Accessories Assembly Instructions for RF500 Maker Construction Kit/Construction Kit/Finished Device Retrofitting Set for Heatable Printing Bed Item no. 1550421 Item no. 1600018 (for Z-expansion) Aluminium Die-Cast Plate Item no. 1544299 Heating Mat Mains Unit Item no. 1544298 Item no. 1599746 (for Z-expansion) Item no. 1544402 LED Light Strips Z-Expansion Item no. 1553485 Item no. 1541307 Metal Housing Acrylic Housing Item no. 1530466 Item no.
Table of contents Page 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 2 Introduction.....................................................................................................................................................................................................3 Explanation of symbols...................................................................................................................................................................................3 Intended use.....
1. Introduction Dear Customer, thank you for purchasing this product. This product complies with the statutory national and European requirements. To maintain this status and to ensure safe operation, you as the user must observe these operating instructions! These operating instructions are part of this product. They contain important notes on commissioning and handling. Also consider this if you pass on the product to any third party.
3. Intended use The products described in these instructions are intended for installation in or attachment to the RF500 Maker construction kit and partially to the RF500 finished device. If the retrofitting set for the heatable printing bed and the metal housing is installed, the RF500 Maker construction kit is identically equipped as the RF500 finished unit. The voltage supply takes place after installation of the heating mat using the external mains unit enclosed in the set only.
Z-expansion (Item no. 1541307): • 4 x aluminium profile 676 mm • 2 x aluminium profile 600 mm • 1 x aluminium profile 137 mm • 2 x guide rail with guide carriage 640 mm • 1 x spindle 571 mm • 6 x cylinder-head screw M5x20 • 10 x cylinder-head screw M3x8 • 10 x slot nut M3 • 1 x line for Z-motor approx. 1020 mm • Operating instructions (as a digital download) Metal housing (Item no.
5. Safety information Read the operating instructions attentively and particularly observe the safety notes. If the safety notes and the information in these operating instructions regarding proper handling are not observed, we assume no liability for any resulting injury/ property damage. In such cases, the warranty/guarantee will also lapse.
c) Set-up, site of operation • Set up the 3D printer only on a stable, horizontal, sufficiently sized surface. • Choose the site of operation so that children cannot reach the product. • When setting up the 3D printer, observe that the mains plug of the mains unit must be easy to reach so that the device can be disconnected from the mains voltage quickly and easily in case of malfunction.
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b) Z-expansion 1 2 3 (1) Longer spindle (571 mm) (2) 2 x aluminium profile 600 mm with 2 x guide rail with guide carriage 640 mm (3) 4 x aluminium profile 676 mm Not illustrate: 1 x aluminium profile 137 mm 9
7. General notes and information for assembly a) General information Take enough time for the assembly. Hurrying often leads to mistakes that may damage components or ruin the time benefit by elaborate rework. The workplace should be sufficiently large and clean so that the different components and assemblies can be put down and installed easily. Always observe the images during assembly. Here, the assembly locations and correct alignment of the components are shown.
c) Use of the slot nuts Push the slot nut into the aluminium profile slot turned by 90° longi- Push, e.g., a small hexagon socket wrench or a similar tool carefully tudinally. into the slot nut's thread. Turn the slot nut up until it "latches" and is held cleanly in the guide. Alternatively, and while the slot of the aluminium profile is still accesNow you can move it back and forth as desired.
8. Assembly of retrofitting kit for heatable printing bed This chapter ("8. Assembly of retrofitting kit for heatable printing bed") applies to the available set as well as to the individual parts (aluminium die-cast plate, heating mat and mains unit). This chapter will also support you in replacing one of these components, e.g. in case of a defect. Before you start, move the printing table roughly to the centre of the printer. Then pull the mains plug from the printer mains unit from the mains socket.
b) Preparation of the new printing plate Gluing together the printing plate 1 x aluminium die-cast plate 1 x heater (self-adhesive) Clear the bottom of the aluminium die-cast plate of dust and grease with a rag and solvent. Remove the protective film from the adhesive side of the heating and First check alignment of the heating by putting it on the bottom of the glue it to the new printing plate without any folds and blisters. aluminium die-cast plate.
c) Assembly of the new printing plate 1 x aluminium die-cast plate with glued-on heating 4 x pressure spring for printing table (length 24 mm) 4 x spacer 7 mm (diameter inside 4.2 mm) 4 x knurled nut, black (plastic) Place a pressure spring on each screw of the printing plate and guide them through the bores in the undertable. Push the plate from above, push one spacer each onto the respective The sequence is as follows: screw from below and secure them with a knurled nut.
d) Connection of the electrical lines Place the cables of the heating mat to the main PCB as illustrated. Connect the two open lines of the heating to connection "D8" of the The cable must be placed behind the left guide rail when viewed from main PCB. The polarity is irrelevant for this. Connect the plug for the temperature sensor to connection "T1". The the front. Thread it through the intended opening in the main PCB. polarity does not matter for this either.
e) Conversion of the mains unit Take the original mains unit and remove the green connection plug. 1 x mains unit new from the set The mains unit and the two wire jumpers are no longer needed. 1 x connection plug from the main PCB (green) The white lines of the mains unit are plus, the black ones are minus. Now connect the white double line of the mains unit to the left terminal of the plug. The 2nd terminal from the left holds the black double line of the mains unit.
f) Important additional information If you will install the metal housing now, perform the following important items only after installing the housing. • Install the firmware that supports the heating plate as well. On this, observe chapter "8. Installation of the software and firmware" in the main instructions. At this occasion, also check if a new firmware version of the firmware may be available. Then install the new version right away.
9. Assembly of LED light strips The LED strip is connected to the main PCB. Once the mains unit supplies the main PCB with power, the LED strip will light up as well. Before you start, move the printing table all the way down. Then pull the mains plug from the printer mains unit from the mains socket. Also disconnect the green plug of the mains unit from the main PCB. 1 x LED light strip (pre-sized) There are two different options for attaching the converter PCB of the LED strip to the printer.
Open the table tie with which the display cable is attached to the front Glue the LED light strip to the front aluminium profile. Do not glue the aluminium profile. strip directly onto the groove, but onto the area behind. You may also have to shift the adhesive base a little to the right (from Degrease the adhesive area first! the rear view). This depends on whether the LED strip completely fits the profile and whether its cable can still be attached to the adhesive base.
Open the 3 cable ties with which the two display cables are attached. If you have chosen the 2nd method (top and right figures), attach the LED strip cable and the other cables with new cable ties. When using the 1st method, attach the converter PCB in the area of the arrow from above. Tighten the cable ties only after connecting the LED strip! Connect the plug of the LED strip to both pins below the X-motor driver.
10. Assembly of Z-expansion If you have already installed the metal housing at your RF500 Maker-construction kit (see the next chapter) or if you have purchased the finished unit, remove the metal housing before installing the Z-expansion. Tighten all M5 cylinder-head screws to a torque of 3 Nm. Tighten the M3 cylinder-head screws of the guide rails to a torque of 1.7 Nm.
Removing the Y-motor Carefully pull off the cable from the motor. Remove all cable ties with which the Y-motor cable and the cable for Loosen the two M5 cylinder-head screws, carefully disconnect the X are attached to the upper aluminium profile. motor from the short belt and put it aside. Remove all adhesive bases here as well. Remove the two slot nuts from the aluminium profile. Removing the cable from the Z-motor Disconnect the cable from the Z-motor.
Disassembly of the infeed unit Release the cable tie. Push the red unlatching ring of the quick-closure and pull out the filament tube. Carefully pull the cable from the infeed motor. Release the two M5 cylinder-head screws and remove the infeed unit. Remove the adhesive base and the two slot nuts from the aluminium profile. Disassembly of the spindle Remove the two cylinder-head screws that the nut attaches to the First lift the table and then pull the spindle from the coupling without table.
Put the table down carefully on the coupling. Turn the nut off of the spindle. Disassembly of the table and the guide rails Remove all 8 M3 cylinder-head screws that attach the table to the Remove the two M3 cylinder-head screws each with which the guide guide carriages. Always remove a left and a right one alternatingly. rails are attached in the aluminium profiles. Take out the table and put it aside. Take out the two guide rails. They are no longer needed.
Remove all 4 slot nuts in which the guide rails were attached. Removing the end caps Finally, remove the 4 end caps that are plugged to all 4 vertical alu- The printer is now ready for installation of the Z-expansion. minium profiles. It will be easiest to lever them out carefully with a flat-head screwdriver or similar.
b) Preparation of the Z-expansion Assembly of the spindle 1 x spindle 571 mm 1 x flange nut Turn the nut onto the new spindle, best from below (side without thread). The nut must be aligned as illustrated.
Insert 7 slot nuts each into the two long aluminium profiles. Attach both guide with 7 M3 cylinder-head screws each to the previAlign them with the guide rails. They must protrude precisely the ously inserted slot nuts. same at the top and bottom. Tighten the upper and lower screw slightly each so that the guide rail Divide the 7 slot nuts evenly across the length. cannot slip anymore. Only tighten the other screws slightly. Remove the 4 green circlips only after installation in the printer.
c) Assembly of the Z-expansion Identification and explanation of the new horizontal aluminium profiles 2 x aluminium profile 676 mm with 4 bores Find the differences of the 4 long aluminium profiles below (from top 2 x aluminium profile 676 mm with 4 bores and 1 cutout for ball bearing down and from the front view of the printer). The milled sides of the respective bore always must point to the outside. The screw is always pushed in from this side as well.
Assembly of the front aluminium profiles Place the prepared printer on its back and support it from below to Remove the foot from the disassembled aluminium profile and put it prevent damage to the main PCB. aside. Position the printer so that the front left aluminium profile is acces- The short aluminium profile is no longer needed. sible. Release and remove the 4 M5 cylinder-head screws that attach the profile. Remove das aluminium profile from the printer.
Position the printer so that the front right aluminium profile is acces- Remove the foot from the disassembled aluminium profile and put it sible. aside. Release and remove the 4 M5 cylinder-head screws that attach the The short vertical aluminium profile is no longer needed. profile. Take the lower transverse profile from the printer and put it aside. Remove das vertical aluminium profile from the printer.
Assembly of the rear aluminium profiles Put the printer on the front and support the 4 M5 cylinder-head screws of the display holder with one of the short aluminium profiles previously removed. Otherwise, the operating head may be damaged. Position the printer so that the rear left aluminium profile is accessible. Relieve the two Y-belts by opening the two screws of the belt tensioners. Release and remove the 4 M5 cylinder-head screws that attach the profile.
Position the printer so that the rear right aluminium profile is accessible. Release and remove the 4 M5 cylinder-head screws that attach the profile. Take the aluminium profile attached across from the filament holder and put it aside. Put the other profile, where the Z-motor is attached, aside as well. Remove das vertical aluminium profile from the printer. Remove the foot from the disassembled aluminium profile and put it aside.
Assembly of the guide rail holder 1 x guide rail-holder incl. guide rails and cart 4 x cylinder-head screw M5x20 Insert the guide rail holder into the printer as illustrated. The small transverse profile must be at the top and point towards the upper rear transverse profile. The plastic insert must be inserted into the small Remove the green circlip at the small transverse profile at the upper transverse profile from above. guide rail (referring to the figure).
Assembly of the undertable and the long spindle 1 x spindle 571 mm with pulled-on flange nut 1 x undertable 8 x cylinder-head screw M3x12 black Loosely attach the undertable to the two guide carriages on either side with 4 M3 cylinder-head screws. Alternatingly screw one screw into the left table tappet and one into the right one. Do this additionally crosswise for every table tappet. When you have attached all screws loosely, tighten them in the order in which you have screwed them in.
Alignment of the guide rails Put the printer on its back. Use a support to prevent damage to the Move the undertable all the way down. PCB. Then tighten the bottom-most screw of the 1st guide rail. Secure the Y-carriage e.g. with a screw (simple push it into a hole of Move the undertable up and down manually several times again. the guide rail and put down the Y-carriage on it). Release the 4 M5 cylinder-head screws that attach the rear vertical aluminium profiles to the rear transverse profiles.
Installation of the deflection shaft Put the printer back on its feet. Remove the two upper M5 cylinder-head screws from the left, vertical aluminium profile from the rear view. Loosen the lower, lateral screw a little. It only needs to be loose. Fold the vertical aluminium profile slightly to the left. Take the deflection shaft and push it into the right ball bearing. Wipe both belts over the deflection shaft. Do not forget the washer on the right (rear view) and the spacer on the left.
Attachment of the table to the flange nut Push the undertable upwards manually and turn the flange nut up Attach the flange nut with the two cylinder-head screws M4x16 mm until you can turn in the screws from below. at the undertable. Put the undertable down on the flange nut and align it. The flat side Tighten the screws. must point backwards. Relief of the printer Before attaching the remaining components to the printer again, relieve it completely first.
d) Attachment of the remaining components Assembly of the Y-motor Insert the two slot nuts for the Y-motor holder into the rear left vertical Attach the short belt into the double knurl. aluminium profile. Then attach the knurl of the motor into the belt as well. Attach the moAlign the slot nuts with the motor holder. tor holder to the slot nuts with the 2 M5-cylinder-head screws. Tension the belt and align the holder straight. Then tighten the screws.
Connection of the Z-motor Connect the new, longer cable for the Z-motor from the inside at the Thread the cable from the inside through the cable feedthrough above Z-motor. Attach the cable as shown in the figure with an adhesive the main PCB and connect it to the connection for the Z-motor. base and cable tie. Ensure correct polarity! The brown pin of the cable must be on top. Observe the terminal plan at the end of this chapter for this.
Assembly of the infeed unit First insert the 2 slot nuts into the vertical aluminium profile (rear left Attach the infeed unit to the slot nuts loosely with the two M5 cylinderfrom the front view). head screws. Align the slot nuts with the infeed unit holder. Push the filament tube back into the quick closure and align the infeed unit in height. Tighten the two attachment screws of the infeed unit.
Assembly of the printing plate The following description refers to the printing plate with heating mat. If you only use the regular printing plate, the assembly itself is identical. The connection of the heating mat can be ignored in this case, however. 1 x aluminium die-cast plate with glued-on heating (long cable) 4 x pressure spring for printing table (length 24 mm) 4 x spacer 7 mm (diameter inside 4.
Connection of the heated printing plate Place the cables of the heating mat to the main PCB as illustrated. The cable must be placed in front of the left guide rail when viewed from the front. Thread it through the intended opening in the main PCB. Connect the two open lines of the heating to connection "D8" of the main PCB. The polarity is irrelevant for this. Connect the plug for the temperature sensor to connection "T1". The polarity does not matter for this either.
Attachment of the lines Attach three adhesive bases as shown in the figure. Attach only the Attack all lines cleanly with cable ties to the main PCB. lines for the Z-motor to the two lower ones. Also attach the line for the Z-motor and for the heating mat to the upper base with a cable tie. Last, plug the 4 end caps back onto the 4 vertical aluminium profiles.
11. Assembly of the metal housing Before you install the metal housing on your RF500 Maker construction kit, install the retrofitting set for the heated printing bed, if present. Tighten all M5 cylinder-head screws to a torque of 3 Nm. a) Preparation of the printer Newly place the connection line for the Z-motor First, the connection line for the Z-motor is newly installed. 44 Remove all cable ties and adhesive bases (incl. the adhesive residues), of the Z-line to the PCB holder.
Remove all cable ties at the PCB holder that attach the cable to the extruder. Remove all cable ties except for the last one that attach the Z-motor line. Also remove the cable tie and adhesive base (incl. glue residue) that attach the extruder cable on the side. Route the line for the Z-motor through the feedthrough at the PCB holder on top and place the cable roughly in parallel to the cable of the heating plate; route it past the guide rail at the back.
Removing the PCB holder Carefully pull the plugged-on additional PCB from the main PCB and Remove both M5 cylinder-head screws of the PCB holder and take it off. fold it up carefully over the deflection shaft. Fasten the plug-on PCB by pushing the X-guide rail towards the PCB Leave the two slot nuts in place. You will need them later. holder. Unscrew the main PCB Carefully remove the 3 plastic screws that attach the main PCB to the PCB holder. The PCB holder is no longer needed now.
Removing the filament holder Remove the filament holder by turning out the M5 cylinder-head Put the filament holder aside. You will only need it again in the end. screw on the inside.
b) Assembly of the housing parts Before you install the metal housing to your RF500 Maker construction kit, the printer should be aligned straight and without any tensions. All screws in the aluminium profiles should also be tightened well. Once the housing is installed, you will be unable to reach the screws anymore. Attach the main PCB to the rear panel 1 x main PCB 3 x spacer 2 mm (diameter inside 3 mm) 3 x spacer 8 mm (diameter inside 3 mm) 1 x rear panel 3 x hexagon screw M2.5x16 (plastic) 3 x nut M2.
Hold the rear panel against the printer and align all slot nuts precisely with the bores in the rear panel. Attach the rear panel to the slot nuts placed before loosely with the 10 M5 cylinder-head screws. Align the rear panel with the outer edges of the aluminium profiles. Tighten the cylinder-head screws. Attaching the main PCB Attaching the lines for the Z-motor and the heating plate Fold down the additional PCB again and plug it onto the main PCB.
Assembly of the left side panel to the printer 8 x cylinder-head screw M5x8 black 8 x slot nut M5 1 x side panel left Hold the side panel against the printer and align all slot nuts precisely with the bores in the side panel. Attach the side panel to the slot nuts placed before loosely with the 8 M5 cylinder-head screws. Align the side panel with the outer edges of the aluminium profiles. Tighten the cylinder-head screws.
Attaching the lines for the Z-motor and heating plate Attaching the filament holder Attach the lines for the extruder to the rear panel or the left side panel Push the filament holder through the left side part into the intended with adhesive bases and cable ties (see arrows in the figure). opening and attach it with the M5-cylinder-head screw again.
Assembly of the right side panel to the printer 8 x cylinder-head screw M5x8 black 8 x slot nut M5 1 x side panel right Hold the side panel against the printer and align all slot nuts precisely with the bores in the side panel. Attach the side panel to the slot nuts placed before loosely with the 8 M5 cylinder-head screws. Align the side panel with the outer edges of the aluminium profiles. Tighten the cylinder-head screws.
Assembly of the front panel to the printer 5 x cylinder-head screw M5x8 black 5 x slot nut M5 1 x front panel Push the 5 slot nuts, as shown in the figure, into the grooves of the aluminium profile. Generally align all 5 slot nuts. The threads should be aligned as illustrated. Hold the front panel against the printer and align all slot nuts precisely with the bores in the front panel. Attach the front panel to the slot nuts placed before loosely with the 5 M5 cylinder-head screws.
Assembly of the bottom panel to the printer 7 x cylinder-head screw M5x8 black 7 x slot nut M5 1 x front panel Put the printer on its front. Screw out two of the four feet. Push the 7 slot nuts, as shown in the figure, into the grooves of the aluminium profile. Generally align all 7 slot nuts. The threads should be aligned as illustrated. Hold the bottom panel against the printer and align all slot nuts pre- Now screw on the two feet you previously removed again.
12. Assembly and mounting of the acrylic housing The acrylic housing adds a dome and a door to the metal housing (see previous chapter). Therefore, the metal housing must be assembled to complete the housing. The housing is completely transparent. Upon delivery, all parts have a protective film attached to both sides. In order to be able to include better photographs in the instructions, this protective film has been removed on one side only.
Explanations for assembly During the assembly, always insert all screw Then put both pieces together. Finally, screw all M3 cylinder head screws The noses of one part must be inserted into through the boreholes of the respective senuts into the slits of the cut-outs. cond part into the nuts inserted previously. The even surface of the screw nut must al- the corresponding cut-out of the other part. ways be inside the cut-out and the tip of the nut must always point outwards.
1x rear plate A3 with the 1. mounted side plate A4 (not in the picture) 1x side plate A4 2x cylinder head screws M3x12 2x screw nuts M3 Please note! The screws and nuts are depicted slightly bigger. 1x rear plate A3 with both side plates attached A4 (not shown in the picture) 1x top plate A2 5x cylinder head screws M3x12 5x screw nuts M3 Please note! The screws and nuts are depicted slightly bigger. Insert the two screw nuts into the slits inside the cut-outs.
Insert two screw nuts into each of the remaining, sloped front side of the two side plates. Remove the protective film on both sides in the respective areas. Fasten the front plate with 4 M3 cylinder head screws as shown in the pictures. Please note! The screws and nuts are depicted slightly The front plate must be aligned in such a way that the cut-out for the bigger. display is on the left (in front view).
b) Assembly of the door Attaching the hinges 1x door 2x hinges 4x cylinder head screws M3x12 4x screw nuts M3 Remove the protective film around the 4 boreholes for the hinges. Screw them tight to the outside of the door using the M3 cylinder head screws and nuts. You can recognise the outside by the magnet. It is inserted into the door from the outside, i.e. the side where you can touch the magnet directly is on the outside.
c) Mounting of the door Attaching the magnet holder 1x magnet holder 1x cylinder head screw M5x16 1x screw nut M5 Attach the magnet holder to the front side of your printer using the M5 cylinder head screws as shown in the picture. In doing so, align the holder straight. Furthermore, the magnet must point towards the inside of the printer.
d) Mounting of the dome Mounting the holding blocks 2x holding blocks 2x cylinder head screws M3x25 2x slot nuts M3 Insert one slot nut into each of the upper aluminium profiles. The slot nuts must be at a distance of only a few millimetres from the front. Insert one of the cylinder head screws through each holding block and tighten it in one of the two slot nuts inserted previously.
13. Disposal Electronic devices are recyclable and should not be disposed of in household waste! Dispose of the product according to the relevant statutory regulations at the end of its service life. 14. Technical data a) Aluminium die-cast plate Material Dimensions (W x H x D) Weight Aluminium die-cast, sand-blasted 290 x 155 x 6 mm 715 g b) Heating mat Operating voltage 12 V/DC Power input max. 16 A Max. power intake 120 W Temperature max.
f) Metal housing Printer dimensions (W x D x H) approx. 500 x 400 x 450 mm (incl. filament tube) approx. 500 x 400 x 650 mm Dimensions of the individual housing parts (W x H) Front panel 399 x 356 mm Bottom plate 398 x 355 mm Rear panel 399 x 356 mm Side panel left 325 x 356 mm Side panel right 325 x 356 mm Thickness of the housing parts 2.5 mm g) Acrylic housing Printer dimensions (W x D x H) Dimensions of the individual housing parts (W x H) Thickness of the housing parts approx.
This publication was published by Conrad Electronic SE, Klaus-Conrad-Str. 1, D-92240 Hirschau (www.conrad.com). All rights including translations reserved. Reproductions of any kind, e.g. photocopy, micro filming or recording in electronic data processing systems require the written approval of the publisher. No part of this publication may be reproduced. This publication corresponds to the technical state of the art at the time of print. Copyright 2018 by Conrad Electronic SE.
