rear centre equipment cupboard door. • Service – a Renishaw Service engineer/Technician can access the following: rear left-hand electrical cupboard, front right-hand electrical cupboard and rear centre equipment cupboard doors.
  • Page 111 RenAM 500Q/S user guide Rear Front Service access – rear left-hand electrical Operator access – front left-hand cupboard cupboard door door Service access – front right-hand electrical Operator access – rear right-hand cupboard door cupboard door Operator access – top, glovebox and Service/Technician access –...

  • Page 112: Esd And Earth Bonding Points

    500Q/S system when carrying out tasks where there is a risk of electrostatic discharge. Figure 24 RenAM 500Q/S Earth bonding point on left-hand side of the filter cupboard and left-hand side of the rear electrical cupboard Fitting an earth bond between the ATEX vacuum cleaner, a build plate, or the user and the RenAM 500Q/S system allows any electrostatic charge that builds up to be discharged. It is mandatory to fit an...

  • Page 113: Laser Controller

    RenAM 500Q/S user guide 7.29 Laser controller The RenAM 500Q/S is fitted with a laser controller (Figure 25) that controls the one or four lasers fitted. The laser controller is located in the electrical cupboard. Figure 25 RenAM 500Q/S laser controller 7.30 Cyclone The purpose of the cyclone separator (Figure 26) is to pre-filter the gas leaving the build chamber before it reaches the large safe change filters. This is done in order to minimise the load on the large safe change filter cartridges and extend the amount of time the system can run unattended. Figure 26 RenAM 500Q/S cyclone separator...

  • Page 114: Cyclone Level Sensors

    Heat energy from the argon gas flow is transferred to the internal fins, which are chilled by a supply of chilled coolant from the chiller. The intercooler is supplied with chilled coolant by the chiller at a constant rate. Figure 27 RenAM 500Q/S intercooler 7-24 Issue 03-C...

  • Page 115: Electrical Cabinets

    RenAM 500Q/S user guide 7.32 Electrical cabinets The RenAM 500Q/S has two electrical cupboards located at the rear left-hand and front right-hand of the system (Figure 28 and Figure 29). Each electrical cupboard is secured with two security locks which are operated by a key. Access to the electrical cupboard is restricted to Renishaw Service Engineers and Technicians.
  • Page 116 Chapter 7: Functional description H-5800-3693 Figure 29 RenAM 500Q/S electrical cupboard – front right-hand 7-26 Issue 03-C...

  • Page 117: Atex Vacuum Cleaner

    RenAM 500Q/S user guide 7.33 ATEX vacuum cleaner The Renishaw RenAM 500Q/S system requires the use of an ATEX vacuum cleaner. The Renishaw recommended ATEX vacuum cleaner is a Ruwac model NA7 (Figure 30). The ATEX vacuum cleaner is used to clean away small remnants of material and waste process emissions. These materials are potentially dangerous and the appropriate procedures as detailed in the manufacturer's instructions must be observed.

  • Page 118: Universal Lifter

    The universal lifter is a general hydraulic lifting and transportation device used to move heavy items to and from the RenAM 500Q/S system. It is a pedestrian propelled lifter with a lifting mast, without tilt, with load-bearing outriggers, equipped with fork arms, a platform, or other load-handling device. The universal lifter is designed to be manually pushed, pulled and steered by one pedestrian operator.

  • Page 119: Hopper Trolley (Renam 500Q/S Excluding Flex)

    • Four castors for ease of positioning • Two latches to secure the hopper trolley to the RenAM 500Q/S • One latch to secure the load hopper to the trolley • Eight rollers to ease loading of the hopper on to the trolley...

  • Page 120: Beacon Light

    Chapter 7: Functional description H-5800-3693 7.36 Beacon light The RenAM 500 system supports beacon lights with four colours (red, amber, green and blue) which are used to give a visual indication of the status of the machine. The colours of the light represent the following: Colour Machine status Explanation Emergency stopped Indicates that the Emergency button has been pressed or is faulty.
  • Page 121 RenAM 500Q/S user guide Green light – Normal process running Green indicates that a process is currently running on the machine. The processes include atmosphere purge, heat soak, heater auto-tune, build running, system tests (empty silo, wiper, elevator, optical, vacuum, gas flow), powder recirculation.
  • Page 122 Chapter 7: Functional description H-5800-3693 • The start of the chamber preparation will raise an alert "Chamber Preparation in Progress" which will turn on the green light. The chamber preparation can have two possibile outcomes – either it will inert the chamber or it will fail / be aborted.
  • Page 123 RenAM 500Q/S user guide Raise Raise Clear Clear Alert title Type Logic to raise alarm Logic to clear alarm Oversized Particle When the oversize particle The user should empty the Separator Warning sensor is triggered oversize particle flask. Powder Level High Intercooler...
  • Page 124 Chapter 7: Functional description H-5800-3693 Raise Raise Clear Clear Alert title Type Logic to raise alarm Logic to clear alarm Insufficient The alert will be cleared as soon Powder to If the powder is insufficient to there is sufficient powder. The Warning Complete the complete the build user should add powder to the Build system.
  • Page 125 RenAM 500Q/S user guide Raise Raise Clear Clear Alert title Type Logic to raise alarm Logic to clear alarm Empty Silo Test Info Completion of empty silo test Not applicable Complete Focus Test Info Start of laser focus test Not applicable...
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  • Page 127: Chapter 8 - Ancillaries

    Chapter 8 – Ancillaries Introduction The RenAM 500Q/S requires the use of ancillary equipment to make the process of preparing and producing builds as simple as possible. The ATEX vacuum cleaner is mandatory and is used to remove small amounts of metal powder when it becomes lodged in difficult-to-access areas of the system.

  • Page 128: Atex Vacuum Cleaner - Mandatory

    ATEX vacuum cleaner – mandatory 8.1.1 ATEX vacuum cleaner general information The Renishaw RenAM 500Q//S system requires the use of an ATEX vacuum cleaner. The Renishaw supplied and approved ATEX vacuum cleaner is a Ruwac model NA7 (Figure 1). The ATEX vacuum cleaner is used to clean away small remnants of material and waste process emissions. These materials are potentially dangerous and the appropriate procedures as detailed in the manufacturer's instructions must be observed.

  • Page 129: Atex Vacuum Cleaner Safety

    RenAM 500Q/S user guide 8.1.2 ATEX vacuum cleaner safety Note: See Chapter 4, "Safety", for full details of applicable safety information. WARNING: DO NOT STORE THE ATEX VACUUM CLEANER IN A CLOSED UNVENTILATED SPACE. WARNING: ALWAYS OPERATE AND MAINTAIN THE ATEX VACUUM CLEANER IN ACCORDANCE WITH THE MANUFACTURER'S INSTRUCTIONS.

  • Page 130: Atex Vacuum Cleaner Maintenance

    FOAMING AGENT (PART NUMBER 792322000). IT IS ESSENTIAL THAT FOAM IS NOT ALLOWED TO BUILD UP, AS IT WILL BE DRAWN INTO THE CLEANER, RESULTING IN CORROSION. Caution: Contact Renishaw for replacement parts. Always use manufacturer's genuine parts. 8.1.4 ATEX vacuum cleaner maintenance WARNING: ENSURE THE ATEX VACUUM CLEANER IS MAINTAINED IN ACCORDANCE WITH THE MANUFACTURER'S INSTRUCTIONS.

  • Page 131: Chiller - Mandatory

    The Renishaw supplied and approved chiller is an SMC Pneumatics model HRSH090-AF-40 (Figure 2). The chiller is a closed-loop cooling circuit and has a direct communication connection to the RenAM 500Q/S system that allows status and warnings to be viewed via the touch screen control panel.

  • Page 132: Chiller Operation

    8.3.1 Bead blaster and extractor general information An optional bead blaster and extractor can be supplied with the RenAM 500Q/S system to enable parts to be rapidly and easily cleaned after the build is complete. The optional bead blaster is a Guyson model Euroblast 4AM.

  • Page 133: Bead Blaster And Extractor Safety

    WITH THE MANUFACTURER'S INSTRUCTIONS. REFER TO THE MANUFACTURER'S WEBSITE www.guyson.co.uk FOR DETAILS. Caution: Contact Renishaw for replacement parts. Always use manufacturer's genuine parts. 8.3.4 Bead blaster and extractor maintenance WARNING: ENSURE THE BEAD BLASTER AND EXTRACTOR ARE MAINTAINED IN ACCORDANCE WITH THE MANUFACTURER'S INSTRUCTIONS.

  • Page 134: Furnace - Optional

    Furnace – optional 8.4.1 Furnace general information An optional furnace can be supplied with the RenAM 500Q/S system to enable parts to be rapidly and easily heat-treated after the build is complete. The optional furnace is a Nabertherm model N41/H (Figure 4).

  • Page 135: Furnace Operation

    WARNING: ENSURE THE FURNACE IS OPERATED IN ACCORDANCE WITH THE MANUFACTURER'S INSTRUCTIONS. REFER TO THE MANUFACTURER'S WEBSITE www.nabertherm.com FOR DETAILS. Caution: Contact Renishaw for replacement parts. Always use manufacturer's genuine parts. 8.4.4 Furnace maintenance WARNING: ENSURE THE FURNACE IS MAINTAINED IN ACCORDANCE WITH THE MANUFACTURER'S INSTRUCTIONS.

  • Page 136: Universal Lifter - Recommended (Mandatory For Renam 500Q/S Flex)

    Chapter 8: Ancillaries H-5800-3693 Universal lifter – recommended (mandatory for RenAM 500Q/S Flex) 8.5.1 Universal lifter general information Operation and maintenance of the universal lifter is described in the universal lifter User guide. Note: It is recommended that any lifting equipment is fully serviced and inspected at regular intervals. By maintaining your lifting equipment regularly, you will prevent failures and thus reduce operating costs.

  • Page 137: Hopper Trolley - Recommended (Renam 500Q/S Excluding Flex)

    Hopper trolley – recommended (RenAM 500Q/S excluding Flex) 8.6.1 Introduction Operation and maintenance of the hopper trolley is described in the hopper trolley User guide (Renishaw part no. H-5800-4481). The hopper trolley is a metal framed trolley used for transporting the hopper to and from the RenAM 500Q/S system (Figure 6).

  • Page 138: Powder Recovery System (Sieve) - Recommended (Mandatory For Renam 500Q/S Flex)

    Powder recovery system (sieve) – recommended (mandatory for RenAM 500Q/S Flex) A powder recovery system (sieve) is required to remove oversized particles from powder that has been used in the chamber. The RenAM 500Q/S Flex does not have any powder recovery system included, hence a sieve is mandatory for operation. A stand-alone sieve is recommended if the user wants to re-use powder that is entrained in the chamber gas flow and ends up in the prefilter cyclone on all models of the RenAM 500Q/S.
  • Page 139 RenAM 500Q/S user guide Place an O-ring seal on an empty powder flask. Engage the empty powder flask KF flange to the bottom flange of the sieve assembly and seal the connection using a quick-release clamp (Figure 8). Figure 8 Insert seal and attach clamp Open the valves of both the sieve assembly and the empty flask to complete connection (levers aligned with direction of flow) (Figure 9).

  • Page 140: Loading Material

    Chapter 8: Ancillaries H-5800-3693 Figure 10 Open sieve upper valve WARNING: DO NOT PRESSURISE THE SIEVE BY MORE THAN 1 BAR (15 PSI), AS THE OVER- PRESSURE VALVE WILL RELEASE THE ARGON . 8.7.2 Loading material Connect a flask full of unsieved powder on to the top of the sieve using an O-ring and quick-release clamp (Figure 11).
  • Page 141 Open both of the upper valves to complete the connection (Figure 12). Figure 12 Open valves Where multiple materials are used, Renishaw recommends colour-coding both sieve and powder flasks – check the correct material is being loaded. Switch on the sieve and start sieving powder (Figure 13).
  • Page 142 Chapter 8: Ancillaries H-5800-3693 Run the sieve for at least 10 minutes to allow sufficient time to sieve all the powder. Set a timer (Figure 14). Caution: Running the sieve for less than 10 minutes may result in powder being left in the sieve – this will overfill the next flask, resulting in a spillage.

  • Page 143: Disassembly Of The Sieve For Cleaning And Maintenance

    RenAM 500Q/S user guide Remove the quick-release clamp (Figure 16). Figure 16 Remove clamp Remove the full powder flask from the bottom of the sieve and repeat for the empty flask on top of the sieve. Ensure that the flask containing the sieved powder is correctly labelled, with both material type and status (that it is sieved).
  • Page 144 Chapter 8: Ancillaries H-5800-3693 Disassemble the clamp connecting the top pipe to the lid of the sieve, then remove the centring ring (Figure 17). Figure 17 Remove top clamp Release the two clamps applied to the lid (Figure 18). Figure 18 Release both clamps 8-18 Issue 03-C...
  • Page 145 RenAM 500Q/S user guide Ensure the argon supply has been switched off. Remove the argon line connection to the sieve lid using two adjustable spanners (Figure 19). Figure 19 Remove argon line Remove the lid (Figure 20). Figure 20 Remove lid...
  • Page 146 Chapter 8: Ancillaries H-5800-3693 Disassemble the seal and main body of the sieve, leaving the mesh grating exposed (Figure 21). Figure 21 Remove body Carefully remove the mesh grating and dispose of the scrap powder remaining on the mesh (Figure 22). Figure 22 Remove sieve and dispose of powder 8-20 Issue 03-C...
  • Page 147 RenAM 500Q/S user guide Disassemble the large seal around the mesh grating (Figure 23). Caution: Sieve mesh is a delicate component and must be removed with care. Do not vacuum or otherwise clean the mesh. Figure 23 Remove outer seal Remove the sieve balls and store in a flask full of IPA Class 3 (Figure 24).
  • Page 148 Chapter 8: Ancillaries H-5800-3693 Remove the perforated plate (Figure 25). Figure 25 Remove perforated plate Remove the sieve funnel top seal (Figure 26). Figure 26 Remove funnel seal 8-22 Issue 03-C...
  • Page 149 RenAM 500Q/S user guide Remove the worm drive hose clamp retaining the top pipe to the upper valve (Figure 27). Figure 27 Remove worm drive hose clamp and pipe Following the same procedure, remove and disassemble the bottom pipe and lower valve assembly (Figure 28 and Figure 29).
  • Page 150 Chapter 8: Ancillaries H-5800-3693 Figure 29 Remove lower valve assembly When all the components have been removed, they need to be cleaned down. Firstly, use the ATEX vacuum cleaner (wet separator) to remove any powder on the sieve components (Figure 30). Figure 30 Use the ATEX vacuum cleaner (wet separator) to vacuum all components 8-24 Issue 03-C...
  • Page 151 Clean the sieve ball by rinsing in IPA Class 3, then wiping clean with disposable cloth (Figure 32). Note: Renishaw recommends a set of sieve balls for each material type used, in which case cleaning during material changeover is not required.

  • Page 152: Disassembly Of The Sieve For Material Changeover

    Chapter 8: Ancillaries H-5800-3693 8.7.4 Disassembly of the sieve for material changeover Follow the instructions given in Section 8.7.3 to disassemble and clean the sieve. Once all components are removed from the sieve station, the sieve frame and stand need to be cleaned down.

  • Page 153: Reassembly Of Sieve

    RenAM 500Q/S user guide 8.7.5 Reassembly of sieve Note: Ensure all components are completely dry before they are reassembled. Reassemble the components of the sieve in reverse order. Replace the funnel seal (Figure 34). Figure 34 Replace the funnel seal Replace the perforated plate (Figure 35).
  • Page 154 Chapter 8: Ancillaries H-5800-3693 Replace the sieving balls (Figure 36). Figure 36 Replace the sieving balls Assemble the large seal around the mesh (Figure 37). Figure 37 Assemble the mesh seal Replace the mesh on top of the sieving balls. Ensure the deeper recess is face down. 8-28 Issue 03-C...
  • Page 155 RenAM 500Q/S user guide Place the main body on top of the mesh (Figure 38. Figure 38 Assemble the main body Place the seal on top of main body. Replace the lid on the sieve. Place the centring O-ring onto the upper KF flange (Figure 39).
  • Page 156 Chapter 8: Ancillaries H-5800-3693 Attach the upper valve using a clamp (Figure 40). Figure 40 Attach the upper valve with clamp Attach the top pipe using a worm drive hose clamp (Figure 41). Figure 41 Attach the top pipe 8-30 Issue 03-C...
  • Page 157 RenAM 500Q/S user guide Slide the worm drive hose clamp over the pipe, locate the insert into the pipe, place the O-ring over the flange and then connect to the lid with a swing clamp (Figure 42). Figure 42 Connect pipe insert to lid using clamp Now tighten the worm drive hose clamp (Figure 43).
  • Page 158 Chapter 8: Ancillaries H-5800-3693 Follow the same process to assemble the lower pipe. Apply the clamps to the sieve (Figure 44). Figure 44 Apply the clamps The clamping torque should periodically be checked using the Russell Finex clamp assist tool (Figure 45). Figure 45 Russel Finex clamp assist tool See the following pages for the operating instructions for the Russell Finex clamp assist tool.

  • Page 159: Operating Instructions For Russell Clamp Assist Tool

    RenAM 500Q/S user guide 8.7.6 Operating instructions for Russell clamp assist tool The Russell clamp (Figure 47) has been developed to assist the operator in setting the correct clamping force on hand-operated sieve clamps. It is for use on both under-clamps and toggle-clamps fitted onto the Russel Finex range of sieves. It has been preset to enable the operator to apply the correct torque setting by hand.
  • Page 160 Chapter 8: Ancillaries H-5800-3693 Engage the clamp using the tool as shown, ensuring the torque arrow on the tool is correctly orientated (Figure 49). Figure 49 Under-clamp type (left), toggle-clamp type 1 (middle) and type 2 (right) Follow the actions in the table to adjust the clamp to the correct settings. When using the clamp assist: Clamp setting Action...

  • Page 161: Working Platform - Recommended (Mandatory For Renam 500Q/S Flex)

    Working platform – recommended (mandatory for RenAM 500Q/S Flex) The 1.4 m working platform (Figure 50) can be used for general tasks that require elevated access around the machine. For the RenAM 500Q/S Flex, these are required to safely complete powder-loading activities, and are used throughout the material change process if necessary. Figure 50 1.4 m working platform Note: It is recommended that any mobile safety steps or platforms are fully serviced and inspected at regular intervals as specified in the manufacturer's instructions. By maintaining your equipment regularly,...
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  • Page 163: Chapter 9 - Operation

    The aim of this chapter is to list and describe the operational tasks that must be completed before builds are started and after builds are completed, and other tasks that are carried out when building components successfully on the RenAM 500Q/S system. The chapter is divided into six sections as follows: •...

  • Page 164: Pre-Build Tasks

    Chapter 9: Operation H-5800-3693 Pre-build tasks 9.1.1 Pre-build tasks (RenAM 500Q/S excluding Flex) The following table lists all the operation tasks that must be carried out BEFORE a build is started on a RenAM 500Q/S system. The tasks must be completed in the order specified in the table below. Task number Task title User level AB-001 Chiller fluid level – Check...

  • Page 165: Pre-Build Tasks (Renam 500Q/S Flex Only)

    RenAM 500Q/S user guide 9.1.2 Pre-build tasks (RenAM 500Q/S Flex only) The following table lists all the operation tasks that must be carried out BEFORE a build is started on a RenAM 500Q/S Flex system. The tasks must be completed in the order specified in the table below. Task number Task title User level AB-001 Chiller fluid level – Check...

  • Page 166: Chiller Fluid Level - Check

    Chapter 9: Operation H-5800-3693 AB-001 – Chiller fluid level – Check Note: The following instructions describe an SMC Pneumatics model HRSH090-AF-40 chiller. Alternative chillers may be used, in which case follow the manufacturer's instructions supplied with the chiller for chiller set-up. On the SMC Pneumatics model HRSH090-AF-40 chiller (Figure 1), check that the fluid level is between the "L"...

  • Page 167: Argon Gas Supply - Set Up

    If the argon supply is depleted, the build process will pause and an alarm will sound. If the argon pressure is below 50 bar (725 psi) at the start of a build, consider replenishing the gas supply. Note: Argon gas can be supplied in a cylinder, bank or Cryospeed (liquid). The choice of method to use is up to the end user. 4. With the argon gas supply to the RenAM 500Q/S system on, listen for any leaks. If leaks are heard, rectify as necessary. Issue 03-C...

  • Page 168: Chiller - Power Up

    Caution: The optical system on the RenAM 500Q/S requires a supply of cooling water to keep it at a constant temperature. The cooling water for the optical system is provided by either a water- cooled or air-cooled chiller, or a heat exchanger.

  • Page 169: Large Safe Change Filter Assemblies - Check

    20 °C (68 °F), then set it to 20 °C (68 °F). Figure 4 "Run/Stop" button and SV temperature on SMC Pneumatics chiller control panel AB-004 – Large safe change filter assemblies – Check At the front of the RenAM 500Q/S system, open the left-hand door (Figure 5). Left-hand door Figure 5 Left-hand door...
  • Page 170 Chapter 9: Operation H-5800-3693 Ensure there are two large safe change filter assemblies fitted (Figure 6). If either of the two large safe change filters assemblies is missing, then fit a replacement filter assembly in accordance with task OT-008. Large safe change filter 1 Large safe change filter 2 Figure 6 Large safe change filter assemblies shown without oversized particle collection flask RenAM 500Q/S (excluding Flex): Ensure the oversized particle collection flask IS NOT fitted (Figure 6). If the oversized particle collection flask is fitted, remove it in accordance with task PB-015- 02. Ensure a blanking plate IS fitted to the oversized particle outlet and secured with a quick-release clamp (Figure 6).

  • Page 171: Renam 500Q/S System - Power Up

    AB-005 – RenAM 500Q/S system – Power up Caution: The optical system on the RenAM 500Q/S requires a supply of cooling water to keep it at a constant temperature. The cooling water for the optical system is provided by either a watercooled or air-cooled chiller, or a heat exchanger.

  • Page 172: Renam 500Q/S System - Log In

    Chapter 9: Operation H-5800-3693 AB-006 – RenAM 500Q/S system – Log in When the controller and main computer have completed their start-up routines, the "Log-in" screen will appear (Figure 8). If "Log-in" box is not visible, press the login button at the upper right side of the screen. Figure 8 "Log-in" screen On the "Log-in" screen, select the level box and use the on-screen keyboard (Figure 9) to enter "Operator".

  • Page 173: Build Chamber - Set Up

    RenAM 500Q/S user guide When log-in is complete, the "Home" screen will appear (Figure 10). The "Home" screen displays various system parameters via the "System status" pane on the left-hand side. Across the "Home" screen are four coloured panes – "Build", "System", "Service" and "Information". These provide information about various parameters of the build and system.
  • Page 174 Chapter 9: Operation H-5800-3693 The "Chamber setup" screen (Figure 12) contains five panes that enable you to control various parameters of the build. The five panes are: "Filters", "Recoater", "Elevator", "Heater" and "Atmosphere". Figure 12 "Chamber setup" screen and five panes Four panes can be maximised to display a larger view and all the controls within the pane by selecting the button in the upper right corner (Figure 13). The "Filters" pane cannot be maximised. Figure 13 Minimised pane and "Maximise"...
  • Page 175 RenAM 500Q/S user guide Selecting the maximise button will maximise the pane to fill the view (Figure 14). Figure 14 Maximised "Recoater" pane and "Minimise" button Selecting the minimise button (Figure 14) will minimise the pane view back to the default view (Figure 12). Select the "Open door" button (Figure 15). A button will appear – "Unlock Top Door". Select the "Unlock Top Door" button and press the blue "Reset" button. The door will release and can be opened by pulling the door handle firmly towards you.
  • Page 176 Chapter 9: Operation H-5800-3693 On the "System status" "Atmosphere" pane (Figure 16), check that the build chamber pressure is zero and the chamber oxygen level is greater than 170,000 ppm. Figure 16 "System status" "Atmosphere" pane Check the system build chamber has been cleaned down. If it is dirty, clean it in accordance with the post-build tasks, see Section 9.3.

  • Page 177: Build Plate - Install

    PLATES ARE SIGNIFICANTLY HEAVIER THAN THESE WEIGHTS. HANDLE BUILD PLATES CAREFULLY TO AVOID INJURY AND DAMAGE TO THE BUILD PLATE. FOR BUILD PLATES THICKER THAN 15 MM (0.6 IN), CONSIDER USING SUITABLE LIFTING EQUIPMENT, SUCH AS A RENISHAW UNIVERSAL LIFTER, TO LOAD THE BUILD PLATE INTO THE BUILD CHAMBER.
  • Page 178 Chapter 9: Operation H-5800-3693 Using a suitable calibrated measuring device such as a micrometer or digital calliper, measure the build plate thickness at all four corners (Figure 19). Figure 19 Measure the four corners of the build plate Take an average of the four readings. Ensure that the mean reading does not deviate more than 0.05 mm (0.002 in) between the highest and lowest measurements. If in doubt, see the drawings in Section 6.2 for details.
  • Page 179 Caution: Ensure a build plate is fitted, as building directly on to the system platform will damage the platform and elevator of the RenAM 500Q/S system. Caution: Although the build plate can be installed in any of four positions, the front of the build plate is marked with a shallow blind hole or slot in the centre of the front edge (Figure 22).
  • Page 180 Chapter 9: Operation H-5800-3693 11. Insert four M5 screws and tighten to between 3 Nm (2.2 lbf/ft) and 5 Nm (3.7 lbf/ft) using a 4 mm (0.15 in) hexagon key and a suitable torque wrench. Tighten opposing corners in pairs. 12. Close the top door. 13. From either the maximised or minimised view of the "Elevator" pane, send the elevator to the top of the z-axis by pressing the "Build Plate Top" button (Figure 23). Figure 23 "Build Plate Top"...

  • Page 181: Recoater Blade - Install

    RenAM 500Q/S user guide 15. This will open a keypad dialog (Figure 25). Enter a value of 0.5 mm (0.02 in) and select the downwards arrow button to move the elevator down by the amount entered (Figure 25). Figure 25 "Move by" keypad dialog and downwards arrow button 16. The build plate installation is now complete.
  • Page 182 Chapter 9: Operation H-5800-3693 The two halves of the recoater blade assembly are secured together with M4 cap screws. Loosen the five M4 cap screws along the entire length of the recoater blade assembly and remove and discard the used recoater blade. A replacement silicone recoater blade is available from your local Renishaw office (Renishaw part no. A-5771-0025). Measure a length of silicone recoater blade to 259 mm ±1 mm (10.15 in to 10.23 in) using a suitable measuring device (Figure 27). Figure 27 Measure the silicone recoater blade Cut the silicone recoater blade using a pneumatic pipe cutter or scalpel (Figure 28).
  • Page 183 RenAM 500Q/S user guide Check the cut length of recoater blade against the recoater blade assembly – it should just fit in the chamfer (Figure 29). If it is too long, it will deform, so re-cut it. Note: An oversize recoater blade can distort in the recoater assembly and this can give a poor powder surface and lead to a failed build. Figure 29 Gauge the length of the cut recoater blade Unscrew the bolts until the head is proud of the recoater blade assembly, but do not remove them completely (Figure 30 and Figure 31).
  • Page 184 Chapter 9: Operation H-5800-3693 Figure 31 Bolt head proud of the recoater blade assembly Insert the cut length of silicone recoater blade into the recoater blade assembly (Figure 32). Figure 32 Insert silicone recoater blade into recoater blade assembly 10. Check the gap left at both ends of the silicone recoater blade – it should not pass the start of the radius (arrowed) on the recoater blade assembly (Figure 33 and Figure 34).
  • Page 185 RenAM 500Q/S user guide Incorrect fit Figure 34 Incorrect alignment of silicone recoater blade end with recoater blade assembly 11. Place the recoater blade assembly on a flat surface such as a surface table. Press down firmly on the reverse side of the recoater housing. Starting at the centre, tighten the five M4 cap screws using a 3 mm (0.11 in) hexagon key and a suitable torque wrench. Tighten to a maximum of 2 Nm (1.5 lbf/ft). Do not overtighten (Figure 35). Figure 35 Tighten the bolts and clamp the silicone recoater blade into the recoater blade assembly...

  • Page 186: Recoater Assembly - Install

    Chapter 9: Operation H-5800-3693 AB-010 – Recoater assembly – Install Ensure that the build plate thickness has been entered and that the build plate is at the top position. Close the top door. Note: The recoater is interlocked to the top door and will not move while the top door is open. From either the maximised or minimised view of the "Recoater"...

  • Page 187: Load Hopper - Fill (Renam 500Q/S Excluding Flex)

    COTTON OR FIRE RETARDANT OVERALLS WITH FULL-LENGTH SLEEVES (MADE OF STATIC- DISSIPATIVE MATERIAL). WARNING: DO NOT LOAD POWDER DIRECTLY FROM THE SUPPLIER'S CONTAINER INTO THE RenAM 500Q/S – POWDER MUST FIRST BE DECANTED INTO A POWDER FLASK. Note: Ensure there is a minimum of four full flasks of powder in the RenAM 500Q/S system before starting the build process. Each full powder flask is approximately 5% of the load hopper capacity. The load hopper can be filled while the build process is running – but not during the "Build chamber atmosphere – Set-up".
  • Page 188 Chapter 9: Operation H-5800-3693 Remove the quick-release clamp securing the blanking plate to the load hopper filling point isolation valve (Figure 39). Figure 39 Quick-release clamp and blanking plate fitted to load hopper filling point isolation valve Place a clean centring ring on the KF40 flange of the load hopper filling point isolation valve (Figure 40). Figure 40 Centring ring on KF flange and load hopper filling point isolation valve closed Ensure that the powder flask isolation valve and load hopper filling point isolation valve are both in the closed position (handle perpendicular to the direction of flow).
  • Page 189 RenAM 500Q/S user guide Open the isolation valve on the powder flask first, and then open the isolation valve on the load hopper filling point. Wait until the powder flask has emptied into the load hopper. Check by tapping the powder flask gently. Close the isolation valve on the powder flask first, and then close the isolation valve on the load hopper. 10. Remove the quick-release clamp and remove the empty powder flask from the system. 11. Repeat the process for the remaining powder flasks until there is sufficient metal powder in the RenAM 500Q/S system. 12. Place a clean centring ring on the KF40 flange of the load hopper filling point isolation valve and refit a blanking plate. Secure with a quick-release clamp (Figure 41). Figure 41 Quick-release clamp and blanking plate fitted to load hopper filling point isolation valve...

  • Page 190: Valves - Set Up (Renam 500Q/S Excluding Flex)

    Chapter 9: Operation H-5800-3693 AB-012 – Valves – Set up (RenAM 500Q/S excluding Flex) On the RenAM 500Q/S, behind the left-hand door, check that the following valves are in the correct position: • Large safe change filter upper isolation valves (2 off) are open (1 and 2) (Figure 42) – valves in line with pipework. • Oversized particle collection point blanking plate (3) is fitted and secured with a quick-release clamp (Figure 42).

  • Page 191: Build Platform Heat Soak Process - Set Up

    RenAM 500Q/S user guide • Sieve inlet valves (2 off) (9 and 10), large gas inlet valves (2 off) (11 and 12) and large gas outlet valves (2 off) (13 and 14) are open (Figure 44). • Small gas inlet valves (2 off) (15 and 16) and small gas outlet valves (2 off) (17 and 18) are open (Figure 44). Figure 44 Sieve and gas inlet and outlet valves AB-013 – Build platform heat soak process – Set up Note: The use of the build platform heater is guided by the choice of material. It can aid material flow and assist the processing of some materials. Note: At build chamber temperatures above 60 °C (140 °F), the top door remains interlocked and cannot be opened.
  • Page 192 Chapter 9: Operation H-5800-3693 From either the maximised or minimised view of the "Heater" pane, select "Target temperature". This will open a keypad dialog (Figure 45). Figure 45 "Target temperature" button and keypad Using the keypad (Figure 45) enter the required material temperature for the heat soak. Refer to the material parameters file supplied with the metal powder you have purchased for the specific temperature to be used for heat soak. From either the maximised or minimised view of the "Heater"...

  • Page 193: Build Chamber Atmosphere - Set Up

    RenAM 500Q/S user guide AB-014 – Build chamber atmosphere – Set up From either the maximised or minimised view of the "Atmosphere" pane, check the "Oxygen target level". The "Oxygen Target Level" is 1 000 ppm (0.1%) (Figure 47). Figure 47 "Oxygen Target Level" From the "Chamber Setup" page, go to "Filters" (Figure 48).
  • Page 194 Caution – RenAM 500Q/S Flex only: If closed, do not attempt to open the overflow flask or overflow pipe isolation valves during chamber preparation. Doing so may cause damage to the machine.

  • Page 195: Powder Dose - Set Up

    RenAM 500Q/S user guide When the oxygen level reaches 1 000 ppm (0.1%) the chamber is ready for a build. Check that the "Current Heater Temperature" and "Heater Target Temperature" are reading the same (Figure 48). AB-015 – Powder dose – Set up From either the maximised or minimised view of the "Recoater" pane, set the number of doses to three and dose the build plate (Figure 51).
  • Page 196 Chapter 9: Operation H-5800-3693 Observe the recoater travelling across the build plate. The aim of the dosing process is to create a first layer that is an even dusting across the entire build plate (Figure 53). Note: It is unlikely that the first layer will dose correctly. Figure 53 First powder layer on build plate If the layer is not an even dusting, from the maximised view of the "Elevator" pane, select the "Move by"...
  • Page 197 RenAM 500Q/S user guide This will open a keypad dialog (Figure 55). Enter a value of 0.1 mm (0.004 in) and select the upwards button to move the elevator up by the amount entered (Figure 55). Figure 55 "Move by" keypad dialog and upwards arrow button From either the maximised or minimised view of the "Recoater" pane, set the number of doses to three and dose the build plate (Figure 51).

  • Page 198: Build File - Transfer

    RenAM 500Q/S. Note: The default FTP login settings are: Username: RenAMResources, Password: RenAM500. Build files should be transferred to the folder: D:\AMResources\Builds\ where "D:\" is the hard drive of the RenAM 500Q/S system. Note: There is a known issue where FTP clients fail to transfer a file entirely. To avoid this, it is recommended to use FTP Active Mode in the client software. AB-017 – Build file – Select From the "Chamber setup"...
  • Page 199 Figure 58 "Select build" screen "Load build" button Your build is now loaded into the RenAM 500Q/S system. Note: A part outside the substrate will be highlighted in red (Figure 59). Figure 59 'Outside the substrate' part highlighted in red Caution: Ensure the build file is loaded every time, even when running the same build multiple times.

  • Page 200: Suppress Part

    Chapter 9: Operation H-5800-3693 AB-018 – Suppress part This is an optional operation which is available for cases where the operator wants to omit some of the parts from the .mtt file. This can also be done during the build. Reasons can include the following: •...
  • Page 201 RenAM 500Q/S user guide Selecting a part in the graphical view selects the corresponding part in the suppress part table, and vice versa. Figure 62 Selection of part from the table or from the graphics view The View/Hide icon shown circled in Figure 63 below allows the operator to toggle hiding a part to allow you to view another part that had been obscured.
  • Page 202 Chapter 9: Operation H-5800-3693 Select OK (circled) to suppress the selected parts (Figure 64). A dialog box will then appear asking you to confirm your selection (Figure 65). Figure 64 Selecting parts to suppress Figure 65 Confirmation of the suppressed parts 9-40 Issue 03-C...

  • Page 203: Cyclone Particle Collection Flask - Fit

    AB-019 – Cyclone particle collection flask – Fit Note: The cyclone filters out particles from the gas flow system that do not meet the physical criteria for use within the RenAM 500Q/S system. Note: The cyclone particle collection flask is located in the rear right cupboard behind the door. WARNING: ENSURE THE CYCLONE PARTICLE COLLECTION FLASK IS COMPLETELY EMPTY BEFORE IT IS ATTACHED TO THE RenAM 500Q/S SYSTEM. Issue 03-C 9-41...
  • Page 204 FULL-LENGTH CLOTHING. Take an cyclone particle collection flask, fit a centring ring and an isolation valve and secure with a quick-release clamp. Ensure the isolation valve is closed. Fit a centring ring to the KF flange on the isolation valve fitted previously to the cyclone particle collection flask. On the RenAM 500Q/S remove the quick-release clamp securing the blanking plate to the cyclone particle outlet and remove the blanking plate. Grip the neck of the cyclone particle collection flask and offer up to the KF flange on the isolation valve on the cyclone particle outlet on the RenAM 500Q/S system. Open the plastic cover (Figure 67) and fit a quick-release clamp around the two KF40 flanges.

  • Page 205: Pre-Build Checklist - Review (Renam 500Q/S Excluding Flex)

    RenAM 500Q/S user guide AB-020 – Pre-build checklist – Review (RenAM 500Q/S excluding Flex) Before starting the build, check and confirm all the following steps have been completed. Serial number Equipment Completed? Check the chiller fluid level is between the L and H mark. Check the regulated argon gas pressure is correct. If using bottled argon gas, check there is sufficient gas pressure in the bottle. Check the chiller is running correctly. Check that there are two large safe change filters fitted. Log into RenAMP software using the touch screen control panel, open the top door and after 30 seconds confirm that the chamber pressure is zero.

  • Page 206: Build - Start

    Chapter 9: Operation H-5800-3693 AB-021 – Build – Start From the "Chamber setup" screen (Figure 68), select "Build Operation". This will launch the "Build Operation" screen. Figure 68 "Chamber Setup" screen The "Build Operation" screen (Figure 69) allows you to view various parameters of the build such as "Total layers", "Layer thickness", "Total build height", "Current layer", etc. Figure 69 "Build operation" screen 9-44 Issue 03-C...
  • Page 207 RenAM 500Q/S user guide There are four tabs in the "Build Operation" screen (Figure 70) – "Controls", "Monitoring", "Trends" and "Layer Viewer". They enable you to view and control various parameters of the build. Figure 70 "Build operation" screen When the build platform heat soak process and atmosphere generation are complete, press the "Play"...

  • Page 208: Feed Hopper - Fill (Renam 500Q/S Flex Only)

    POWDER FLASKS A-6252-0570 AND A-6252-0696 ONLY. USING ANY OTHER FLASK PRESENTS A DROP RISK AND MAY CAUSE INJURY. WARNING: FULL 1.7 L POWDER FLASKS CAN WEIGH UP TO 10 KG IN RENISHAW STANDARD MATERIALS. DO NOT CARRY MORE THAN ONE FLASK UP TO THE WORKING PLATFORM AT ONE TIME.
  • Page 209 Caution: The feed hopper and its supporting bracket are rated to take a maximum powder load of 135 kg. Some non-Renishaw supplied materials may cause this mass to be exceeded before the hopper is full. For these materials, care should be taken to monitor the mass of powder being added to the system.
  • Page 210 Chapter 9: Operation H-5800-3693 Invert the flask and place into the flask grip on the powder loading arm (Figure 72). Figure 72 Powder flask in powder loading arm Place a clean centring ring on the KF40 flange on the feed hopper top isolation valve. 9-48 Issue 03-C...
  • Page 211 RenAM 500Q/S user guide Rotate the powder loading arm until the flask is over the feed hopper and it lowers into position (Figure 73). Figure 73 Flask in position on top of the feed hopper 10. Ensure the centring ring is seated correctly between the isolation valves of the feed hopper and the powder flask. 11. Slide half the collar of the quick-release clamp over the edge of the flanges. Issue 03-C...
  • Page 212 Chapter 9: Operation H-5800-3693 12. Close the second half of the quick-release clamp, attach the spring-loaded lever and close the quick- release clamp (Figure 74). Figure 74 Powder flask on feed hopper with swing clamp connected 9-50 Issue 03-C...
  • Page 213 RenAM 500Q/S user guide 13. Open the isolation valve on the powder flask first, and then open the isolation valve on the feed hopper Figure 75). Figure 75 Powder flask and feed hopper valves open 14. Wait until the powder flask has emptied into the feed hopper. Check by tapping the powder flask gently. 15. Close the isolation valve on the powder flask first, and then close the isolation valve on the feed hopper. 16. Remove the quick-release clamp, lift the powder loading arm and rotate and then remove the empty powder flask.

  • Page 214: Overflow Flasks - Fit (Renam 500Q/S Flex Only)

    18. Repeat the process for the remaining powder flasks until there is sufficient metal powder in the RenAM500Q/S Flex system. 19. Place a clean centring ring on the KF40 flange of the feed hopper filling point isolation valve and refit a blanking plate. Secure with a quick-release clamp. AB-023 – Overflow flasks – Fit (RenAM 500Q/S Flex only) Note: The overflow flasks store excess powder dosed from the system until the end of the build, at which point the material can be sieved to remove any oversized particles ready for re-use. Note: The overflow flasks are located in the front left cupboard behind the door.
  • Page 215 RenAM 500Q/S user guide Place the flask in the cabinet then it slide towards the rear overflow pipe and offer the flask up to the KF flange on the isolation valve of the overflow pipe (Figure 76). Figure 76 Rear overflow flask Fit a quick-release clamp around the two KF40 flanges. Issue 03-C 9-53...
  • Page 216 Chapter 9: Operation H-5800-3693 Close the quick-release clamp to secure the overflow flask to the RenAM 500Q/S Flex (Figure 77). Figure 77 Overflow flask with swing-clamp attached 9-54 Issue 03-C...
  • Page 217 RenAM 500Q/S user guide Repeat the process for the front overflow flask (Figure 78). Figure 78 Overflow flasks Issue 03-C 9-55...

  • Page 218: Valves - Set Up (Renam 500Q/S Flex Only)

    Chapter 9: Operation H-5800-3693 AB-024 – Valves – Set Up (RenAM 500Q/S Flex only) On the RenAM 500Q/S Flex, behind the left-hand door, check that the following valves are in the correct position: • Large safe change filter upper isolation valves (2 off) are open (1 and 2) (Figure 79) – valves in line with pipework. Figure 79 Large safe change filter upper valves (1 and 2)
  • Page 219 RenAM 500Q/S user guide • Large safe change filter lower isolation valves (2 off) are open (3 and 4) (Figure 80) – valves in line with pipework. • Overflow pipe isolation valves (2 off) (5 and 6) and overflow flask isolation valves (2 off) (7 (not shown) and 8) are open (Figure 80) – valves in line with pipework. Figure 80 Large safe change filter lower valves and overflow flask isolation valves Issue 03-C 9-57...
  • Page 220 Chapter 9: Operation H-5800-3693 • Feed hopper filling point isolation valve (1 off) (9) is closed Figure 81) – valve at 90° to the pipework. Figure 81 Feed hopper filling point isolation valve 9-58 Issue 03-C...

  • Page 221: Pre-Build Checklist - Review (Renam 500Q/S Flex Only)

    RenAM 500Q/S user guide AB-025 – Pre-build checklist – Review (RenAM 500Q/S Flex only) Before starting the build, check and confirm all the following steps have been completed. Serial number Equipment Completed? Check the chiller fluid level is between the L and H mark. Check the regulated argon gas pressure is correct. If using bottled argon gas, check there is sufficient gas pressure in the bottle. Check the chiller is running correctly. Check that there are two large safe change filters fitted. Log into RenAMP software using the touch screen control panel, open the top door and after 30 seconds confirm that the chamber pressure is zero.

  • Page 222: Monitoring The Build

    NOT STARE AT THE BUILD FOR LONG PERIODS OF TIME, AS THE MELTING PROCESS LIGHT EMISSIONS ARE VERY BRIGHT AND FLASH. Once started, the RenAM 500Q/S system will run automatically. During the build, monitor the touch screen control panel for any alarms. If any alarms are generated, respond to them appropriately.

  • Page 223: Safe Change Filters

    RenAM 500Q/S user guide 9.2.1 Safe change filters • On the "Chamber setup" screen (Figure 82), the large safe change filters are displayed in graphic form. As the build progresses, the filter will slowly fill with nanoparticles from the AM process. As a result of the filter filling, the air flow through the filter will reduce. The air flow is displayed in the form of a green, amber and red band against the filter graphic (Figure 82). • Using the information on the touch screen control panel, identify the affected filter assembly, isolate the filter and remove it in accordance with task OT-005. Fit a clean filter assembly in accordance with task OT-008. The filter element in the removed filter assembly must be removed and replaced in accordance with tasks OT-006 and OT-007, which can be done when time permits. Figure 82 "Chamber Setup" and safe change filters graphic Note: The RenAMP software automatically controls the rate at which the changeover from a dirty to a clean safe change filter occurs; this function is called switching type. Switching type helps to negate any...
  • Page 224 OT-006 and OT-007, which can be done when time permits. Note: In the event of an incident, press the "Emergency Stop" button to stop the RenAM 500Q/S. Following assessment of the situation, either perform a restart procedure, if safe, in accordance with task OT-010 or, if not recoverable, abort the build and clean down the system in accordance with the post-build tasks.

  • Page 225: Powder Dosing (Renam 500Q/S Flex Only)

    Powder dosing (RenAM 500Q/S Flex only) As the RenAM 500Q/S Flex machine uses a total loss powder system, whereby all deposited but unmelted material is transferred to overflow flasks for offline sieving, it is important that the powder dose settings for any given build are set correctly.

  • Page 226: Overflow Flasks (Renam 500Q/S Flex Only)

    Feed hopper (RenAM 500Q/S Flex only) If completing large builds on a RenAM 500Q/S Flex, it is possible for the feed hopper to have insufficient volume to store enough powder to complete the build without intervention. Point level sensors in the silo will alert the user when powder level in the machine is running low, and then, if configured to do so, pause the build when powder is critically low.

  • Page 227: Post-Build Tasks

    RenAM 500Q/S user guide Post-build tasks 9.3.1 Post-build tasks (RenAM 500Q/S excluding Flex) The following table lists all the operation tasks that must be carried out AFTER a build is completed on a RenAM 500Q/S (excluding Flex) system. The tasks must be completed in the order specified in the table below before the next build can begin.

  • Page 228: Post-Build Tasks (Renam 500Q/S Flex Only)

    The following table lists all the operation tasks that must be carried out AFTER a build is completed on a RenAM 500Q/S Flex system. The tasks must be completed in the order specified in the table below before the next build can begin.

  • Page 229: Build Plate - Cool Down

    RenAM 500Q/S user guide PB-001 – Build plate – Cool down After the build has completed, the build plate heater will switch off automatically. Before opening the top door, check that the heater temperature is below 60 °C (140 °F). In the "System Status" pane (Figure 85) is the temperature pane; look down the list and check the heater temperature. Figure 85 "System Status" pane and equipment temperature pane WARNING: THE LEVEL OF HEAT RETAINED BY THE PART AND SURROUNDING UNUSED POWDER DEPENDS ON THE BUILD GEOMETRY AND POWDER TYPE.

  • Page 230: Build Report - Generate

    Chapter 9: Operation H-5800-3693 PB-002 – Build report – Generate From the RenAMP "Home" page, select the "Build Reports" button, circled (Figure 86). Figure 86 RenAMP "Home" page and "Build Reports" button This will display the "Build History" (Figure 87). Figure 87 "Build History"...

  • Page 231: Build Chamber Metal Powder - Remove

    Figure 88 Generate "Build Reports" Build reports generated can be extracted from the folder "D:\AMResources\reports\" via FTP, where "D:\" is the hard drive of the RenAM 500Q/S system. PB-003 – Build chamber metal powder – Remove WARNING: DO NOT VACUUM UNPASSIVATED METAL CONDENSATE.
  • Page 232 Carefully and slowly open the top door, to avoid disturbing powder in the build chamber. If any metal powder falls from the RenAM 500Q/S build chamber, immediately vacuum it up using the ATEX vacuum cleaner. Leave the top door open for 5 minutes to allow a passivation cycle to occur. Allowing the oxygen to rise slowly should help to passivate any condensate by allowing it to oxidise at a controlled rate.
  • Page 233 91). The tools are used during build chamber clean-down. Note: If multiple powder types are being used in a facility, Renishaw strongly recommends that all powder- handling equipment is labelled and colour-coded for each powder type. Figure 91 Suitable tools for cleaning the build chamber...
  • Page 234 Chapter 9: Operation H-5800-3693 Close the top door. On the touch screen control panel, re-inert the build chamber to an oxygen level of less than 7% (70 000 ppm) as follows. From the "Home" page select "Remove build", then from the "Atmosphere" pane, select the "De-Build Purge" button (Figure 92). WARNING: THE BUILD CHAMBER OXYGEN LEVEL MUST BE LESS THAN 7% BEFORE BEGINNING CHAMBER CLEAN-DOWN.
  • Page 235 RenAM 500Q/S user guide 11. On the touch screen control panel, from the "Home" page select "Remove build" (Figure 93). Figure 93 Home" page and "Remove build" 12. From "Remove build", click in the "Move by" box (Figure 94). Figure 94 "Remove build" and "Move by" box...
  • Page 236 Chapter 9: Operation H-5800-3693 13. This will open a keypad dialog (Figure 95). Figure 95 "Remove build", keypad dialog, return button and "Move elevator up" button 14. Enter a suitable value of up to 60 mm (2.4 in), select the return button and select the "Move elevator up" button (Figure 95). 15. This will raise the elevator by the value specified. 16. The build chamber will be at a positive pressure of up to 30 mbar-gauge (0.43 psi-gauge). To prevent the gloves from inflating outwards when the glovebox door is opened, it is necessary to equalise the pressure in the build chamber. To do this, on the touch screen control panel select the "Open door" button.
  • Page 237 RenAM 500Q/S user guide Figure 96 "Remove build" and "Move elevator up" button 19. This will move the elevator up by the value entered and expose more powder. 20. Repeat the steps to raise the elevator and brush powder down the overflows until the elevator is at the top of the z-axis and there is no more powder on the build plate.

  • Page 238: Build Plate - Remove

    (Figure 98). Figure 98 "Remove build", "Absolute Top" button 23. Brush any remaining powder from the build plate down the front overflow. PB-004 – Build plate – Remove Note for RenAM 500Q/S Flex machines only: The supplied overflow caps should be fitted to the front and rear overflow slots prior to starting this task. Using the glovebox and 4 mm (0.15 in) hexagon key, remove all four bolts that secure the build plate (Figure 99). Figure 99 Removing the four build plate securing bolts...

  • Page 239: Build Chamber - Clean

    The internal surfaces of the build chamber need to be clear of any metal powder residue and condensate (black deposits). Open the top door. WARNING: THE OPERATOR, BUILD, RenAM 500Q/S, ATEX VACUUM CLEANER AND BENCH MUST ALL BE EARTHED WHEN REMOVING THE BUILD FROM THE BUILD CHAMBER AND WHEN CLEANING THE BUILD CHAMBER.
  • Page 240 Using the ATEX vacuum cleaner, ensure that the bolt holes on the build platform are completely clear of powder. Note: Apply small amounts of Class 3 IPA to a cloth. Do not apply it directly to RenAM 500Q/S components. When as much of the powder and residue as possible has been removed with the non-static- generating brush and ATEX vacuum cleaner, the next step is to clean the build chamber surfaces with Class 3 IPA and a disposable cloth.

  • Page 241: Lower Chamber - Clean

    RenAM 500Q/S user guide PB-007 – Lower chamber – Clean Before the RenAM 500Q/S system can be used for the next build, the lower chamber must be cleaned of any metal powder or process emissions. WARNING: DO NOT INTERFERE WITH THE ELEVATOR MOTOR OR BRAKE (FIGURE 101) WHEN CLEANING THE LOWER CHAMBER.

  • Page 242: Recoater Blade - Remove

    Chapter 9: Operation H-5800-3693 PB-008 – Recoater blade – Remove Ensure you are wearing the correct PPE for the cleanliness of the recoater blade assembly. On the recoater blade assembly that was removed and set aside previously, loosen the five M4 bolts of the recoater blade housing using a 3 mm (0.12 in) hexagon key (Figure 102). Figure 102 Recoater blade assembly M4 bolts Remove the used recoater blade and dispose of it in accordance with the applicable local rules for the safe disposal of contaminated waste.

  • Page 243: Renam 500Q/S System - Shut Down

    RenAM 500Q/S user guide PB-009 – RenAM 500Q/S system – Shut down Note: If another build is to be built on the RenAM 500Q/S system immediately, ignore this task and proceed to the next task. From any RenAMP screen, select the "Function" button, circled in the upper left-hand corner (Figure 103).

  • Page 244: Renam 500Q/S System - Power Down

    Select "PC Control". This will display the "PC Control" dialog box (Figure 105). Select "Shutdown" to shut down the PC. Note: Do not carry out the task PB-010 – RenAM 500Q/S system – Power down, until the PC has shut down completely. Figure 105 PC control dialog box "Shutdown"...

  • Page 245: Chiller - Power Down

    RenAM 500Q/S user guide PB-011 – Chiller – Power down Note: If another build is to be built on the RenAM 500Q/S system immediately, ignore this task and proceed to the next task. Note: The chiller must have been running for a minimum of 3 hours before starting a build. This is to ensure that the optical module is at the optimum operating temperature.

  • Page 246: Build Plate Parts - Remove

    The choice of removal method (water jet, bandsaw, wire erosion, etc) is dependent upon the build material, type of build, etc. Contact Renishaw using the "Contact details" in Section 3.8 if you need advice or assistance in selecting the correct method of part removal to suit your AM application. PB-013 – Build plate – Refurbish Build plates must be cleaned up after use and before they are reused.

  • Page 247: Heat Treatment Of Parts (Optional) - Set Up

    PB-014-02 – Wrapping parts prior to heat treatment Renishaw recommends that parts are wrapped in furnace foil wrap as follows: Ensure enough foil is used to wrap the part (Figure 109). Figure 109 Figure 109 Amount of foil to wrap the part...
  • Page 248 Chapter 9: Operation H-5800-3693 Fold and cover approximately 1/4 of the part (Figure 110). Figure 110 Fold and cover Flip the part over and fold the remaining foil under (Figure 111). Figure 111 Fold remaining foil under Crimp any open ends of the foil parcel (Figure 112). Figure 112 Crimp any open ends 9-86 Issue 03-C...
  • Page 249 RenAM 500Q/S user guide Flip the part over again (Figure 113). Figure 113 Flip over part again Fold over the edges (Figure 114). Figure 114 Fold over edges The part is now fully wrapped (Figure 115). Figure 115 Part fully wrapped...
  • Page 250 Chapter 9: Operation H-5800-3693 Place the fully wrapped part in a furnace box (Figure 116). Figure 116 Place the part in furnace box With the part in the furnace box, cover with an additional piece of furnace foil that extends to the edges of the furnace box (Figure 117).
  • Page 251 RenAM 500Q/S user guide 10. Fit the lid to the furnace box and place the box in the furnace (Figure 118). Figure 118 Fit the lid to the furnace box and place in furnace WARNING: ENSURE THE FURNACE IS OPERATED IN ACCORDANCE WITH THE MANUFACTURER'S INSTRUCTIONS.

  • Page 252: Oversized Particle Collection Flask - Refit, Remove And Empty

    PB-015 – Oversized particle collection flask – Refit, remove and empty (RenAM 500Q/S excluding Flex) Note: The oversized particle collection flask collects oversized particles from the powder distribution system that do not meet the physical criteria for use within the RenAM 500Q/S system. Note: The oversized particles should be emptied from the RenAM 500Q/S after every build. Note: The oversized particle collection flask is located in front of the large safe change filters in the left- hand cupboard.
  • Page 253 RenAM 500Q/S user guide Fit a quick-release clamp to the KF flanges, close it and secure the powder flask to the RenAM 500Q/S (Figure 119). Ensure the isolation valve is in the isolated position with the handle at 90° to the pipework. Oversized particle collection flask Figure 119 Oversized particle collection flask From the RenAMP "Home" page select "Remove build" (Figure 120). Figure 120 "Remove build" Issue 03-C 9-91...
  • Page 254 Chapter 9: Operation H-5800-3693 From the "Remove build" page (Figure 121) select the "Remove oversized particles" button. Figure 121 "Remove build" and "Remove oversized particles" button This will display a confirmation dialog box (Figure 122). Select "Yes" and the process to Remove oversized particles will begin. Figure 122 Remove oversized particles confirmation dialog box 9-92 Issue 03-C...
  • Page 255 RenAM 500Q/S user guide A confirmation dialog box (Figure 123) will display. Select "Confirm" to confirm that an empty powder flask has been connected to the motorised valve (the flask was fitted in steps 1 to 4 previously). Figure 123 "Connect empty flask to motorised valve" confirmation dialog box On the powder flask fitted previously, open the isolation valve. The handle will be in line with the pipework. On the dialog box (Figure 124) confirm that the isolation valve has been moved to the open position. Figure 124 "Open manual valve to flask" confirmation dialog box Issue 03-C 9-93...
  • Page 256 Chapter 9: Operation H-5800-3693 10. A dialog box will display, advising that the oversized particles are being transferred to the powder flask (Figure 125) and indicating how long this will take in seconds. Figure 125 "Wait for automated valve operation" dialog box 11. When the transfer of oversized particles is complete, a dialog box will display (Figure 126). On the powder flask, close the manual isolation valve. The handle will be at 90° to the pipework. On the dialog box (Figure 126), confirm that the isolation valve has been moved to the closed position. Figure 126 "Close manual valve to flask" dialog box 9-94 Issue 03-C...

  • Page 257: Pb-015-02 - Remove

    RenAM 500Q/S user guide PB-015-02 – Remove The "Remove flask of oversized particles from motorised valve" dialog box will be displayed (Figure 127). Grip the neck of the oversized particle collection flask. Remove the quick-release clamp securing the oversized particle collection flask isolation valve KF flange to the system outlet KF flange. Separate the oversized particle collection flask from the RenAM 500Q/S. Remove the centring ring. Refit the blanking plate to the oversized particle outlet and secure with a quick-release clamp. On the "Remove flask of oversized particles from motorised valve" dialog box (Figure 127), select "Confirm" to confirm that the flask has been removed. This will return you to the "System controls" page. The removal of oversized particles is now complete. Figure 127 "Remove flask of oversized particles from motorised valve" dialog box PB-015-03 – Empty Dispose of the contents of the oversized particle collection flask in accordance with the local rules for the disposal of metal waste products.

  • Page 258: Lens Protection System - Inspect

    Chapter 9: Operation H-5800-3693 PB-016 – Lens protection system – Inspect Caution: The lens protection system is made from fused silica, and has an optical coating that will scratch if handled incorrectly. Caution: Do not touch the surface of the lens protection system. Caution: The lens protection system needs to be completely clear, removing all nanoparticles and leaving no smudges that can affect laser beam coupling efficiency and focus.

  • Page 259: Cyclone Filter Particle Collection Flask - Remove And Empty

    RenAM 500Q/S user guide PB-017 – Cyclone filter particle collection flask – Remove and empty Note: The cyclone filter particle collection flask collects oversized particles from the gas flow system that do not meet the physical criteria for use within the RenAM 500Q/S system. Note: The cyclone filter particle collection flask should be emptied from the RenAM 500Q/S after every build. Note: The cyclone filter collection flask is located in the rear right cupboard behind the door. WARNING: ENSURE YOU ARE WEARING THE CORRECT PPE: ESD SAFETY FOOTWEAR, EYE PROTECTION, FULL FACE RESPIRATOR (TO EN143 TYPE P3 + A1), PROTECTIVE GLOVES AND FULL-LENGTH CLOTHING.

  • Page 260: Pb-017-02 - Empty

    FLASK. THE MATERIAL WILL NEED TO BE SIEVED, TESTED AND EXAMINED BEFORE IT CAN BE REUSED. YOU MUST SATISFY YOURSELF THAT THE MATERIAL MEETS THE MATERIAL SPECIFICATION FOR THE RenAM 500Q/S SYSTEM BEFORE IT CAN BE REUSED; THIS IS THE RESPONSIBILITY OF THE END USER AND THEIR ORGANISATION.

  • Page 261: Pb-018-01 - Remove (1.7 L Flask)

    RenAM 500Q/S user guide PB-018-01 – Remove (1.7 L flask) Open the front left cupboard door. On the RenAM 500Q/S Flex overflow pipe, close the isolation valve (Figure 130). On the overflow flask, close the isolation valve (Figure 130) Figure 130 Isolation valves in the closed position on the overflow pipe and overflow flask Grip the neck of the overflow flask. Remove the quick-release clamp securing the overflow flask isolation valve to the overflow pipe isolation valve. Separate the overflow flask from the RenAM 500Q/S Flex. Remove the centring ring. Lift the flask from the powder cabinet, gripping the neck and bottom of the flask. Repeat for the rear overflow flask.

  • Page 262: Pb-018-02 - Remove (10 L Flask)

    WARNING: 10 L OVERFLOW FLASKS (A-6810-6040) FULL OF POWDER CAN WEIGH IN EXCESS OF 60 KG. ATTEMPTING TO LIFT THESE FLASKS MANUALLY MAY RESULT IN INJURY. ALWAYS USE THE RENISHAW UNIVERSAL LIFTER TO MOVE THESE FLASKS WHEN THEY CONTAIN POWDER. FOR SPECIFIC LIFTER INSTRUCTIONS, REFER TO THE UNIVERSAL LIFTER USER GUIDE.
  • Page 263 RenAM 500Q/S user guide Remove the quick-release clamp securing the overflow flask isolation valve to the overflow pipe isolation valve. Separate the overflow flask from the RenAM 500Q/S Flex. Remove the centring ring. Manoeuvre the universal lifter so that the cut-outs in the arm align with the bosses on the flask (Figure 132). Figure 132 Universal lifter aligned with 10 L flask Raise the lifter until it engages with the boss on the flask. Check that both sides are engaged correctly. Issue 03-C 9-101...
  • Page 264 Chapter 9: Operation H-5800-3693 Raise the lifter until the flask is just clear of the floor (Figure 133), then move the lifter back until it is clear of the cabinet. Figure 133 Flask lifted clear of the floor Move the lifter to the desired location and lower the lifter until it is completely disengaged from the flask. 10. Check that the rear flask isolation valve and overflow pipe isolation valve are both in the closed position 11.
  • Page 265 RenAM 500Q/S user guide 13. Wrap a 2 m sling around the back of the flask, then pull the flask towards the front of the cabinet (Figure 134). Figure 134 Use sling to remove flask 14. Remove the sling then use the universal lifter to the remove the flask using the same method as the front flask. Issue 03-C 9-103...

  • Page 266: Occasional Tasks

    Powder flask – Fill Operator OT-005 Large safe change filter assembly – Remove Operator OT-006 Large safe change filter element – Remove Operator OT-007 Large safe change filter element – Refit Operator OT-008 Large safe change filter assembly – Refit Operator OT-009 Chiller fluid – Remove Operator OT-010 RenAM 500Q/S system – Build recovery Operator OT-011 Feed hopper – Remove (RenAM 500Q/S Flex only) Technician OT-012 Feed hopper – Refit (RenAM 500Q/S Flex only) Technician OT-013 Powder loading arm – Adjust (RenAM 500Q/S Flex only) Operator OT-014 10 L flask – Decant powder Operator 9-104 Issue 03-C...

  • Page 267: Chiller Fluid Level - Top Up

    RenAM 500Q/S user guide OT-001 – Chiller fluid level – Top up On the front of the chiller, unscrew the filler cap, circled (Figure 135). Figure 135 SMC Pneumatics chiller coolant filler Top-up the chiller to the "H" mark using pre-mixed Nalco chiller fluid (part no. P-HX04-0003) (Figure 136). Caution: Do not fill above the "H" mark on the sight glass. Caution: Do not use water or any other liquid in place of pre-mixed Nalco chiller fluid.

  • Page 268: Argon Gas Cylinder - Replace

    Caution: Do not exceed 10 bar (145 psi) gas supply pressure to the RenAM 500Q/S system. Exceeding 10 bar (145 psi) will cause the RenAM 500Q/S system to stop due to a gas overpressure alarm.

  • Page 269: Powder Flask - Fill

    WARNING: DO NOT LOAD POWDER DIRECTLY FROM THE SUPPLIER'S CONTAINER INTO THE RenAM 500Q/S – POWDER MUST FIRST BE DECANTED INTO A POWDER FLASK. WARNING: DO NOT ATTEMPT TO FILL THE RenAM 500Q/S WHILE THE SYSTEM IS UNDER VACUUM. WARNING: WHEN USING TITANIUM POWDER, THE SILICA DESICCANT BAG MUST BE REMOVED FROM THE SUPPLIER CONTAINER TO PREVENT IT BEING TRANSFERRED INTO A POWDER FLASK.

  • Page 270: Large Safe Change Filter Assembly - Remove

    11. Remove the quick-release clamp securing the two isolation valve KF flanges and separate the powder bottle and flask. 12. The powder is now ready to be loaded into the RenAM 500Q/S system. OT-005 – Large safe change filter assembly – Remove WARNING: ENSURE YOU ARE WEARING THE CORRECT PPE: ESD SAFETY FOOTWEAR, EYE PROTECTION, FULL-FACE RESPIRATOR (TO EN143 TYPE P3 + A1), PROTECTIVE GLOVES AND FULL-LENGTH CLOTHING.
  • Page 271 RenAM 500Q/S user guide Note: Ensure that the oversized particle collection flask is not fitted to the system, as it is not possible to remove the large safe change filters assemblies with it in place. If fitted, remove in accordance with task PB-015. On the touch screen control panel, from the 'Home' screen select "Chamber setup". From "Chamber Setup" in the "Filters" pane identify which large safe change filter is to be replaced. Note: From the front of the RenAM 500Q/S system, with the filter access door open, filter 1 is on the left- hand side and filter 2 is on the right-hand side. The "Filters" pane (Figure 137) enables you to set whether the large safe change filters are "Present" or "Absent". Before either filter is removed, set the appropriate toggle switch to "Absent". Figure 137 Large safe change filter "Present" and "Absent" toggle switches There are two isolation valves on each large safe change filter assembly, one on the system outlet (upper) and one on the filter outlet (lower) (Figure 138). Check both isolation valves are in the isolated...
  • Page 272 AM system. Keep the dirty filter assembly upright, do not rotate it and keep it in the same orientation as it was in the AM system. Renishaw recommends that this task is risk assessed in accordance with the user's local rules before it is carried out.
  • Page 273 RenAM 500Q/S user guide In the same orientation as it was removed from the machine, place the large safe change filter assembly on a secure surface or bracket that prevents the filter from falling over or being dropped. Renishaw recommends using a Renishaw universal lifter (Renishaw part no. A-6810-3500) fitted with the universal lifting attachment or a Renishaw safe change filter wall bracket (Renishaw part no. A-6521-2109) (Figure 139). Figure 139 Renishaw universal lifter, shown here with a substrate lifting plate (left) and safe change filter wall bracket (right) If using the Renishaw universal lifter, move the large safe change filter assembly to a suitable location with water tap and hose pipe fitting. 10. Filling the large safe change filter assembly with water will increase its weight to approximately 30 kg (66 lb). Do not attempt to lift or move the filter during the passivation process or when it is full of water, even if you are using the Renishaw universal lifter. 11. Place a clean centring ring on the KF50 flanges of the dirty large safe change filter assembly upper isolation valve. 12. Locate and obtain a KF50 quick-release clamp. Issue 03-C 9-111...
  • Page 274 Chapter 9: Operation H-5800-3693 13. Place the passivation tank (Figure 140) on top of the dirty large safe change filter assembly, align the two KF50 flanges and hold in place. Note: This task may be easier to carry out with two people. Figure 140 Passivation tank with KF50 flange 14. Secure the two KF50 flanges with a quick-release clamp. 15. Ensure the passivation tank and large safe change filter assembly are secured against movement, as the centre of gravity is above the support equipment. 16.
  • Page 275 RenAM 500Q/S user guide 17. Place a bucket or suitable receptacle such as a dirty filter disposal drum underneath the dirty large safe change filter assembly. This is to capture dirty water flowing from the safe change filter assembly. 18. On the dirty large safe change filter assembly (Figure 142), fully open the upper isolation valve and allow water to flow into the dirty filter assembly. WARNING: THERE IS A RISK OF HYDROGEN BEING GENERATED. DO NOT CLOSE THE UPPER ISOLATION VALVE AFTER SOAKING THE FILTER IN WATER. Figure 142 Open the upper isolation valve 19.
  • Page 276 Chapter 9: Operation H-5800-3693 22. Allow water to fully drain (Figure 143) into a bucket or suitable receptacle. Figure 143 Draining dirty filter water into a suitable receptacle (dirty filter disposal drum shown here) 23. Check inside the passivation tank for signs of any particulate. Use a hose to wash away any that is present (Figure 144). Figure 144 Wash away particulate from passivation tank with hosepipe 24.

  • Page 277: Large Safe Change Filter Element - Remove

    RenAM 500Q/S user guide 28. Ensure the contaminated water is disposed of by suitably licensed waste contractors in accordance with the applicable local legislation. WARNING: IMMEDIATELY CLEAN UP ANY WATER SPILLAGES AND MOP THE AREA CLEAN AND DRY AFTER USE.
  • Page 278 Chapter 9: Operation H-5800-3693 Place the large safe change filter assembly on a suitable workbench or support bracket. Using a 5 mm (0.19 in) hexagon key, remove the six M5 bolts securing the access cover of the large safe change filter assembly (Figure 146). Figure 146 Removing the access cover Lift the access cover off the large safe change filter assembly (Figure 147). Due to the close fit between the access cover and the filter, the filter may be attached to the access cover; separate as necessary. Remove the used filter element and filter support plate. Remove the filter support plate from the used filter (Figure 147) and retain the plate for cleaning. WARNING: THE FILTER ELEMENT WILL BE WET AND DIRTY WHEN IT IS REMOVED FROM THE SAFE CHANGE FILTER ASSEMBLY. Figure 147 Removing the filter (left-hand), filter and filter support plate (right-hand) 9-116 Issue 03-C...
  • Page 279 10. To reduce system downtime, Renishaw recommends that spare large safe change filter assemblies are kept in a state ready to be installed in the RenAM 500Q/S system when required. 11. After cleaning the filter chamber, access cover and filter support plate, they will need to dry before they can be reassembled and reused. Drying time will depend upon ambient humidity and temperature.

  • Page 280: Large Safe Change Filter Element - Refit

    OT-007 – Large safe change filter element – Refit Caution: Never refit a used filter. Once the filter chamber is fully dry, fit a filter support plate to the filter and install them into the filter chamber as follows. Open the filter kit packaging (part number A-5778-6000) and remove a filter element. Note: Filters are supplied in sealed plastic bags dried to a specification of 0.5 g/m³ (0.0134844 oz/yard³) of water. Opening the sealed plastic bag and leaving the filter exposed to atmospheric air for ten minutes will negate the benefits of drying it. To gain the benefits from a dried filter, Renishaw recommends opening the filter plastic bag and immediately installing in the filter chamber. Fit a filter support plate to the closed end of the filter (Figure 150). Figure 150 Fit a filter support plate to the filter 9-118 Issue 03-C...

  • Page 281: Large Safe Change Filter Assembly - Refit

    RenAM 500Q/S user guide Fit the filter element and filter support plate into the filter chamber. The closed end of the filter element must be at the closed end of the filter chamber (Figure 151). Caution: Ensure that the open end of the filter element is at the open end of the filter chamber. Figure 151 Open end of filter element Ensure the filter element and support plate are centred in the filter chamber. Refit the access cover to the filter chamber. When refitting the access cover on to the filter chamber, place the access cover on one side of the filter chamber and angle the access cover down to complete the sealing of the cover onto the chamber.
  • Page 282 Chapter 9: Operation H-5800-3693 Grip the large safe change filter assembly handle with the right hand and support the weight at the base with the left hand. Lift the large safe change filter assembly on to the support bracket in the RenAM 500Q/S system, and slide it fully home (Figure 152). Figure 152 Large safe change filters installed Obtain the two quick-release clamps and two centring rings removed previously. Check the two centring ring seals are free from damage and deformation. Replace the seals as necessary.

  • Page 283: Chiller Fluid - Remove

    RenAM 500Q/S user guide Note: From the front of the RenAM 500Q/S system, with the filter access door open, filter 1 is on the left- hand side and filter 2 is on the right-hand side. 14. The "Filters" pane (Figure 153) enables you to set the whether the large safe change filters are "Present" or "Absent". After a filter has been replaced, set the appropriate toggle switch to "Present". Figure 153 Large safe change filter "Present" and "Absent" toggle switches 15. The large safe change filter is now ready for use. OT-009 – Chiller fluid – Remove Ensure the over-full chiller is powered down and electrically isolated.

  • Page 284: Renam 500Q/S System - Build Recovery

    PROTECTION, FULL-FACE RESPIRATOR (TO EN143 TYPE P3 + A1), PROTECTIVE GLOVES AND FULL-LENGTH CLOTHING. On occasion, it may be required to remove the feed hopper from the RenAM 500Q/S Flex system without performing a full material change, such as for hopper cleaning, or when changing to an alternative size hopper.
  • Page 285 RenAM 500Q/S user guide Isolate the machine from the power supply using the main isolation switch. Remove the rear skirt from the machine. Disconnect the balance line (Figure 156) at the hopper and insert a 10 mm blanking plug into the hopper connector. Disconnect/unscrew the cable from the feed hopper capacitive sensor (Figure 156), then unscrew and remove the sensor from the hopper.
  • Page 286 Chapter 9: Operation H-5800-3693 Close the feed hopper flow isolation valve (Figure 157). Open the feed hopper flow valve interlock (not shown), then remove the KF40 quick-release swing clamp (Figure 157). Figure 157 Feed hopper flow isolation valve and swing clamp 9-124 Issue 03-C...
  • Page 287 RenAM 500Q/S user guide 10. Remove the two M8 thumbscrews below the feed hopper support bracket that retain the hopper (Figure 158). Figure 158 Feed hopper retaining thumbscrews 11. Fit the universal lifting attachment to the universal lifter in the orientation shown in Figure 159.
  • Page 288 ATTACHMENT WITHOUT THE SECURITY BOLT INSTALLED, AS DOING SO INCREASES THE RISK OF THE LOAD DROPPING FROM THE LIFTER AND CAUSING INJURY. 13. Raise the lifter mast so that the attachment forks are clear of the top of the RenAM 500Q/S Flex machine.
  • Page 289 Note: While raising and lowering the lifter, ensure the carriage plate does not catch on any cables or earth braids. 17. Manoeuvre the lifter until the lifting attachment forks are clear of the RenAM 500Q/S Flex machine. 18. Lower the lifter mast to a safe height, then manoeuvre the lifter to the desired location to store the hopper off the lifting attachment.

  • Page 290: Feed Hopper - Refit (Renam 500Q/S Flex Only)

    Chapter 9: Operation H-5800-3693 OT-012 – Feed hopper – Refit (RenAM 500Q/S Flex only) WARNING: ENSURE YOU ARE WEARING THE CORRECT PPE: ESD SAFETY FOOTWEAR, EYE PROTECTION, FULL-FACE RESPIRATOR (TO EN143 TYPE P3 + A1), PROTECTIVE GLOVES AND FULL-LENGTH CLOTHING.
  • Page 291 RenAM 500Q/S user guide Once the feed hopper is seated on the support bracket, lower the lifting mast so the end-stops clear the lifting points on the hopper and pull the lifter back away from the machine, ensuring the lifter does not catch on any cables or earth braids.
  • Page 292 Chapter 9: Operation H-5800-3693 10. Open the feed hopper flow isolation valve. 11. Screw the feed hopper capacitive sensor into the pocket on the feed hopper, then screw the cable connector to the sensor (Figure 165). 12. Remove the 10 mm blanking plug from the balance line connector, then fit the balance line, ensuring it is pushed fully into the connector (Figure 165). Figure 165 Feed hopper capacitive sensor and balance line installed 13.

  • Page 293: Powder Loading Arm - Adjust (Renam 500Q/S Flex Only)

    RenAM 500Q/S user guide OT-013 – Powder loading arm – Adjust (RenAM 500Q/S Flex only) WARNING: ENSURE YOU ARE WEARING THE CORRECT PPE: ESD SAFETY FOOTWEAR, EYE PROTECTION, FULL-FACE RESPIRATOR (TO EN143 TYPE P3 + A1), PROTECTIVE GLOVES AND FULL-LENGTH CLOTHING.

  • Page 294: Ot-013-02 - Docking Position Adjustment

    Chapter 9: Operation H-5800-3693 To adjust the arm height, loosen the M10 × 60 cap screw (Figure 167) and carefully move the horizontal section up or down. Re-tighten and repeat step 2. Continue to repeat steps 2 to 4 until the gap is within range. Figure 167 Height adjustment screw OT-013-02 –...
  • Page 295 RenAM 500Q/S user guide Loosen the wheel guide block by slackening the three M6 × 14 button head screws on the arm base (Figure 168). Rotate as required so the wheels can drop into the slots at the required rotational angle for the flask to dock with the hopper inlet. Re-tighten the three screws once the correct position has been determined. Figure 168 Docking position adjustment screws Issue 03-C 9-133...

  • Page 296: Ot-013-03 - Reach Adjustment

    Chapter 9: Operation H-5800-3693 OT-013-03 – Reach adjustment Place a centring seal in the hopper inlet KF fitting and fit a full flask to the arm. Rotate the arm until the flask is directly above the hopper inlet. Check that the bottle is positioned correctly over the centring seal on the top of the feed hopper. If the arm is not at the correct reach position, move on to step 3. If it does, no adjustment is necessary. Loosen the two screws on the arm claw (Figure 169) and move the claw in or out in its slots until the two KF flanges on the flask and hopper are correctly aligned. Once the correct position is found, retighten the two screws to a torque of 5 Nm.

  • Page 297: 10 L Flask - Decant Powder

    RenAM 500Q/S user guide OT-014 – 10 L flask – Decant powder Before loading overflow powder contained in a 10 L flask into the powder recovery system, it should first be transferred into 1.7 L flasks. This ensures the powder recovery system is not overloaded which can cause it to fail to properly process material. WARNING: ENSURE YOU ARE WEARING THE CORRECT PPE: ESD SAFETY FOOTWEAR, EYE PROTECTION, FULL-FACE RESPIRATOR (TO EN143 TYPE P3 + A1), PROTECTIVE GLOVES AND FULL-LENGTH CLOTHING.
  • Page 298 Chapter 9: Operation H-5800-3693 Raise the lifter until the flask is at an appropriate working height, approximately 1 m from the floor (Figure 171). Figure 171 Correct working height for powder decanting 9-136 Issue 03-C...
  • Page 299 RenAM 500Q/S user guide Fit an empty 1.7 L flask to the isolation valve on top of the flask using a centring seal and quick- release clamp (Figure 172). Figure 172 10 L flask with 1.7 L flask attached above Issue 03-C 9-137...
  • Page 300 Chapter 9: Operation H-5800-3693 Holding the 1.7 L flask securely with one hand, release the locking pin with the other (Figure 173) and rotate the flask 180°, with the upper 1.7 L flask initially moving away from the lifter, until the 1.7 L flask is on the bottom. The locking pin will automatically re-engage, securing the two flasks to prevent further rotation. Figure 173 10 L flask with locking pin (circled) before rotation 9-138 Issue 03-C...
  • Page 301 RenAM 500Q/S user guide Open the isolation valves on both flasks (Figure 174) to allow powder to start flowing into the 1.7 L flask. Figure 174 Isolation valves in the open position Once the bottle is full, close the isolation valve on the 10 L flask (Figure 175). Figure 175 10 L flask isolation valve in closed position Issue 03-C 9-139...
  • Page 302 Chapter 9: Operation H-5800-3693 Tap the flask and the valves several times with a rubber mallet to remove any powder between the valves, then close the isolation valve on the 1.7 L flask (Figure 176). This page is intentionally left blank. Figure 176 Isolation valves in the closed position 10. Gripping the 1.7 L flask securely with one hand, remove the quick-release swing clamp and centring ring to remove the 1.7 L flask ready for sieving. 11. Attach an empty 1.7 L flask with a centring ring and quick-release swing clamp and repeat the process from step 7 until the 10 L flask is empty. 12. Release the locking pin, rotate the 10 L flask 180°, then transport and deposit the 10 L flask at the desired location. 9-140 Issue 03-C...

  • Page 303: Technician Level Tasks

    RenAM 500Q/S user guide Technician level tasks The following table lists all the technician level tasks that can be carried out before a build is started on a RenAM 500Q/S system. Task number Task title User level TT-001 Change date and time...
  • Page 304 Chapter 9: Operation H-5800-3693 The "Set Parameters" screen (Figure 178) contains three buttons. Select the "System" button (circled). It will open up the "System" screen (Figure 179). Figure 178 "Set Parameters" screen and "System" button The "System" screen (Figure 179) contains the "User Settings" pane with the "Date and Time" displayed (circled). Figure 179 User Settings" pane with "Date and Time" on "Systems" screen 9-142 Issue 03-C...
  • Page 305 RenAM 500Q/S user guide Clicking on the Date and Time field produces a dialog box with a calendar and a time edit box (Figure 180). Figure 180 "User Settings" pane with "Date and Time" on "Systems" screen The date can be selected from the calendar. To change the time, click on the "Time" edit field. This will open a keypad dialog box (Figure 181). Enter the time using the keypad and select the return button (Figure 181).

  • Page 306: Flex Settings (Renam 500Q/S Flex Only)

    Select "Cancel" to close the dialog box without implementing the changes. TT-002 – Flex settings (RenAM 500Q/S Flex only) This setting is applicable to RenAM 500Q/S Flex machines only and will not be available for other configurations. RenAMP provides the option to configure the behaviour of the build when: •...
  • Page 307 RenAM 500Q/S user guide To configure any of the above mentioned settings: From the "Home" screen (Figure 183), select "Set Parameters" (circled). This will open the "Set Parameters" screen (Figure 184). Figure 183 "Home" screen with "Set Parameters" circled The "Set Parameters" screen (Figure 184) contains three buttons. Select the "System" button (circled), which will open the "System" screen. Figure 184 "Set Parameters" screen and "System" button...
  • Page 308 Chapter 9: Operation H-5800-3693 The "System" screen (Figure 185) contains the "User Settings" pane with the "Flex Settings" highlighted. Figure 185 "Flex Settings" Configure the settings as required. Setting Explanation Pause Build on Low Powder Pause the build as soon as powder goes below the silo low level sensor. Inhibit Build on Low Powder Do not allow the build to start if powder is below the silo low level sensor.

  • Page 309: Add/Update Material Information

    RenAM 500Q/S user guide TT-003 – Add/Update material information RenAMP allows you to add or update materials information. If the user wants to run builds with a different powder material, then the correct material needs to be selected using RenAMP.
  • Page 310 Chapter 9: Operation H-5800-3693 The "System Controls" screen (Figure 188) contains two buttons. Select the "Recirculation" button (circled). It will open the "Recirculation" screen. Figure 188 "System Controls" screen with "Recirculation" button The "Recirculation" screen (Figure 189) contains the "Materials" pane as highlighted. Figure 189 "Recirculation" screen with "Materials" pane 9-148 Issue 03-C...

  • Page 311: Tt-003-01 - Change Material

    RenAM 500Q/S user guide TT-003-01 – Change material The material currently in use can be changed by selecting from the list of available materials (as highlighted in Figure 190). Figure 190 Dropdown list of materials available TT-003-02 – Adding a new material Select "Other"...
  • Page 312 Chapter 9: Operation H-5800-3693 Add a suitable material name and density in the "Other Material" dialog box (circled) in Figure 192. Figure 192 "Other Material" dialog box Each material has filter switch and warning limits associated with it. "Differential Pressure Limits" are highlighted in Figure 193. Figure 193 "Differential Pressure Limits" pane 9-150 Issue 03-C...
  • Page 313 RenAM 500Q/S user guide Differential Pressure Limit Explanation Warning An alert will be displayed as soon the filter differential pressure reaches this limit. Switch A filter switch will happen if the differential pressure reaches this limit, with a condition that the other filter should be marked present and is clean.

  • Page 314: Optical Tests

    Chapter 9: Operation H-5800-3693 Optical tests The following table lists the optical tests that can be carried out on a RenAM 500Q/S system. Optical test Test title User level ST-002 Laser power health check Service ST-003 Laser focus health check...
  • Page 315 RenAM 500Q/S user guide As mentioned previously, the Controls section (highlighted in Figure 196) is common for all the tests. Figure 196 Controls for optical tests Once you have placed the test equipment (required for a specific test) in the chamber, the chamber can be prepared using the Controls section. The elevator can be moved using the buttons shown in Figure 197.
  • Page 316 Chapter 9: Operation H-5800-3693 After the desired elevator position is achieved, the chamber should be purged without vacuum so that the laser can be fired (Figure 198). Figure 198 Purge chamber without vacuum for optical test Once the chamber is prepared, optical tests can be run. 9-154 Issue 03-C...

  • Page 317: Laser Power Health Check

    RenAM 500Q/S user guide ST-002 – Laser power health check To confirm that the correct laser power is being delivered into the build, it is necessary to measure the output power by mounting a power meter into the chamber and firing the laser at multiple demand powers. Using the Laser Power screen (Figure 199) you can perform a power test for each laser in the system. Use the four buttons highlighted to select the laser to test. Figure 199 Laser power test Issue 03-C 9-155...
  • Page 318 Chapter 9: Operation H-5800-3693 The Power Meter button (Figure 200), enables selection of the test equipment on which the test is performed. Caution: This is important, as selecting the wrong equipment could damage the equipment itself. Figure 200 "Power Meter" button in laser power test The Alignment Laser button (Figure 201) turns the Alignment Laser ON for the desired number of seconds, input in the "On Time"...
  • Page 319 RenAM 500Q/S user guide The Laser Power test button "Primes Cube", runs the laser power test. The calibration file is selected from the folder "D:\config\lasercalibration". The test is run without powder dosing. Figure 202 "Laser Power Test" button in laser power test The Ophir Power Meter test comes with similar options as above, but an additional option is provided to control the laser power (Figure 203). Upon selection of the different laser power, a different calibration file is selected from the folder "D:\config\lasercalibration" which controls the laser power.

  • Page 320: Laser Focus Health Check

    Chapter 9: Operation H-5800-3693 ST-003 – Laser focus health check This confirms that the position of the laser focus (beam waist) is at the surface of the powder bed. Select the "Focus" test screen (Figure 204) to move to the Focus test. Figure 204 "Focus" test screen The Focus Test button (Figure 205) starts the test. The calibration file is selected from the folder "D:\config\lasercalibration". The test is run without powder dosing. Figure 205 "Focus Test" button 9-158 Issue 03-C...

  • Page 321: Laser Scanfield Health Check

    RenAM 500Q/S user guide ST-004 – Laser ScanField health check This check uses the Mylar Scanfield calibration procedure which allows for the x, y positional accuracy of the laser to be determined. Select "Scan Field" test button to move to the desired screen (Figure 206). Figure 206 "Optical Tests" screen and "Scan Field" button Press the Scan Field Test button (Figure 207) to start the test. The calibration file is selected from the...

  • Page 322: Laser Beam Profile Health Check

    Chapter 9: Operation H-5800-3693 ST-005 – Laser beam profile health check This check includes optically measuring the size and shape of the beam spot of the laser at different power values. Figure 208 "Optical Tests" screen and "Beam Profile" button The Beam Profile screen (Figure 209) allows you to perform a beam profile test for each laser in the system.
  • Page 323 RenAM 500Q/S user guide The Alignment Laser button (Figure 210) turns the Alignment Laser ON for the desired number of seconds, input in the "On Time" text box. Figure 210 "Alignment Laser" button in Beam Profile test The Select laser power option (Figure 211) allows you to choose the power with which the laser should be fired. Figure 211 "Select laser power" options in Beam Profile test...
  • Page 324 Chapter 9: Operation H-5800-3693 The Beam Profile RunTest button runs the laser power test. The calibration file is selected from the folder "D:\config\lasercalibration" folder. The test is run without powder dosing. Figure 212 "Run Test" button in Beam Profile test 9-162 Issue 03-C...

  • Page 325: Chapter 10 - Preventative Maintenance Schedule

    RenAM 500Q/S system. It is important that the RenAM 500Q/S is maintained so that its performance does not deteriorate to the extent that it puts people at risk or adversely impacts on any applicable warranty.

  • Page 326: Personal Protective Equipment (Ppe)

    WARNING: BEFORE STARTING ANY MAINTENANCE TASK, ENSURE YOU ARE WEARING THE CORRECT PPE: ESD SAFETY FOOTWEAR, EYE PROTECTION, FULL-FACE RESPIRATOR (TO EN143 TYPE P3 + A1), PROTECTIVE GLOVES AND FULL-LENGTH CLOTHING. Note: Renishaw recommends that full-length clothing is made from non-static-generating fabric such as cotton (avoid wool and synthetic fabrics). Avoid turn-ups or pockets that may trap powder. Refer to NFPA 484 for details.

  • Page 327: Renam 500Q/S Preventative Maintenance Schedule

    Build chamber lights Check 6 months Operator PM-028 Elevator position encoder brush Replace 6 months Operator PM-036 Top rear of chamber (RenAM 500Q/S Flex Clean 6 months Technician PM-037 only) Powder loading arm (RenAM 500Q/S Flex Inspect 6 months Operator...

  • Page 328: Ancillary Equipment Preventative Maintenance Schedule

    Maintain in accordance with the Renishaw powder recovery system User guide (Renishaw part no. H-5800-4613) Load hopper trolley Maintain in accordance with the Renishaw load hopper trolley User guide (Renishaw part no. H-5800-4481) Renishaw universal lifter Maintain in accordance with the Renishaw universal lifter User guide 10.5 Preventative maintenance records...

  • Page 329: Preventative Maintenance Checklists

    Operator PM-023 Build chamber lights Check Operator PM-028 Elevator position encoder brush Replace Operator PM-036 Top rear of chamber (RenAM 500Q/S Flex Clean Technician PM-037 only) Powder loading arm (RenAM 500Q/S Flex Inspect Operator PM-038 only) Feed hopper lifting brackets...
  • Page 330 Chapter 10: Preventative maintenance schedule H-5800-3693 This page is intentionally left blank. 10-6 Issue 03-C...

  • Page 331: Chapter 11 - Preventative Maintenance Tasks

    The aim of this chapter is to describe, in the form of a method statement, the preventative maintenance tasks that must be carried out on the RenAM 500Q/S system. The list of preventative maintenance tasks and the frequency at which they must be carried out is contained in Chapter 11 "Preventative maintenance schedule".

  • Page 332: Preventative Maintenance Tasks

    Ensure the system controls and displays are free from damage or defect. Ensure there are no obvious signs of damage or defect to the RenAM 500Q/S system. Check that the area around the RenAM 500Q/S is tidy and free of obstructions and that emergency exits are clear.

  • Page 333: Renam 500Q/S Safety Devices - Check

    11. Check the "Alerts log" and ensure the "Glovebox door open" alert is present. 12. Ensure the RenAM 500Q/S system is powered up, in an operational condition but is not building parts. 13. Operate an "Emergency stop" on the system.

  • Page 334: Renam 500Q/S System Hoses And Coolant System - Check

    OT-001. PM-004-03 – Post completion For advice on repairs or to schedule a repair visit, contact Renishaw AM Service using the contact details in Section 3.8. Record the completion of the maintenance task in the maintenance records.

  • Page 335: Process Room - Clean

    Note: Renishaw recommends that full-length clothing is made from non-static-generating fabric such as cotton (avoid wool and synthetic fabrics). Avoid turn-ups or pockets that may trap powder. Refer to NFPA 484 for details. Clean the process room where the RenAM 500Q/S is located and remove all traces of metal powder. Deposits of powder should be cleaned up by gentle sweeping using a non-synthetic non-static- generating brush into a metal receptacle (anti-static dustpan and brush).

  • Page 336: Build Chamber Viewing Window - Inspect

    Ensure the window is clean, free of scratches, cracks, damage or defects. If the window is dirty, clean it with IPA and a disposable cloth. For advice on repairs or to schedule a repair visit, contact Renishaw AM Service using the contact details in Section 3.8.

  • Page 337: User Guide - Check

    Use the contact details in Section 3.8 or visit www.renishaw.com/contact For advice on repairs or to schedule a repair visit, contact Renishaw AM Service using the contact details in Section 3.8. Record the completion of the maintenance task in the maintenance records.

  • Page 338: Pm-010-02 - Large Safe Change Filters

    More seriously defective valves may need to be removed, discarded and replaced with new valves. PM-010-03 – Post completion For advice on repairs or to schedule a repair visit, contact Renishaw AM Service using the contact details in Section 3.8. Record the completion of the maintenance task in the maintenance records.

  • Page 339: Vacuum Pump Oil Level - Check

    If the oil level is below the "MIN" mark on the sight gauge, top up with oil (type LVO120) until the oil level is between the "MIN" and "MAX" mark. For advice on repairs or to schedule a repair visit, contact Renishaw AM Service using the contact details in Section 3.8.

  • Page 340: Vacuum Pump Gas Ballast Valve Filter - Check

    "Elevator" maximise button. From the maximised view of the "Elevator" pane, select "Send elevator to top position. 11. For advice on repairs or to schedule a repair visit, contact Renishaw AMPD Service using the contact details in Section 3.8.

  • Page 341: Inert Gas Supply Safety - Check

    Check the argon gas supply and gas hoses and pipework that supply the RenAM 500Q/S with argon. Ensure all hoses and pipework are free of damage and deformation. Turn on the gas supply to the RenAM 500Q/S and listen for leaks from the hoses and pipework. Pay particular attention to joints and connections.

  • Page 342: Build Chamber - Clean

    The build chamber liner is secured by four screws, two at the top and two at the bottom on the front of the liner. Remove the four screws and set them aside for reuse. WARNING: DO NOT OPERATE THE RenAM 500Q/S SYSTEM WITH THE BUILD CHAMBER LINER REMOVED.

  • Page 343: Lens Protection Window - Clean

    "Elevator" maximise button. From the maximised view of the "Elevator" pane, select "Send elevator to top position". 23. For advice on repairs or to schedule a repair visit, contact Renishaw AMPD Service using the contact details in Section 3.8.
  • Page 344 Caution: Removing the lens protection window exposes the system optics to the environment. Renishaw recommends cleaning the lens protection window while it is installed in the RenAM 500 system. Note: Regularly inspect the condition of the lens protection window. Over time the lens protection window will require cleaning, will degrade and will require replacement in order to maintain system performance and part quality. Care and attention when inspecting and cleaning will significantly improve the life of the...

  • Page 345: Pm-035-01 - Lens Protection Window - Inspect

    RenAM 500Q/S user guide PM-035-01 – Lens protection window – Inspect Ensure that the build chamber has been emptied of metal powder and thoroughly cleaned in accordance with tasks PB-003 and PB-005. Put on protective clothing in the following order: hair net, face mask/spit guard, safety glasses/eye protection, clean laboratory coat and clean gloves.
  • Page 346 Chapter 11: Preventative maintenance tasks H-5800-3693 Figure 3 High-power LED torch illuminating lens protection window Note: Ensure that the torch does not touch the surface of the window. Inspect the window for contamination including but not restricted to: dust, oil, grease, film, condensate, fingerprints, smudges, metallic particles and mechanical damage (prominent scratches and digs). The torch may need to be held close to the window surface, typically 20 mm to 30 mm away from the window, and also at various angles to highlight and illuminate all possible contamination types (Figure 4, Figure 5 and Figure 6).
  • Page 347 RenAM 500Q/S user guide Figure 5 Contamination illuminated on lens protection window Figure 6 Contamination illuminated on lens protection window If signs of contamination are present, the window must be cleaned in accordance with the following steps of this document.

  • Page 348: Pm-035-02 - Lens Protection Window - First Stage Cleaning

    Chapter 11: Preventative maintenance tasks H-5800-3693 PM-035-02 – Lens protection window – First stage cleaning The first stage of cleaning is to remove any loose metallic particles using a manual blower or compressed gas. Manual blower Using a manual blower (part number P-0PTA-0121) (Figure 7) remove any loose particles that are visible on the window surface (Figure 8). Figure 7 Manual blower Figure 8 Loose particles present on the window 11-18 Issue 03-C...
  • Page 349 RenAM 500Q/S user guide Ensure the nozzle of the blower does not come into contact with the surface of the window. Keep the nozzle at least 50 mm away from the surface of the window (Figure 9). Figure 9 Manual blower removing particles It may be necessary to use the high-intensity torch to help to identify the position of the loose particles and to determine if they have been removed.
  • Page 350 Chapter 11: Preventative maintenance tasks H-5800-3693 Ensure the nozzle of the gas container does not touch the surface of the window. Keep the nozzle tip at least 50 mm away from the surface of the window (Figure 11). Figure 11 Manual blower removing particles It may be necessary to use the high-power torch to help to identify the position of the loose particles and to determine if they have been removed.

  • Page 351: Pm-035-03 - Lens Protection Window - Second Stage Cleaning

    RenAM 500Q/S user guide PM-035-03 – Lens protection window – Second stage cleaning The second stage of cleaning is to remove metallic particles. If any metallic particles, or potential metallic particles, are still present on the surface of the window (Figure 12) then use sticky swabs (part number P-WI01-0004) to remove the individual particles.
  • Page 352 Chapter 11: Preventative maintenance tasks H-5800-3693 Open the plastic case and using clean plastic tweezers (part number P-TL50-0424) grip the lower half of the sticky swab and remove it from the plastic case (Figure 14). Close the plastic case to keep the sticky swabs clean. Figure 14 Grip the sticky swab with tweezers Ensure the sticky tip of the swab is kept clean, kept in air and does not touch any surface other than the window that it will be used to clean (Figure 15).
  • Page 353 RenAM 500Q/S user guide Grip the lower half of the sticky swab stick with fingers and place the tweezers into a clean container (Figure 16). Figure 16 Grip the lower half of the stick with fingers Identify the position of the metallic particles on the lens protection window with the aid of the high- power torch. Hold the sticky swab in a vertical orientation and position the gel tip directly over the metallic particles on the lens protection window (Figure 17).
  • Page 354 Chapter 11: Preventative maintenance tasks H-5800-3693 Lower the sticky swab, keeping it in a vertical orientation. The particle should be attached to the gel tip and be pulled away from the surface of the window (Figure 18). Figure 18 Sticky swab removing particle from lens protection window 10.
  • Page 355 RenAM 500Q/S user guide 14. If the sides of the sticky swab are used then, after each use, the swab must be rotated through 90° so that a new uncontaminated section of the swab is available to be used. 15. Each section of the sticky swab may only be used once. Further inspection of the lens protection window Repeat the inspection procedure carried out in section PM-035-01 of this task to ensure that all large individual surface particles are removed from the surface of the lens protection window.

  • Page 356: Pm-035-04 - Lens Protection Window - Third Stage Cleaning

    Chapter 11: Preventative maintenance tasks H-5800-3693 PM-035-04 – Lens protection window – Third stage cleaning The third stage of cleaning is to remove surface residues, smears, films of contamination, etc. Note: The lens cleaning tissues described in the following paragraphs are packaged in a clean cardboard box sealed with adhesive tape. Dust from the cardboard box and adhesive from the sealing tape can cause contamination of the gloves.
  • Page 357 RenAM 500Q/S user guide Repeat the folding across the long edge for a further four times (Figure 22) until the folded tissue measures approximately 20 mm × 25mm (Figure 23). Figure 22 Small lens cleaning tissue – continue folding Figure 23 Small lens cleaning tissue fully folded...
  • Page 358 Chapter 11: Preventative maintenance tasks H-5800-3693 Take a pair of plastic tweezers (part number P-TL50-0424) and insert the tips into both folded sides of the lens tissue. The tweezers must fit inside the lens tissue (Figure 24). Figure 24 Tweezers inserted into small lens cleaning tissue Position the tips of the tweezers so that there is a gap of approximately 2 mm (0.078 in) between the fold of the tissue and the tips of the tweezers (Figure 25). This is to ensure that there is no contact between the tweezers and the surface of the window, even if the tissue paper splits due to it being wet with solvent.
  • Page 359 RenAM 500Q/S user guide Spray clean IPA from an aerosol (part number P-AD99-0131) on to the top fold of the lens tissue (Figure 26). Note: IPA is highly flammable. Ensure IPA is applied to the lens tissue outside of the chamber, sprayed away from the body and face, and any overspray or spillage occurs in a safe area. Figure 26 IPA being applied to a small lens cleaning tissue from an aerosol can Hold the tissue with the tweezers and place it onto the centre of the lens protection window to be cleaned (Figure 27).
  • Page 360 Chapter 11: Preventative maintenance tasks H-5800-3693 Apply light pressure and drag the tweezers to the outer edge of the lens protection window so that the tissue wipes the window surface (Figure 28). Figure 28 Lens cleaning tissue wiping surface of lens protection window As the tissue is moved across the window gradually angle the tweezers so that the contamination is rolled away from the lens protection window surface and into the side of the tissue (Figure 29).
  • Page 361 RenAM 500Q/S user guide 10. When the tissue is at the outer edge of the window lower the tissue away from the window (Figure 30). Figure 30 Removing lens cleaning tissue from surface of lens protection window 11. Only wipe the tissue across the lens protection window in a straight line in one direction from the centre to the outer edge.
  • Page 362 Chapter 11: Preventative maintenance tasks H-5800-3693 14. As the tissue is moved across the window gradually angle the tweezers back so that the contamination is rolled away from the window surface and into the second side of the tissue (Figure 32). Figure 32 Angled tweezers 15.
  • Page 363 RenAM 500Q/S user guide 18. Place the lens cleaning tissue in the centre of the lens protection window as before and wipe the next adjacent area of the window that is to be cleaned. Both sides of the tissue can be used as described previously.

  • Page 364: Pm-035-05 - Lens Protection Window - Fourth Stage Cleaning

    Chapter 11: Preventative maintenance tasks H-5800-3693 PM-035-05 – Lens protection window – Fourth stage cleaning The fourth stage of cleaning is a secondary clean to remove surface residues, smears, films of contamination, etc. Note: The lens cleaning tissues described in the following paragraphs are packaged in a clean cardboard box sealed with adhesive tape. Dust from the cardboard and adhesive from the sealing tape can cause contamination of the gloves.
  • Page 365 RenAM 500Q/S user guide Repeat the folding across the long edge for a further five times (Figure 37) until the folded tissue measures approximately 40 mm × 25mm (Figure 37). Figure 37 Large lens cleaning tissue folded Cleaning the outer edge of the lens protection window Take a clean large lens cleaning tissue and fold it as described in Sections 1 and 2 at the start of task PM-035-05.
  • Page 366 Chapter 11: Preventative maintenance tasks H-5800-3693 Place the folded edge of the lens cleaning tissue against the interface edge between the window and the metal supporting (Figure 39). Figure 39 Cleaning around the edge of the lens protection window Apply light pressure to the lens cleaning tissue and wipe around the perimeter of the glass to metal interface ensuring that the glove surface does not touch the lens protection window (Figure 40).
  • Page 367 RenAM 500Q/S user guide Remove the lens cleaning tissue and inspect for evidence of contamination (Figure 41). Figure 41 Contaminated lens cleaning tissue Repeat the folding and preparation of a large lens cleaning tissue, and continue cleaning the perimeter of the glass to metal interface until the lens cleaning tissue is visibly clean and there is no more contamination present.
  • Page 368 Chapter 11: Preventative maintenance tasks H-5800-3693 Apply light pressure to the lens cleaning tissue and slowly wipe across the window from the centre to the edge ensuring that the glove does not touch the window (Figure 43). Figure 43 Wipe from the centre to the edge Remove the lens cleaning tissue from the window and turn the tissue inside out to expose a new clean section of tissue.
  • Page 369 RenAM 500Q/S user guide Circular cleaning of the lens protection window Take a clean large lens cleaning tissue and fold it as described in Sections 1 and 2 at the start of task PM-035-05. Place the folded edge of the cleaning tissue against the centre of the window (Figure 45).
  • Page 370 Chapter 11: Preventative maintenance tasks H-5800-3693 Remove the lens cleaning tissue from the window and turn the lens tissue inside out to expose a new clean section of tissue. Place the folded edge of the tissue against the centre of the window apply light pressure and repeat the circular motion from the centre to the outside.

  • Page 371: Pm-035-06 - Lens Protection Window - Examples Of Surface Contamination

    Note: In the following images of the lens protection window, some of the images were captured when the window was viewed in a Renishaw illuminated inspection jig. This highlights the entire surface of the window. The same defects will be detected using a high-power LED torch, however, the illuminated area will be smaller and the entire window will need to be scanned with the torch to allow inspection of the whole window.
  • Page 372 Chapter 11: Preventative maintenance tasks H-5800-3693 Figure 49 Condition of chamber window prior to cleaning – general surface residue and smearing visible Figure 50 Dense spot of residue and a haze of contamination is uniformly spread over the window 11-42 Issue 03-C...
  • Page 373 RenAM 500Q/S user guide Figure 51 Residue wiped with a gel stick Figure 52 Residue across the entire surface of the window Issue 03-C 11-43...
  • Page 374 Chapter 11: Preventative maintenance tasks H-5800-3693 Figure 53 Contamination on the window surface – appears to be due to wiping Figure 54 Contamination on the window surface – appears to be due to wiping 11-44 Issue 03-C...
  • Page 375 RenAM 500Q/S user guide Figure 55 Residue across the entire surface of the window – appears to be due to wiping with a contaminated cloth Figure 56 Smears across the centre of the window Issue 03-C 11-45...
  • Page 376 Chapter 11: Preventative maintenance tasks H-5800-3693 Figure 57 Residue at the edge of the window Contamination – fingerprints and general contamination Figure 58 Finger prints on the surface of the window 11-46 Issue 03-C...
  • Page 377 RenAM 500Q/S user guide Figure 59 Finger prints on the surface of the window Figure 60 General light contamination on the surface of the window Mechanical damage – digs and scratches Issue 03-C 11-47...
  • Page 378 Chapter 11: Preventative maintenance tasks H-5800-3693 Figure 61 Multiple surface scratches Figure 62 Condition of lens protection window prior to cleaning – surface contamination and possible mechanical damage to the window 11-48 Issue 03-C...
  • Page 379 RenAM 500Q/S user guide Figure 63 Condition of lens protection window after cleaning – mechanical damage is visible on the surface of the window Dust and particles Figure 64 Small cluster of particles on the window surface Issue 03-C 11-49...
  • Page 380 Chapter 11: Preventative maintenance tasks H-5800-3693 Figure 65 Excessive amount of dust and particles on the surface of the window Figure 66 Excessive amount of dust and particles on the surface of the window 11-50 Issue 03-C...
  • Page 381 RenAM 500Q/S user guide Figure 67 Larger particles and potentially metallic due to the shape and colour Figure 68 Larger particles and potentially metallic due to the shape and colour Issue 03-C 11-51...
  • Page 382 Chapter 11: Preventative maintenance tasks H-5800-3693 Figure 69 A small amount of fine dust will almost always be observed on the window surface when inspected with a high-power LED torch Figure 70 A small amount of fine dust will almost always be observed on the window surface when inspected with a high-power LED torch 11-52 Issue 03-C...

  • Page 383: Pm-035-07 - Lens Protection Window - Post Completion

    RenAM 500Q/S user guide Figure 71 A small amount of fine dust will almost always be observed on the window surface when inspected with a high-power LED torch PM-035-07 – Lens protection window – Post completion Once complete, there should be no visible dirt, debris, dust or other contamination remaining on the lens protection window.

  • Page 384: Elevator Position Encoder Brush - Replace

    Chapter 11: Preventative maintenance tasks H-5800-3693 PM-036 – Elevator position encoder brush – Replace WARNING: BEFORE STARTING THIS TASK, ENSURE YOU ARE WEARING THE CORRECT PPE FOR WORKING WITH METAL POWDER: ESD SAFETY FOOTWEAR, EYE PROTECTION, FULL-FACE RESPIRATOR (TO EN143 TYPE P3 + A1), PROTECTIVE GLOVES AND FULL-LENGTH CLOTHING. Open the lower door as follows.
  • Page 385 11. Fit the new brush assembly to the hat and secure it to the encoder read head bracket with the M5 screw removed previously. Do not overtighten the M5 screw. 12. For advice on repairs or to schedule a repair visit, contact Renishaw AM Service using the contact details in Section 3.8.

  • Page 386: Top Rear Of Chamber - Clean (Renam 500Q/S Flex Only)

    Close the rear centre door, ensuring the security latches are turned to the locked position. For advice on repairs or to schedule a repair visit, contact Renishaw AM Service using the contact details in Section 3.8. Record the completion of the maintenance task in the maintenance records.

  • Page 387: Powder Loading Arm - Inspect (Renam 500Q/S Flex Only)

    Rotate the powder arm and ensure that bearings are smooth running. Check that the arm can be raised and lowered on the bearing track as expected. For advice on repairs or to schedule a repair visit, contact Renishaw AM Service using the contact details in Section 3.8.

  • Page 388: Feed Hopper Lifting Brackets - Inspect (Renam 500Q/S Flex Only)

    Ensure all visible fasteners are correctly tightened and there are no loose components. For advice on repairs or to schedule a repair visit, contact Renishaw AM Service using the contact details in Section 3.8. Record the completion of the maintenance task in the maintenance records.

  • Page 389: Chapter 12 - Consumables Parts And Spare Parts

    Chapter 12 – Consumables parts and spare parts Introduction The aim of this chapter is to provide a list of the consumables parts for the RenAM 500Q/S system. The consumable parts are those which are replaced on a regular basis, such as the recoater blade and large safe change filters which are replaced after every build.

  • Page 390: Consumable Parts

    Powder flask 0.85 l (51.9 in³) M-6521-2310 Powder flask 10 l (610 in³) M-5778-1370 Powder filter M-5778-3176 Glove box door fastener tool A-5774-0346 Renishaw powder adaptor P-PF07-0124 Renishaw powder adaptor KF50 to KF40 adaptor P-0PTA-0121 Manual blower P-AD99-0130 Clean canned compressed gas P-WI01-0004 Sticky swabs P-TL50-0424 Plastic tweezers – clean P-WI02-0002...

  • Page 391: Spare Parts

    RenAM 500Q/S user guide 12.2 Spare parts Renishaw stocks a vast range of spare parts and can make recommendations on which critical spares to keep in stock to maximise the running time of your AM system. Renishaw has a global network of skilled staff, trained and equipped to provide you with technical assistance remotely or directly at your site.
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  • Page 394 Renishaw plc +44 (0) 1453 524524 +44 (0) 1453 524901 New Mills, Wotton-under-Edge uk@renishaw.com Gloucestershire, GL12 8JR www.renishaw.com United Kingdom For worldwide contact details, visit www.renishaw.com/contact *H-5800-3693-03* Issued: 07.2021 Part no. H-5800-3693-03-C © 2018–2021 Renishaw plc...

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