Kuhling&Kuhling RepRap Industrial User manual

Operating manual
If your RepRap Industrial 3D printer is of hardware revision 1.0.0 and has not been updated, you are
probably still running RepRapOnRails version 1.0.5.
Clicking here will redirect you to the respective manual.
The high-resolution 10“-TFT touchscreen mounted at the front panel enables direct operation of the
RepRap Industrial.
This manual describes the initial commissioning of the 3D printer after installation, the operation via
the RepRapOnRails operating software and the all manual operating tasks that must be performed
during normal day-today use.
RepRapOnRails Software version lists
v1.1.0 (current)
v1.0.5 (05/2013 - 02/2015)
Operation
With the release of RepRapOnRails version
v1.1.0, all basic functions are now represented
on the start-up Print screen.
The newly designed Configuration menu
enables the operator to preselect temperature
The newly ordered operating menus of
RepRapOnRails v1.1.0.

profiles for the extruders and the print bed and
build chamber more directly which simplifies
preheating and priming according to current
needs.
Setup offers the operating wizards for guided
day-to-day functions.
More advanced features like program-
independent operation of the axes have been
moved to the Expert control screen which now
also provides direct setting of the extruder
temperatures and test extrusion.
The Log menu provides the history of machine
code input and output as well as the keyboard
for direct input of operating instructions.
The following paragraphs provide detailed
information of the software's operating screens
and explain the specific functions.
Additional information for the preparation of
print jobs can be found in Tips and tricks and the
manual of the slicing software.
Starting the 3D printer
There are two possible states from which to start the 3D printer: “switched off” and in “standby”.
Either way starting the 3D printer is a one-button-only procedure. After the boot sequence the
operating screen starts with the Print screen in IDLE mode.
Switching on
If the 3D printer is switched off via the main
switch at the rear cover (position <0>) toggle
the switch to <I> (ON).
The 3D printer will boot automatically.
It may take a few minutes until the touchscreen
has fully loaded the operating screen - wait
patiently without interfering.
The first screen will be the Print screen with the
(empty) print-job queue and the top-left status
message displaying Idle.
Waking from standby
If the 3D printer has only been shut down via the
touchscreen and set into standby mode (see

section Print screen), press the wake button at
the front cover. The light ring of the button lights
up and the 3D printer boots automatically.
Waking the 3D printer from standby.
[Print] screen
After starting the 3D printer the Print screen will
appear as the start-up screen. Here you activate
the 3D printer and start the print jobs previously
uploaded to the queue via the web interface.
No. Description Content/Function
1 Status message
Idle: apparatus is
waiting for next user
input
Printing: apparatus is
busy printing
2 Menu selection
Select the operating
menu and mode:
Print represents the
main production mode
Configuration allows
choosing material
based temperature
profiles for each
extruder and
bed/chamber
Setup provides
wizards for different
preset operating
procedures
Expert Control
provides access to
motors and direct
temperature control
Log represents the
communication
history of
microcontroller,
BeagleBone Black,
and touchscreen
Print screen (descriptions may apply to other
screens as well if not explicitly given there)

No. Description Content/Function
3 Queue
List of uploaded print
jobs sorted by
time/date (oldest
first); estimated time
required for printing
the respective job.
4Temperature/profile
overview
Displays current and
set temperature of
each extruder, print
bed and build
chamber as well as
the selected material
profiles (see
Configuration).
Temperatures colored
red are set and
currently being
actuated.
5[Emergency STOP]
button
see also
→ Emergency stop
→ Safety information
in the Manual
6 [Shut-down] button Tap to shut down the
3D printer properly.
7[Build Chamber
ON/OFF] button
Tap to
activate/deactivate
drives and heaters
after start-up.
8
[Preheat
Chamber/Bed
ON/OFF] button
Tap to
activate/deactivate
preheating of the
build chamber/print
bed according to the
settings made under
Configuration.
9 [delete] button
Tap to delete the
respective print job
from the queue.
10 [print] button Tap to start the
respective print job.
11 Browse buttons
Use [Previous], [Next]
and [page number] to
browse the print job
list.
Starting print jobs
Tap the [print] button next to a print job in the
queue to start the print job. You will be asked to
confirm that all preparations for the print job
have been performed. Tap [OK, Start Print] to
definitely begin printing or [Cancel] to return to

the queue.
No. Description Content/Function
1 Checklist
Please make sure that all
displayed requirements
have been met before
proceeding.
2[OK, Start
Print] button
If all preparations have
been made, tap to proceed.
3[Cancel]
button
Tap to abort if any
requirements has not been
met.
“Ready to print?” query
After confirmation the RepRap Industrial starts
processing the print job and the status message
changes to Printing. All other menus are
deactivated during a print. The print job name,
the current progress, and the estimated
remaining time are displayed and the [Abort
Print] button is active.
No. Description Content/Function
4 Print job name
The name of the slicing
file uploaded to the
queue.
5 Countdown
Displays the estimated
remaining time
(calculated from the G-
code).
6 Progress bar Indicates the progress of
the print job graphically.
7[Pause/Resume
Print] button
Allows interrupting a
print job for interference
and subsequent
resumption.
8[Abort Print]
button Tap to abort a print job.
Print status screen (top half only).
Pause function
The pause function was built in for the case that
a print job needs to be interrupted and later
resumed for other reasons than “out-of-filament”
(see below).
After tapping the [Pause Print] button, the
printer keeps printing until the cache is empty.
This may take a few minutes, according to the
complexity of the current g-code. Afterwards,
the print bed is lowered into its home position,
the extruders are turned off and the print head
moves to the maintenance position.
Interrupting the print with the pause function.

Now you have access to the Expert Controls and
some of the Setup functions to adjust whatever
might be necessary.
To continue printing tap [Resume Print]
(replaced [Pause Print]). Print bed and extruder
head move to their last position and after re-
heating the extruders the print seamlessly
continues.
Continuing the print after pause.
Finishing a print job
There are two ways to finish a print job:
automatic finish after completion or abortion by
the operator.
After regularly completing a print job all axes are
moved to their home position and the extruder
heating resistors are switched off.
If you need to abort a print job because the
outcome does not meet expectations for
example or mechanical problems appear during
the print, tap the [Abort Print] button. The
system will then print the last G-code
information from cash and move the print table
and the extruder head to their home positions
afterwards.
Either way, the 3D printer returns to idle mode
and displays a status message and a request
how you wish to continue. Simply tap the
respective button on the screen to proceed.
After standstill of all drives you can remove the
print bed and take off the model.
No. Description Content/Function
9[Keep in
Queue] Returns to the Print menu.
10 [Print Again] Immediately restarts the
current print job.
11 [Delete
Printjob]
Deletes the finished print
job from the queue
without confirmation and
returns to the Print menu.
Print job finished.
Switching off the 3D printer
NOTICE
Switch off the 3D printer via the power button without turning it into standby may cause damage of
the heating elements and neighboring components due to residual heat.

The cool-down performed during shut-down ensures that the fans are only switched off after the
heating elements could shed all residual heat.
For switching the RepRap Industrial into standby
tap the shut-down button. The system will then
perform the cool-down sequence for safety
reasons before deactivating the preheating and
the build chamber.
The 3D Printer is in standby mode when:
the screen turns black,
the illuminated ring of the wake button
dims,
the build chamber lighting switches off.
To wake the machine from standby see Starting
the 3D printer.
Always use this button for regular shutdown.
For completely shutting down the 3D printer,
perform the procedure described above and set
the main switch at the rear cover to <0> (OFF)
afterwards. The 3D printer is now powered off
and the green status indicators of the limit
switches darken.
To reactivate the 3D printer see Starting the 3D
printer.
INFO
For day-to-day use, the power
supply should stay connected to
mains power (main switch in
position <I> (ON).
Emergency stop
NOTICE
The emergency stop function does not provide a cool down sequence. Do not use the emergency
stop button to abort current print jobs, as this may lead to damage of the 3D printer due to
uncontrolled heat accumulation. Do not use the main switch as an emergency stop button. You risk
loosing or corrupting data.
When the emergency stop is triggered:
The microcontroller board is reset, all
movement of the axes stops, lights,
heaters and fans are turned off. The status
indicator displays Emergency Stop! .
After a few seconds the microcontroller
returns to Idle state.
Status display after triggering the emergency
stop. The 3D printer returns to IDLE state after a
short time. The emergency stop is written into
the log-file.

The 3D printer now is in a safe state for troubleshooting.
For repairing any defects of the electronic equipment or major mechanical damages shut down
the 3D printer completely:
Open the Print screen.
Shut down the 3D printer by tapping the [Shutdown] button and switching off the main switch
(<0> position) after the shutdown procedure has been finished.
NOTICE
Before restarting or reactivating the 3D printer:
Make sure that the axes are in no collision position.
Make sure that the reason for the emergency stop has been detected and fixed, before
resuming production.
After troubleshooting or if the reason for the emergency stop was minor and you want to continue
production:
Remove the print bed from the build chamber and replace or clean it before further use.
Restart the 3D printer (if necessary).
Open the Print screen.
Switch on the build chamber. The 3D printer will run the homing routine.
You can now resume normal operation.
[Configuration] screen
The Configuration menu is a new feature that
enables you to preselect material-specific
temperature profiles for each extruder and, in
combination, the print bed/build chamber. The
latter was developed to make preheating and
leveling more precise with regard to different
material settings. The according profiles can be
set up at the web interface setup menu.
No. Description Content/Function
1Left extruder
profile selection
The currently selected
profile is displayed.
Tap [Select] to open the
list of available filament
profiles or [Clear] to delete
the active profile.
2Right extruder
profile selection
GUI Configuration screen with temperature
profile selection.

No. Description Content/Function
3Bed/chamber
profile selection
The currently selected
profile is displayed.
Tap [Select] to open the
list of available filament
profiles or [Clear] to delete
the active profile.
After selection of a profile,
deactivate the preheating
function in the Print menu
(touch button no. 8) and
activate it by tapping the
button again to apply the
settings.
After opening the list, tap [Set] to choose a
profile for the selected component. The profile is
set and the screen returns to the prior menu.
To activate the selected profile open the Print
screen and first deactivate, then re-activate the
chamber/bed preheating.
The list of filament temperature profiles of the
configuration menu. More profiles can be added
via the web-interface.
The selected profiles are displayed in the footer
of every screen in the order Current and Target
(= set) temperature. While aiming for a target
temperature, both values are highlighted red.
When displayed gray, the temperature value is
either not set or currently not triggered.
The selected profiles are displayed in the footer
of the GUI on every screen.
INFO
Observe that the temperature
shown in the footer is measured at
the hot end heater and may be 5 -
10 °C lower at the nozzle tip.
See section Extrusion temperature
in the knowledgebase for
information on finding the suitable
extrusion temperature.
When no filament profile is
activated for an extruder, the
default temperature is 180 °C.

Creating profiles via the web interface
During a print job all necessary temperature data are provided by the respective G-code. For priming
the extruders outside a print job the temperature setting required for extruding a material is provided
by the Filament profiles.
Similarly, precise print bed leveling needs defined bed and chamber temperatures according to the
printed material before a G-code is executed. These settings are provided by the Chamber/Bed
Preheating Profiles.
To create a filament profile open the web
interface of your 3D printer, choose the Setup
menu and:
Select Filament Profiles and click [Add1.
Profile] to set material properties.
Enter the material Name in the1.
according input field.
Enter the Extrusion Temperature2.
in °C in the according input field.
Click [Add] or press <Enter> to save the2.
settings. The new filament profile is added
to the list, newest at the bottom.
To change the settings click [edit] and
enter the new properties.
To delete a profile click [remove] and
confirm the safety query.
Filament profile setup via the web interface.
To create a preheating profile open the web
interface of your 3D printer, choose the Setup
menu and:
Select Chamber/Bed Preheating Profiles1.
and click [Add Profile] to set material
properties.
Enter the profile Name in the1.
according input field.
Enter the required Chamber2.
Temperature in °C in the according
input field.
Enter the necessary Bed3.
Temperature in °C in the according
input field.
Click [Add] or press <Enter> to save the2.
settings. The new preheating profile is
added to the list, newest at the bottom.
Preheating profile setup via the web interface.

To change the settings click [edit] and
enter the new properties.
To delete a profile click [remove] and
confirm the safety query.
[Setup] screen
The Setup menu displays walkthrough instructions (wizards) for different operations needed during
daily operation, initial commissioning, servicing and troubleshooting. If you choose one of the wizards,
a step-by-step guide will provide all necessary information for completing the respective task.
This screen also provides system information and the web address needed to connect to the 3D
printer via the network.
Wizard selection on the setup screen. Beginning with ReRapOnRails v1.3.0, the nozzle change wizard
has been replaced by the backlash calibration wizard.

No. Description Content/Function
1
Wizards for daily
operation
Different wizards for
different tasks;
needed to keep your
3D printer up and
running.
Print Bed Leveling
Ensures that print bed and nozzle tip are evenly distanced at
every point of the surface.
→ tips
Unload Filament
False removal of filament from the supply system can damage
the limit switch in the feed unit. Follow the given instructions
when filament must be removed.
→ additional information
Load Filament
False insertion of filament can damage the 3D printer or lead to
coiling of the filament and thereby ruining the print. Follow the
given instructions when filament must be refilled or changed.
→ additional information
Prime Extruders
After changing/refilling filament or subsequent to nozzle change
the extruders must be primed to remove enclosed air from the
nozzle tip.
→ additional information
2
Calibration wizards
These wizards are
needed during
commissioning, during
change of material
and other more rarely
tasks.
Nozzle Change
obsolete since v1.3.0 To change the nozzle tips (e.g. for printing
with another bore diameter for higher troughput) follow the
given instructions. Make sure not do damage the extruder nozzle
barrel.
Calibrate Extrusion
When printing material with other properties than before, it
might be necessary to adjust the throughflow of the nozzle. To
find the correct Extrusion multiplier to be entered in the
Filament settings of Slic3r, run this wizard. Also regard the
description given in the respective initial commissioning section.
Calibrate Extruder Offset
This function is needed for dual extruder prints. To teach the
offset distance between the nozzle tips in X- and Y-direction, run
this wizard.
Calibrate Backlash
new in v1.3.0 This function replaces the backlash calibration
procedure described in the Service Guide.

No. Description Content/Function
3 Web Interface URL Needed to connect to your RepRap Industrial via the network
→ additional information
4 Version numbers
The valid version numbers of your RepRap Industrial's hardware, the installed
RepRapOnRails software and the microcontroller firmware for your
information. Please provide these numbers for identification in case of service
requests.
Changing the filament
When the filament limit switch at the filament supply registers the end of the filament strand on the
spool, the 3D printer stops automatically and signals lack of material at the touchscreen.
If you want to remove the filament for other reasons (e.g. to use a differently colored material), the
following description applies also.
Required tools
diagonal cutters
Refilling
If you want to continue printing with the same type of plastic, the change of the filament spool is
quite easy. You have to manually remove remaining filament from the supply hose, change and, if
need be, adjust the spool carriers and insert the new strand.
Go to the Setup menu and start the [Unload Filament] wizard and follow the on-screen1.
instructions.
Then open Setup menu again, and follow the [Load Filament] wizard.2.

Material change
If you want to continue printing with another
type of plastic (e.g. PETG instead of ABS), the
change of the filament spool becomes a little bit
more complex since you have to change the
extruder nozzle barrel also.
INFO
Using the same extruder nozzle
barrel for materials with different
properties may lead to clogging of
the nozzle tip due to coking or
sooting.
Kühling&Kühling recommend either
thorough cleaning of the extruder
nozzle barrel with a suitable solvent
and pipe cleaners or using a single
barrel for every type of material.
Unload the current filament as described1.
in Refilling.
Subsequent to unloading you have to2.
change the extruder nozzle barrel as
described in the Service guide.
Afterwards, install (and adjust) the new3.
filament spool, run the [Load Filament]
wizard and the [Priming] wizard.
INFO
Make sure to choose the
appropriate filament profile from
the material database. If you have
not installed the adequate profile
yet, do so by following the
instructions given below.
Adjusting the spool carriers
Required tools
Allen wrench #2.5
Procedure
If you want to use a different filament spool
diameter (less or more material), you have to
adjust the spool carrier position.
INFO
With an appropriate Allen key you
can carry out the following steps
without removing the filament
spool.
Use the Allen key to loosen the fixing

screws of the carrier.
Loosening the fixing screws of spool carriers.
Slide the carrier to or away from the
filament inlet to a position that leaves
approximately 1 cm between the spool's
outer rim and the limit switch. Make sure
that the filament enters the inlet at an
angle of 85-90°.
Refasten the fixing screws.
Admissible distance and inlet angle.
[Expert Control] screen
NOTICE
The Expert Control menu should be used by skilled operators only. It has been designed for test and
troubleshooting purposes. Persons unfamiliar with the 3D printer must not mess around with functions
provided here.
The positions of the extruder head and the print table are not compared during manual operation.
Incautious operation may lead to massive damage of the extruder head and the print bed.
Be careful not to crash the print table and the extruder head.
For maintenance and test reasons, after a crash
or to reduce lead times, e.g. if you still need to
work on a print file but want the 3D printer to be
ready for operation, manually moving the

motors or preheating the build chamber and the
print table may be necessary or advantageous.
No. Description Content/Function
1
Drive control -
negative
direction
Moves every axis
individually once for every
tap in negative direction,
according to the selected
step width.
2
[Printhead
Maintenance
Position]
Tap to move the extruder
head into a preset position
in the upper center of the
build chamber directly in
front of the doors where it is
easily accessible for
maintenance purposes.
3Homing
buttons
Tap to separately or
simultaneously move the
axes to their starting
positions.
4
Drive control -
positive
direction
Moves every axis
individually once for every
tap in positive direction,
according to the selected
step width.
5
Extruder
temperature
control
Enables directly setting the
temperature and extruding
filament for one extruder at
a time (see the chapter
"Extrusion temperature" in
the “Material” section of the
knowledgebase).
Expert Control screen
[Log] screen
All communication between touchscreen,
BeagleBone Black and microcontroller is stored
and displayed on the log screen. Print job
statuses are stored also.
Direct G-code programming can be effected via
the G-code input field.
No. Description Content/Function
1 History list
communication history
sorted top down by date
and time¹
SENT: BeagleBone Black to
microcontroller
RECV: microcontroller to
BeagleBone Black
2 Browse buttons
Use [Previous], [Next] and
[page number] to browse
the history.
The log screen provides additional information
about sent and received G-code commands and
the possibility of directly influencing the 3D
printer via G-code command input.

No. Description Content/Function
3G-code input
field
Enter G-code lines here and
[Send] them.
¹ The time is stated in universal time coordinated (UTC)
notation so do not wonder if does not match your local
time.
NOTICE
The G-code input field is an advanced feature and requires sound knowledge of G-code programming.
Inappropriate G-codeing may damage the 3D printer massively.
The web interface
The web interface provides the communication between your PC and the 3D Printer. Uploading print
job GCODES to the 3D Printer and creating temperature profiles are the main functions.
You can also check system's information and settings, install firmware updates and download the
LOG-file for troubleshooting purposes.
To open the web interface enter the web interface URL into the address line of your internet browser.
You can find the web interface URL on the Setup screen of the GUI.
Initial commissioning
Loading material1.
Spool adjustment
Printer preparation2.
Calibration3.
First print job4.
Setting up the slicing software
Model preparation
Model upload
Print
After the installation the RepRap Industrial is
ready for initial commissioning. The first few
steps will prepare your RepRap Industrial for its
day-to-day duty:
Make sure that no foreign objects are left
in the build chamber (transport locks, tools
or the like).
Close the build chamber.

Toggle the main switch to <I> (ON).
When the power supply is switched on the
3D printer will boot automatically. Please
wait patiently until the full operating
screen is loaded on the touchscreen at the
machine front. The screen displays the
Print screen and the top-left status
message reads Idle.
Loading material
First, material for the following print jobs must
be provided:
Tap [Load Filament] to start the wizard
that will guide you through the material
feed process. The print head will move to a
middle front position for convenient
handling.
Read and follow the wizard's on-screen
instructions step by step.
Load the left extruder with
Kühling&Kühling white ABS material
included in the delivery for the first print.
INFO
For installing other than the 750g
spools delivered, adjusting the
spool carriers may be necessary.
The filament and chamber/bed
profiles have been preset during
factory test and are ready for use.
For later changing the profiles refer
to Configuration.
At the end of the Load Filament wizard,
follow the suggestion to run the Prime
Extruders wizard by tapping the respective
button.
Choose the left extruder and check that
the filament profile Kühling&Kühling white
ABS is selected before continuing.
After finishing the wizard, repeat these
steps for loading the right extruder if
required.
Display of the selected filament profile after
extruder selection.
Preheating
After material has been loaded and the hot-ends
have been primed the next step is preheating
the build chamber and the print bed in order to
enable calibration at operating temperature:
Check if the footer reads Preheating for
ABS for the Bed/Chamber profile. The
footer is the same on every page of the
GUI.
Activate the build chamber by tapping
Display of the selected chamber/bed profile in
the footer.

[Build Chamber ON]. The LEDs light up,
the fans start running and all axes perform
a home-positioning routine.
Then start the heating by tapping [Preheat
Chamber/Bed ON]. The temperature
indicators in the footer now show both
current and target temperature.
Let the build chamber heat for
approximately 45 minutes until the
target temperature is reached.
Calibration
Leveling the print bed
When the target temperature is reached and stable level the print bed in the given order to ensure
that the hot-end nozzle tips have the same distance to the print bed at every point.
Tap [Setup] to change to the Setup screen.1.
Tap [Print Bed Leveling] to start the wizard that will guide you through the leveling process.2.
The wizard provides all necessary instructions on-screen. Read them thoroughly and follow3.
them step by step.
Determining the extrusion multiplier
This is the first print job you will execute
on your RepRap Industrial 3D printer.
All required files and settings are preinstalled on
the 3D printer and need no further interference
beside the instructions given in the following.
The “extrusion multiplier” allows for
compensation of varying filament properties,
first of all the cutting depths of the drive gear
into the filament but also deviations of the
diameter (also see Slic3r manual and Tips &
Tricks). The extrusion properties of any material,
although chemically exactly the same, may
differ from one filament spool to the other so
that it is impossible to determine the correct
extrusion multiplier prior to delivery. After
leveling the print bed, it is therefore mandatory
to calibrate the extrusion to adapt your printer
to the installed filament in order to ensure a
correct printing performance.
INFO
When printing ABS it may be
necessary to run the [Extrusion
calibration] wizard after changing
the filament spool without changing
the material itself.
It is necessary to find the correct
extrusion multiplier after changing
the material. The respective
procedure is described here.
To calibrate the extrusion: INFO

Choose the [Calibrate Extrusion] wizard
from the Setup screen at the touchscreen.
Select the respective extruder by tapping
[Left Extruder Calibration] or [Right
Extruder Calibration]. A preinstalled print
job will be loaded into the queue.
Change to the Print menu and select and
start the print job.
After the print job has been finished,
return to the [Extrusion Calibration]
wizard.
Enter the measured value via the touch
buttons.
The necessary extrusion multiplier is
calculated automatically. Record the value
for later use in the slicing software (see
slicing-the-3D-model).
Regard that the preinstalled
extrusion calibration print job is
solely for printing ABS with the
0.35mm nozzle tip on both hot
ends. Printing it with other materials
or nozzle tip diameters requires
altered settings as described in the
Tips & Tricks section of this manual.
The extrusion multiplier is calculated
automatically from the measurement and must
be saved in the filament profile of the slicing
software.
Creating your own first print job
You will find all necessary installation and setup
procedures required for the first print in the
following paragraphs. All software mentioned
additionally is available “Open Source”.
INFO
The manufacturer cannot be held
liable for any malfunction resulting
from use of other than the
recommended software.
Installation and setup of the slicing software
First you need to install a slicing software on
your computer to translate .stl-files (Surface
Teselation Language - a 3D format with
triangulated surfaces needed for processing)
into printable G-codes.
Kühling&Kühling recommend using the Slic3r
slicing software to prepare your digital 3D
models for printing. This slicing software
provides a lot of features necessary for