Renishaw RenAM 500D Original Instructions Manual

RenAM 500Q/T/D/S

additive manufacturing system

User guide

H-5800-3693-02-A

ORIGINAL INSTRUCTIONS

Renishaw part no: H-5800-3693-02-A

Issued: 05.2018

Revised: 07.2019

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.

The publication of material within this document does not imply freedom from the patent rights of

Renishaw plc.

RenAM 500Q/T/D/S user guide

Issue 02-A i

Contents

Chapter 1 – Before you begin

Introduction....................................................................1-1

1.1 Disclaimer .................................................................1-2

1.2 Trade marks................................................................1-2

1.3 Warranty ..................................................................1-2

1.4 Changes to equipment .......................................................1-2

1.5 Patents ...................................................................1-3

1.6 WEEE directive .............................................................1-3

1.7 EU declaration of conformity ...................................................1-3

1.8 FCC information to user (USA only) .............................................1-4

1.8.1 47CFR section 15.21 ...................................................1-4

1.8.2 47CFR section 15.105 ..................................................1-4

1.9 REACH ...................................................................1-4

1.10 Control of pollution, applicable in the People’s Republic of China......................1-4

Chapter 2 – Scope of supply

Introduction....................................................................2-1

2.1 Standard equipment .........................................................2-2

2.2 Required accessories ........................................................2-2

2.3 Optional items ..............................................................2-3

Chapter 3 – Document control

Introduction....................................................................3-1

3.1 Document control ...........................................................3-2

3.2 Document history ...........................................................3-3

3.3 Product bulletins ............................................................3-3

3.4 Release notes ..............................................................3-3

3.4.1 Revision 01-B – affected chapters .........................................3-3

3.4.2 Revision 01-C – affected chapters .........................................3-4

3.4.3 Revision 01-D – affected chapters .........................................3-6

3.4.4 Revision 01-E – affected chapters .........................................3-8

3.4.5 Revision 01-F – affected chapters.........................................3-10

3.4.6 Revision 02-A – affected chapters ........................................3-12

Contents

ii Issue 02-A

H-5800-3693

Chapter 4 – Introduction

Introduction....................................................................4-1

4.1 Summary..................................................................4-2

4.2 Reference documentation .....................................................4-2

4.3 Deﬁnitions .................................................................4-3

4.4 Abbreviations...............................................................4-4

4.5 Safety information in this User guide.............................................4-5

4.5.1 Warning..............................................................4-5

4.5.2 Caution ..............................................................4-5

4.5.3 Note.................................................................4-5

4.6 Training schedule............................................................4-5

4.7 Contact details..............................................................4-6

Chapter 5 – Safety

Introduction....................................................................5-1

5.1 General safety information ....................................................5-2

5.1.1 Introduction ...........................................................5-2

5.1.2 Responsibilities ........................................................5-2

5.1.3 Basic safety measures ..................................................5-3

5.1.4 Explosion prevention document ...........................................5-4

5.1.5 What to do in an emergency ..............................................5-4

5.1.6 Normal operation.......................................................5-5

5.1.7 Approvals, compliance and certiﬁcation .....................................5-5

5.1.8 Residual risks, maintenance and protective measures..........................5-5

5.1.9 Housekeeping .........................................................5-5

5.1.10 Electro-magnetic compatibility ...........................................5-5

5.2 Personal safety .............................................................5-6

5.2.1 Manual handling .......................................................5-6

5.2.2 Fire-ﬁghting ...........................................................5-6

5.2.3 Laser safety precautions .................................................5-7

5.2.4 Oxygen level monitoring within the process room..............................5-7

5.2.5 Training ..............................................................5-8

5.2.6 Correct usage .........................................................5-8

5.2.7 Improper use..........................................................5-8

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Issue 02-A iii

5.2.8 Personal protective equipment ............................................5-9

5.2.8.1 Eye protection ...................................................5-11

5.2.9 Toxicity and personnel exposure ..........................................5-11

5.2.10 Thermal hazards .....................................................5-12

5.2.11 Hazards due to latent energy sources ....................................5-12

5.3 Powder safety .............................................................5-13

5.3.1 Metal powder handling advice............................................5-13

5.3.2 Handling of metal powders ..............................................5-15

5.3.3 Flammability .........................................................5-16

5.3.3.1 Combustibility ...................................................5-16

5.3.3.2 Explosivity ......................................................5-17

5.3.4 Safe disposal of waste products ..........................................5-18

5.3.5 Handling and processing................................................5-18

5.3.6 Storage .............................................................5-19

5.3.7 Spills ...............................................................5-19

5.3.8 Metal powder safety checklist ............................................5-20

5.3.9 Hazards due to ﬁre or explosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-21

5.3.10 Identiﬁable ignition sources.............................................5-22

5.3.11 Hydrogen gas .......................................................5-23

5.3.12 Safety data sheets....................................................5-24

5.3.13 Metal condensate ....................................................5-24

5.4 System safety .............................................................5-25

5.4.1 Safety function diagrams................................................5-25

5.4.1.1 RenAM 500Q/T/D/S front view – safety functions........................5-25

5.4.1.2 RenAM 500Q/T/D/S rear view – safety functions ........................5-26

5.4.1.3 RenAM 500Q/T/D/S top view – safety functions .........................5-27

5.4.2 Safety signs and laser safety labels .......................................5-28

5.4.2.1 Safety signs.....................................................5-28

5.4.2.2 Laser safety labels ...............................................5-31

5.4.3 Transport and system relocation ..........................................5-34

5.4.4 Decommissioning .....................................................5-34

5.4.5 Hazards due to unexpected malfunctions ...................................5-35

5.5 Gas safety ................................................................5-35

5.5.1 Inert gas safety .......................................................5-35

Contents

iv Issue 02-A

H-5800-3693

Chapter 6 – Overview

Introduction....................................................................6-1

6.1 RenAM 500Q/T/D/S front view .................................................6-2

6.2 RenAM 500Q/T/D/S rear view..................................................6-3

6.3 RenAM 500Q/T/D/S right-hand end view .........................................6-4

6.4 RenAM 500Q/T/D/S front view with powder ﬁll and large safe change ﬁlter door open ......6-5

6.5 RenAM 500Q/T/D/S rear view with rear right-hand cupboard door open .................6-6

6.6 RenAM 500Q/T/D/S plan view .................................................6-7

Chapter 7 – System speciﬁcation

Introduction....................................................................7-1

7.1 RenAM 500Q/T/D/S system speciﬁcation .........................................7-2

7.2 Build plate speciﬁcation.......................................................7-4

7.2.1 Mild steel build plate ....................................................7-4

7.2.2 Titanium build plate – RenAM 500M/L ......................................7-5

7.2.3 Aluminium build plate ...................................................7-6

7.2.4 Stainless steel build plate ................................................7-7

7.2.5 Full build titanium build plate..............................................7-8

7.2.6 Long life stainless steel build plate .........................................7-9

7.2.7 Full build stainless steel build plate........................................7-10

7.2.8 Long life aluminium build plate ...........................................7-11

7.2.9 Full build aluminium build plate ...........................................7-12

7.2.10 Long life mild steel build plate ...........................................7-13

7.2.11 Long life titanium build plate ............................................7-14

7.2.12 Full build mild steel build plate ..........................................7-15

Chapter 8 – Functional description

Introduction....................................................................8-1

8.1 RenAM 500Q/T/D/S main isolating switch ........................................8-2

8.2 "Emergency Stop" button .....................................................8-2

8.3 Operator touch screen control panel.............................................8-3

8.4 Programmable logic controller..................................................8-4

RenAM 500Q/T/D/S user guide

Issue 02-A v

8.5 Main computer..............................................................8-4

8.6 System software ............................................................8-5

8.7 Laser .....................................................................8-6

8.8 Chiller ....................................................................8-6

8.9 Lens protection window.......................................................8-7

8.10 Build chamber viewing window ................................................8-7

8.11 Powder recirculation system ..................................................8-8

8.12 Load hopper ..............................................................8-8

8.13 Dosing silo................................................................8-9

8.14 Renishaw ultrasonic sieve ....................................................8-9

8.15 Pneumatic transfer ........................................................8-10

8.16 Powder delivery...........................................................8-11

8.17 Recoater assembly ........................................................8-11

8.18 Gas circuit ...............................................................8-12

8.19 Build plate ...............................................................8-12

8.20 Heating/temperature control .................................................8-13

8.21 Large safe change ﬁlter (LSCF50) ............................................8-14

8.22 Oxygen monitoring sensors..................................................8-16

8.23 Keys and user accessibility ..................................................8-16

8.24 ESD and earth bonding points ...............................................8-18

8.25 Laser controller ...........................................................8-19

8.26 Cyclone .................................................................8-19

8.26.1 Cyclone level sensors .................................................8-20

8.27 Intercooler ...............................................................8-20

8.28 Electrical cabinets .........................................................8-21

8.29 ATEX vacuum cleaner......................................................8-22

8.30 Silo lift ..................................................................8-23

8.31 Hopper trolley ............................................................8-24

Contents

vi Issue 02-A

H-5800-3693

Chapter 9 – Ancillaries

Introduction....................................................................9-1

9.1 ATEX vacuum cleaner – mandatory .............................................9-2

9.1.1 ATEX vacuum cleaner general information ...................................9-2

9.1.2 ATEX vacuum cleaner safety .............................................9-3

9.1.3 ATEX vacuum cleaner operation...........................................9-3

9.1.4 ATEX vacuum cleaner maintenance ........................................9-4

9.2 Chiller – mandatory..........................................................9-5

9.2.1 Chiller general information ...............................................9-5

9.2.2 Chiller safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-5

9.2.3 Chiller operation .......................................................9-6

9.2.4 Chiller maintenance ....................................................9-6

9.3 Bead blaster and extractor – optional ............................................9-6

9.3.1 Bead blaster and extractor general information ...............................9-6

9.3.2 Bead blaster and extractor safety ..........................................9-7

9.3.3 Bead blaster and extractor operation .......................................9-7

9.3.4 Bead blaster and extractor maintenance.....................................9-7

9.4 Furnace – optional ..........................................................9-8

9.4.1 Furnace general information ..............................................9-8

9.4.2 Furnace safety ........................................................9-8

9.4.3 Furnace operation......................................................9-9

9.4.4 Furnace maintenance ...................................................9-9

9.5 Silo lift – recommended.......................................................9-9

9.5.1 Silo lift general information ...............................................9-9

9.6 Hopper trolley – recommended................................................9-10

9.6.1 Introduction ..........................................................9-10

RenAM 500Q/T/D/S user guide

Issue 02-A vii

Chapter 10 – Operation

Introduction...................................................................10-1

10.1 Pre-build tasks............................................................10-2

AB-001 – Chiller ﬂuid level – Check ............................................10-3

AB-002 – Argon gas supply – Set-up ...........................................10-4

AB-003 – Chiller – Power-up..................................................10-4

AB-004 – Large safe change ﬁlter assemblies – Check .............................10-6

AB-005 – RenAM 500Q/T/D/S system – Power-up.................................10-7

AB-006 – RenAM 500Q/T/D/S system – Log-in ...................................10-7

AB-007 – Build chamber – Set-up..............................................10-9

AB-008 – Build plate – Install ................................................10-12

AB-009 – Recoater blade – Install ............................................10-17

AB-010 – Recoater assembly – Install .........................................10-21

AB-011 – RenAM 500Q/T/D/S load hopper – Fill .................................10-23

AB-012 – Valves – Set-up ...................................................10-26

AB-013 – Build platform heat soak process – Set-up ..............................10-28

AB-014 – Build chamber atmosphere – Set-up...................................10-30

AB-015 – Powder dose – Set-up..............................................10-32

AB-016 – Build ﬁle – Transfer ................................................10-35

AB-017 – Build ﬁle – Select..................................................10-35

AB-018 – Cyclone particle collection ﬂask – Fit ..................................10-36

AB-019 – Pre-build checklist – Review .........................................10-38

AB-020 – Build – Start .....................................................10-39

10.2 Monitoring the build.......................................................10-41

10.3 Post-build tasks ..........................................................10-44

PB-002 – Build plate – Cool down ............................................10-45

PB-003 – Build chamber metal powder – Remove ................................10-46

PB-004 – Build plate – Remove ..............................................10-53

PB-005 – Build chamber – Clean .............................................10-54

PB-016 – Lens protection system – Inspect .....................................10-56

PB-007 – Lower chamber – Clean ............................................10-57

PB-008 – Recoater blade – Remove...........................................10-58

Contents

viii Issue 02-A

H-5800-3693

PB-015 – Oversized particle collection ﬂask – Reﬁt, remove and empty ...............10-58

PB-015-01 – Reﬁt .....................................................10-59

PB-015-02 – Remove...................................................10-63

PB-015-03 – Empty ....................................................10-64

PB-017 – Cyclone ﬁlter particle collection ﬂask – Remove and empty .................10-64

PB-017-01 – Remove...................................................10-64

PB-017-02 – Empty ....................................................10-65

PB-009 – RenAM 500Q/T/D/S system – Shutdown ...............................10-66

PB-010 – RenAM 500Q/T/D/S system – Power down .............................10-67

PB-011 – Chiller – Power down...............................................10-68

PB-012 – Build plate parts – Remove..........................................10-69

PB-013 – Build plate – Refurbish .............................................10-69

PB-014 – Heat treatment of parts (optional) – Set-up..............................10-70

PB-014-01 – Introduction ................................................10-70

PB-014-02 – Wrapping parts prior to heat treatment ...........................10-70

10.4 Occasional tasks .........................................................10-76

OT-001 – Chiller ﬂuid level – Top-up ...........................................10-77

OT-002 – Argon gas cylinder – Replace ........................................10-78

OT-003 – Powder ﬂask – Fill .................................................10-79

OT-005 – Large safe change ﬁlter assembly – Remove ............................10-81

OT-006 – Large safe change ﬁlter element – Remove .............................10-88

OT-007 – Large safe change ﬁlter element – Reﬁt ................................10-92

OT-008 – Large safe change ﬁlter assembly – Reﬁt ...............................10-93

OT-009 – Chiller ﬂuid – Remove ..............................................10-95

OT-010 – RenAM 500Q/T/D/S system – Restart..................................10-96

Chapter 11 – Preventative maintenance schedule

Introduction...................................................................11-1

11.1 Personal protective equipment ...............................................11-2

11.2 Deﬁnitions of maintenance ..................................................11-2

11.3 RenAM 500Q/T/D/S preventative maintenance schedule ...........................11-3

11.4 Ancillary equipment preventative maintenance schedule ...........................11-4

RenAM 500Q/T/D/S user guide

Issue 02-A ix

11.5 Preventative maintenance records ............................................11-4

11.6 Preventative maintenance checklists...........................................11-5

11.6.1 One week tasks......................................................11-5

11.6.2 Two week tasks ......................................................11-5

11.6.3 One month tasks.....................................................11-5

11.6.4 Six month tasks......................................................11-5

Chapter 12 – Preventative maintenance tasks

Introduction...................................................................12-1

12.1 Preventative maintenance tasks ..............................................12-2

PM-001 – RenAM 500Q/T/D/S system – Inspect ..................................12-2

PM-002 – RenAM 500Q/T/D/S system – Clean ...................................12-2

PM-003 – RenAM 500Q/T/D/S safety devices – Check .............................12-3

PM-004 – RenAM 500Q/T/D/S system hoses and coolant system – Check..............12-4

PM-004-01 – System hoses – Check........................................12-4

PM-004-02 – Coolant system – Check ......................................12-4

PM-004-03 – Post completion .............................................12-4

PM-005 – Process room – Clean ..............................................12-5

PM-006 – Build chamber viewing window – Inspect ................................12-6

PM-007 – Top and bottom door seals – Check ....................................12-6

PM-008 – Safety signs and laser safety labels – Inspect ............................12-6

PM-009 – User guide – Check ................................................12-7

PM-010 – Powder ﬂasks and large safe change ﬁlters – Check .......................12-7

PM-010-01 – Powder ﬂasks ...............................................12-7

PM-010-02 – Large safe change ﬁlters ......................................12-8

PM-010-03 – Post completion .............................................12-8

PM-011 – Chiller settings – Check .............................................12-8

PM-012 – Vacuum pump oil level – Check .......................................12-9

PM-024 – Inert gas supply safety – Check .......................................12-9

PM-035 – Lens protection system – Clean ......................................12-10

PM-013 – Elevator position encoder and reading strip – Clean ......................12-12

Contents

x Issue 02-A

H-5800-3693

PM-015 – Vacuum pump gas ballast valve ﬁlter – Check . . . . . . . . . . . . . . . . . . . . . . . . . . .12-14

PM-030 – Build chamber – Clean .............................................12-14

PM-023 – Metal powder safety – Check ........................................12-16

PM-028 – Build chamber lights – Check........................................12-16

PM-036 – Elevator position encoder brush – Replace .............................12-17

Chapter 13 – Consumables parts and spare parts

Introduction...................................................................13-1

13.1 Consumable parts .........................................................13-2

13.2 Spare parts ..............................................................13-3

Issue 02-A 1-1

RenAM 500Q/T/D/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.

Chapter 1: Before you begin H-5800-3693

Issue 02-A1-2

1.1 Disclaimer

RENISHAW HAS MADE CONSIDERABLE EFFORTS TO ENSURE THE CONTENT OF THIS

DOCUMENT IS CORRECT AT THE DATE OF PUBLICATION BUT MAKES NO WARRANTIES OR

REPRESENTATIONS REGARDING THE CONTENT. RENISHAW EXCLUDES LIABILITY, HOWSOEVER

ARISING, FOR ANY INACCURACIES IN THIS DOCUMENT.

1.2 Trade marks

RENISHAW and the probe symbol used in the RENISHAW logo are registered trade marks of

Renishaw plc in the United Kingdom and other countries. apply innovation and names and designations

of other Renishaw products and technologies are trade marks of Renishaw plc or its subsidiaries.

All other brand names and product names used in this document are trade names, trade marks, or

registered trade marks of their respective owners.

1.3 Warranty

Equipment requiring attention under warranty must be returned to your equipment supplier. Unless

otherwise speciﬁcally agreed in writing between you and Renishaw, if you purchased the equipment from

a Renishaw company, the warranty provisions contained in Renishaw’s CONDITIONS OF SALE apply. You

should consult these conditions in order to ﬁnd out the details of your warranty but, in summary, the main

exclusions from the warranty are if the equipment has been:

• neglected, mishandled or inappropriately used; or

• modiﬁed or altered in any way except with the prior written agreement of Renishaw.

If you purchased the equipment from any other supplier, you should contact them to ﬁnd out what repairs

are covered by their warranty.

1.4 Changes to equipment

Renishaw reserves the right to change equipment specifications without notice.

Issue 02-A

RenAM 500Q/T/D/S user guide

1-3

1.5 Patents

Features of the RenAM 500Q/T/D/S additive manufacturing system, and other similar systems, are the

subject of one or more of the following patents and/or patent applications:

CA 2971675 EP 2318164 JP 2016-516886 US 2014-0287080 WO2014/125258

CA 2731121 EP 2323787 JP 2016-517357 US 2015-0352668 WO2014/125280

CA 2738618 EP 2331232 JP 2016-527101 US 2016-0001401 WO2014/199134

CA 2738619 EP 2342042 JP 5514210 US 2016-0114432 WO 2016/079495

EP 2620241 US 2017-0189961 WO 2016/079496

CN 102186554 EP 2687305 US 8753105 WO 2016102970

CN 103357874 EP 2875855 US 8794263 WO 2017/013454

CN 105102160 EP 2956261 US 9114478 WO 2017/085469

CN 105228775 EP 2956262 US 9669583 WO 2017/085470

CN 105414544 EP 3007879

CN 105492188

1.6 WEEE directive

The use of this symbol on Renishaw products and/or accompanying documentation indicates that the

product should not be mixed with general household waste upon disposal. It is the responsibility of the

end user to dispose of this product at a designated collection point for waste electrical and electronic

equipment (WEEE) to enable reuse or recycling. Correct disposal of this product will help to save valuable

resources and prevent potential negative effects on the environment. For more information, please contact

your local waste disposal service or Renishaw distributor.

1.7 EU declaration of conformity

Renishaw plc hereby declares that the RenAM 500Q/T/D/S is in compliance with the essential

requirements and other relevant provisions of Directives 2006/42/EC and 2014/30/EU.

Contact Renishaw plc or visit www.renishaw.com for the full EU declaration of conformity.

Chapter 1: Before you begin H-5800-3693

Issue 02-A1-4

1.8 FCC information to user (USA only)

1.8.1 47CFR section 15.21

The user is cautioned that any changes or modiﬁcations not expressly approved by Renishaw plc or

authorised representative could void the user’s authority to operate the equipment.

1.8.2 47CFR section 15.105

This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant

to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful

interference when the equipment is operated in a commercial environment. This equipment generates,

uses, and can radiate radio frequency energy and, if not installed and used in accordance with the

instruction manual, may cause harmful interference to radio communications. Operation of this equipment

in a residential area is likely to cause harmful interference in which case the user will be required to correct

the interference at his own expense.

1.9 REACH

Information required by Article 33(1) of Regulation (EC) No. 1907/2006 ("REACH") relating to products

containing substances of very high concern (SVHCs) is available at:

www.renishaw.com/REACH

1.10 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.

RenAM 500Q/T/D/S user guide

2-1Issue 02-A

Chapter 2 – Scope of supply

Introduction

The following chapter describes the items of equipment supplied with the RenAM

500Q/T/D/S system as standard, and the equipment available as options.

Chapter 2: Scope of supply

2-2

H-5800-3693

Issue 02-A

2.1 Standard equipment

The following equipment and services are supplied as standard when you purchase a RenAM 500Q/T/D/S

system from Renishaw.

• Renishaw RenAM 500Quad/Triple/Dual/Single, referred to as 'RenAM 500Q/T/D/S', additive

manufacturing system

• WelcomePac

• RenAM 500Q/T/D/S Installation guide – H-5800-3692

• RenAM 500Q/T/D/S User guide – H-5800-3693

• Operator training course

• Sign-off kit – to suit the material being processed

• Powder flask kit – one powder flask complete with isolating valve

• Chiller – to supply cooled water to the system optical equipment

• Filter passivation kit – A-6521-5060

2.2 Required accessories

• ATEX vacuum cleaner

• Suitable lifting equipment – a speciﬁcation can be supplied upon request

• Computer for offline file preparation – user to supply

• Argon gas supply – cylinder, bank or liquid – user to supply

• Personal protective equipment – user to supply

• Oxygen gas low-level detector – user to supply

• File preparation software – for example Renishaw QuantAM or Materialise Magics™

• Metal powder

RenAM 500Q/T/D/S user guide

2-3Issue 02-A

2.3 Optional items

• Furnace

• Bead blast unit

• Additional powder flasks – complete with isolating valves

• Hopper trolley

• SCF50 lifting bracket – A-6521-3607

• SCF50 Wall mounted bracket – A-6521-2111

Chapter 2: Scope of supply

2-4

H-5800-3693

Issue 02-A

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