Renishaw RenAM 500Q User manual

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

Renishaw part no: H-5800-3693-03-C
First Issued: 05.2018
Revised: 07.2021
© 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.
Company no: 1106260.
Registered office: New Mills, Wotton-under-Edge, Gloucestershire, GL12 8JR, UK.

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 Battery safety .............................................................1-4
1.7.1 Disposal of batteries .................................................1-4
1.8 Declaration of conformity ....................................................1-5
1.9 FCC information to user (USA only ............................................1-5
1.9.1 47CFR section 15.21 .................................................1-5
1.9.2 47CFR section 15.105 ................................................1-5
1.10 REACH..................................................................1-5
1.11 Control of pollution, applicable in the People's Republic of China .....................1-6
1.12 China RoHS ..............................................................1-6
1.13 Industrial,ScienticandMedicalEquipment(ISM)forCanada .......................1-6
Chapter 2 – Scope of supply
Introduction ...................................................................2-1
2.1 Standardequipment(RenAM500Q/SexcludingFlex) .............................2-2
2.2 Standardequipment(RenAM500Q/SFlexonly)..................................2-2
2.3 Required accessories.......................................................2-3
2.4 Optional items ............................................................2-3
Chapter 3 – Introduction
Introduction ...................................................................3-1
3.1 Summary ................................................................3-2
3.2 Modelcongurations .......................................................3-2
3.3 Reference documentation ...................................................3-2
3.4 Denitions ...............................................................3-3
3.5 Abbreviations .............................................................3-4
3.6 Safety information in this User guide ...........................................3-5
3.6.1 Warning ...........................................................3-5
3.6.2 Caution............................................................3-5
3.6.3 Note ..............................................................3-5
3.7 Training schedule ..........................................................3-5
3.8 Contact details ............................................................3-6
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Issue 03-C i

Chapter 4 – Safety
Introduction ...................................................................4-1
4.1 General safety information ...................................................4-2
4.1.1 Introduction ........................................................4-2
4.1.2 Responsibilities .....................................................4-2
4.1.3 Basic safety measures................................................4-3
4.1.4 Explosion prevention document.........................................4-4
4.1.5 What to do in an emergency ...........................................4-4
4.1.6 Normal operation ....................................................4-5
4.1.7 Approvals,complianceandcertication...................................4-5
4.1.8 Residual risks, maintenance and protective measures .......................4-5
4.1.9 Housekeeping ......................................................4-5
4.1.10 Electro-magnetic compatibility ..........................................4-5
4.2 Personal safety............................................................4-6
4.2.1 Manual handling.....................................................4-6
4.2.2 Fire-ghting ........................................................4-6
4.2.3 Laser safety precautions ..............................................4-7
4.2.4 Oxygen level monitoring within the process room ...........................4-7
4.2.5 Training ...........................................................4-8
4.2.6 Correct usage ......................................................4-8
4.2.7 Improper use .......................................................4-9
4.2.8 Personalprotectiveequipment(PPE) ....................................4-9
4.2.9 Toxicity and personnel exposure .......................................4-11
4.2.10 Thermal hazards ...................................................4-12
4.2.11 Hazards due to latent energy sources ...................................4-12
4.3 Powder safety............................................................4-13
4.3.1 Metal powder handling advice .........................................4-13
4.3.2 Handling of metal powders ...........................................4-15
4.3.3 Flammability.......................................................4-15
4.3.3.1 Combustibility ..............................................4-16
4.3.3.2 Explosivity.................................................4-16
4.3.4 Safe disposal of waste products .......................................4-17
4.3.5 Handling and processing .............................................4-18
4.3.6 Storage ..........................................................4-18
4.3.7 Spills ............................................................4-18
4.3.8 Metal powder safety checklist .........................................4-19
4.3.9 Hazardsduetoreorexplosion .......................................4-20
4.3.10 Identiableignitionsources ...........................................4-21
4.3.11 Hydrogen gas......................................................4-22
4.3.12 Safety data sheets ..................................................4-22
4.3.13 Metal condensate...................................................4-23
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4.4 System safety............................................................4-24
4.4.1 Safety function diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24
4.4.1.1 RenAM 500Q/S front view – safety functions ......................4-24
4.4.1.2 RenAM 500Q/S rear view – safety functions ......................4-25
4.4.1.3 RenAM 500Q/S top view – safety functions .......................4-26
4.4.2 Safety signs and laser safety labels.....................................4-27
4.4.2.1 Safety signs ...............................................4-27
4.4.2.2 Laser safety labels ..........................................4-30
4.4.3 Transport and system relocation .......................................4-33
4.4.4 Decommissioning...................................................4-33
4.4.5 Hazards due to unexpected malfunctions ................................4-34
4.4.6 RenAM 500Q/S ergonomics ..........................................4-34
4.5 Gas safety ..............................................................4-35
4.5.1 Inert gas safety ....................................................4-35
Chapter 5 – Overview
Introduction ...................................................................5-1
5.1 RenAM 500Q/S front view ...................................................5-2
5.2 RenAM 500Q/S rear view ...................................................5-3
5.3 RenAM 500Q/S right-hand end view ...........................................5-4
5.4 RenAM500Q/S(excludingFlex)frontviewwithpowderllandlargesafechangelter
door open................................................................5-5
5.5 RenAM500Q/S(Flexonly)frontviewwithoverowandlargesafechangelterdoor
open ....................................................................5-6
5.6 RenAM 500Q/S rear view with rear right-hand cupboard door open ...................5-7
5.7 RenAM 500Q/S plan view ...................................................5-8
Chapter 6 – System specication
Introduction ...................................................................6-1
6.1 RenAM500Q/Ssystemspecication...........................................6-2
6.2 Buildplatespecication .....................................................6-4
6.2.1 RenAM 500Q/S standard build plates ....................................6-4
6.2.1.1 Standard build plate – mild steel.................................6-4
6.2.1.2 Standard build plate – titanium..................................6-5
6.2.1.3 Standard build plate – aluminium ................................6-6
6.2.1.4 Standard build plate – stainless steel.............................6-7
6.2.1.5 Standard build plate – full build titanium...........................6-8
6.2.1.6 Standard build plate – long life stainless steel ......................6-9
6.2.1.7 Standard build plate – full build stainless steel.....................6-10
6.2.1.8 Standard build plate – long life aluminium ........................6-11
6.2.1.9 Standard build plate – full build aluminium ........................6-12
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6.2.1.10 Standard build plate – long life mild steel .........................6-13
6.2.1.11 Standard build plate – long life titanium ..........................6-14
6.2.1.12 Standard build plate – full build mild steel ........................6-15
Chapter 7 – Functional description
Introduction ...................................................................7-1
7.1 RenAM 500Q/S main isolating switch ..........................................7-2
7.2 "Emergency Stop" button....................................................7-2
7.3 Operator touch screen control panel ...........................................7-3
7.4 Programmable logic controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4
7.5 Main computer ............................................................7-4
7.6 System software...........................................................7-5
7.7 Laser ...................................................................7-6
7.8 Chiller...................................................................7-6
7.9 Lens protection window .....................................................7-7
7.10 Build chamber viewing window ...............................................7-7
7.11 Powderrecirculationsystem(RenAM500Q/SexcludingFlex) .......................7-8
7.12 Loadhopper(RenAM500Q/SexcludingFlex)....................................7-8
7.13 Feedhopper(RenAM500Q/SFlexonly) ........................................7-9
7.14 Dosingsilo(RenAM500Q/SexcludingFlex) ....................................7-10
7.15 Dosingsilo(RenAM500Q/SFlexonly) ........................................7-11
7.16 Renishawultrasonicsieve(RenAM500Q/SexcludingFlex) . . . . . . . . . . . . . . . . . . . . . . . .7-11
7.17 Pneumatictransfer(RenAM500Q/SexcludingFlex)..............................7-12
7.18 Powder delivery ..........................................................7-13
7.19 Recoater assembly .......................................................7-13
7.20 Overowasks(RenAM500Q/SFlexonly) .....................................7-14
7.21 Powderloadingarm(RenAM500Q/SFlexonly) .................................7-15
7.22 Gas circuit ..............................................................7-16
7.23 Build plate ..............................................................7-17
7.24 Heating/temperature control.................................................7-18
7.25 Largesafechangelter(LSCF50) ............................................7-18
7.26 Oxygen monitoring sensors .................................................7-20
7.27 Keys and user accessibility .................................................7-20
7.28 ESD and earth bonding points...............................................7-22
7.29 Laser controller ..........................................................7-23
7.30 Cyclone ................................................................7-23
7.30.1 Cyclone level sensors ...............................................7-24
7.31 Intercooler ..............................................................7-24
7.32 Electrical cabinets ........................................................7-25
7.33 ATEX vacuum cleaner .....................................................7-27
7.34 Universal lifter ...........................................................7-28
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7.35 Hoppertrolley(RenAM500Q/SexcludingFlex) .................................7-29
7.36 Beacon light .............................................................7-30
Chapter 8 – Ancillaries
Introduction ...................................................................8-1
8.1 ATEX vacuum cleaner – mandatory............................................8-2
8.1.1 ATEX vacuum cleaner general information ................................8-2
8.1.2 ATEX vacuum cleaner safety ...........................................8-3
8.1.3 ATEX vacuum cleaner operation ........................................8-3
8.1.4 ATEX vacuum cleaner maintenance .....................................8-4
8.2 Chiller – mandatory ........................................................8-5
8.2.1 Chiller general information.............................................8-5
8.2.2 Chiller safety .......................................................8-5
8.2.3 Chiller operation.....................................................8-6
8.2.4 Chiller maintenance ..................................................8-6
8.3 Bead blaster and extractor – optional...........................................8-6
8.3.1 Bead blaster and extractor general information .............................8-6
8.3.2 Bead blaster and extractor safety .......................................8-7
8.3.3 Bead blaster and extractor operation.....................................8-7
8.3.4 Bead blaster and extractor maintenance ..................................8-7
8.4 Furnace – optional .........................................................8-8
8.4.1 Furnace general information ...........................................8-8
8.4.2 Furnace safety ......................................................8-8
8.4.3 Furnace operation ...................................................8-9
8.4.4 Furnace maintenance ................................................8-9
8.5 Universallifter–recommended(mandatoryforRenAM500Q/SFlex) ................8-10
8.5.1 Universal lifter general information .....................................8-10
8.6 Hoppertrolley–recommended(RenAM500Q/SexcludingFlex) ....................8-11
8.6.1 Introduction .......................................................8-11
8.7 Powderrecoverysystem(sieve)–recommended(mandatoryforRenAM500Q/SFlex) ..8-12
8.7.1 Attaching the argon supply ...........................................8-12
8.7.2 Loading material ...................................................8-14
8.7.3 Disassembly of the sieve for cleaning and maintenance .....................8-17
8.7.4 Disassembly of the sieve for material changeover..........................8-26
8.7.5 Reassembly of sieve ................................................8-27
8.7.6 Operating instructions for Russell clamp assist tool ........................8-33
8.8 Workingplatform–recommended(mandatoryforRenAM500Q/SFlex) ..............8-35
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Chapter 9 – Operation
Introduction ...................................................................9-1
9.1 Pre-build tasks ............................................................9-2
9.1.1 Pre-buildtasks(RenAM500Q/SexcludingFlex)............................9-2
9.1.2 Pre-buildtasks(RenAM500Q/SFlexonly) ................................9-3
AB-001–Chilleruidlevel–Check ............................................9-4
AB-002 – Argon gas supply – Set up ...........................................9-5
AB-003 – Chiller – Power up .................................................9-6
AB-004–Largesafechangelterassemblies–Check.............................9-7
AB-005 – RenAM 500Q/S system – Power up....................................9-9
AB-006 – RenAM 500Q/S system – Log in .....................................9-10
AB-007 – Build chamber – Set up ............................................9-11
AB-008 – Build plate – Install ................................................9-15
AB-009 – Recoater blade – Install ............................................9-19
AB-010 – Recoater assembly – Install .........................................9-24
AB-011–Loadhopper–Fill(RenAM500Q/SexcludingFlex) ......................9-25
AB-012–Valves–Setup(RenAM500Q/SexcludingFlex) ........................9-28
AB-013 – Build platform heat soak process – Set up..............................9-29
AB-014 – Build chamber atmosphere – Set up ..................................9-31
AB-015 – Powder dose – Set up .............................................9-33
AB-016–Buildle–Transfer ................................................9-36
AB-017–Buildle–Select .................................................9-36
AB-018 – Suppress part....................................................9-38
AB-019–Cycloneparticlecollectionask–Fit ..................................9-41
AB-020–Pre-buildchecklist–Review(RenAM500Q/SexcludingFlex) ..............9-43
AB-021 – Build – Start .....................................................9-44
AB-022–Feedhopper–Fill(RenAM500Q/SFlexonly)...........................9-46
AB-023–Overowasks–Fit(RenAM500Q/SFlexonly) .........................9-52
AB-024–Valves–SetUp(RenAM500Q/SFlexonly) ............................9-56
AB-025–Pre-buildchecklist–Review(RenAM500Q/SFlexonly) ..................9-59
9.2 Monitoring the build .......................................................9-60
9.2.1 Safechangelters ..................................................9-61
9.2.2 Powderdosing(RenAM500Q/SFlexonly) ...............................9-63
9.2.3 Overowasks(RenAM500Q/SFlexonly)...............................9-64
9.2.4 Feedhopper(RenAM500Q/SFlexonly).................................9-64
9.3 Post-build tasks ..........................................................9-65
9.3.1 Post-buildtasks(RenAM500Q/SexcludingFlex) ..........................9-65
9.3.2 Post-buildtasks(RenAM500Q/SFlexonly) ..............................9-66
PB-001 – Build plate – Cool down ............................................9-67
PB-002 – Build report – Generate ............................................9-68
PB-003 – Build chamber metal powder – Remove................................9-69
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PB-004 – Build plate – Remove ..............................................9-76
PB-005 – Build chamber – Clean.............................................9-77
PB-007 – Lower chamber – Clean ............................................9-79
PB-008 – Recoater blade – Remove ..........................................9-80
PB-009 – RenAM 500Q/S system – Shut down..................................9-81
PB-010 – RenAM 500Q/S system – Power down ................................9-82
PB-011 – Chiller – Power down ..............................................9-83
PB-012 – Build plate parts – Remove .........................................9-84
PB-013 – Build plate – Refurbish .............................................9-84
PB-014–Heattreatmentofparts(optional)–Setup .............................9-85
PB-014-01 – Introduction...........................................9-85
PB-014-02 – Wrapping parts prior to heat treatment......................9-85
PB-015–Oversizedparticlecollectionask–Ret,removeandempty(RenAM500Q/S
excludingFlex)...................................................9-90
PB-015-01–Ret ................................................9-90
PB-015-02 – Remove .............................................9-95
PB-015-03 – Empty ...............................................9-95
PB-016 – Lens protection system – Inspect.....................................9-96
PB-017–Cyclonelterparticlecollectionask–Removeandempty ................9-97
PB-017-01 – Remove .............................................9-97
PB-017-02 – Empty ...............................................9-98
PB-018–Overowask–Removeandempty(RenAM500Q/SFlexonly) ............9-98
PB-018-01–Remove(1.7Lask)....................................9-99
PB-018-02–Remove(10Lask) ...................................9-100
9.4 Occasional tasks ........................................................9-104
OT-001–Chilleruidlevel–Topup ..........................................9-105
OT-002 – Argon gas cylinder – Replace.......................................9-106
OT-003–Powderask–Fill................................................9-107
OT-005–Largesafechangelterassembly–Remove ...........................9-108
OT-006–Largesafechangelterelement–Remove ............................9-115
OT-007–Largesafechangelterelement–Ret ...............................9-118
OT-008–Largesafechangelterassembly–Ret..............................9-119
OT-009–Chilleruid–Remove.............................................9-121
OT-010 – RenAM 500Q/S system – Build recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-122
OT-011–Feedhopper–Remove(RenAM500Q/SFlexonly) .....................9-122
OT-012–Feedhopper–Ret(RenAM500Q/SFlexonly) ........................9-128
OT-013–Powderloadingarm–Adjust(RenAM500Q/SFlexonly) .................9-131
OT-013-01 – Height adjustment .....................................9-131
OT-013-02 – Docking position adjustment .............................9-132
OT-013-03 – Reach adjustment .....................................9-134
OT-014–10Lask–Decantpowder ........................................9-135
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9.5 Technician level tasks.....................................................9-141
TT-001 – Change date and time.............................................9-141
TT-002–Flexsettings(RenAM500Q/SFlexonly) ..............................9-144
TT-003 – Add/Update material information.....................................9-147
TT-003-01 – Change material ......................................9-149
TT-003-02 – Adding a new material ..................................9-149
9.6 Optical tests ...........................................................9-152
ST-002 – Laser power health check ..........................................9-155
ST-003 – Laser focus health check ..........................................9-158
ST-004 – Laser ScanField health check.......................................9-159
ST-005–Laserbeamprolehealthcheck .....................................9-160
Chapter 10 – Preventative maintenance schedule
Introduction ..................................................................10-1
10.1 Personalprotectiveequipment(PPE) .........................................10-2
10.2 Denitionsofmaintenance..................................................10-2
10.3 RenAM 500Q/S preventative maintenance schedule..............................10-3
10.4 Ancillary equipment preventative maintenance schedule ..........................10-4
10.5 Preventative maintenance records............................................10-4
10.6 Preventative maintenance checklists ..........................................10-5
10.6.1 Weekly tasks ......................................................10-5
10.6.2 Monthly tasks......................................................10-5
10.6.3 Six-monthly tasks...................................................10-5
Chapter 11 – Preventative maintenance tasks
Introduction ..................................................................11-1
11.1 Preventative maintenance tasks .............................................11-2
PM-001 – RenAM 500Q/S system – Inspect ....................................11-2
PM-002 – RenAM 500Q/S system – Clean .....................................11-2
PM-003 – RenAM 500Q/S safety devices – Check ...............................11-3
PM-004 – RenAM 500Q/S system hoses and coolant system – Check................11-4
PM-004-01 – System hoses – Check .................................11-4
PM-004-02 – Coolant system – Check ................................11-4
PM-004-03 – Post completion .......................................11-4
PM-005 – Process room – Clean .............................................11-5
PM-006 – Build chamber viewing window – Inspect ..............................11-6
PM-007 – Top and bottom door seals – Check...................................11-6
PM-008 – Safety signs and laser safety labels – Inspect...........................11-6
PM-009 – User guide – Check ...............................................11-7
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