First Time Startup

Machine:

XR3

Steps:

20

Level:

Intermediate

Time:

1-2 hrs

IMPORTANT SAFETY WARNING!

DO NOT ATTEMPT TO POWER UP THE MACHINE ON YOUR OWN UNTIL INSTRUCTED ON THIS CHAPTER!
THERE IS A CRUCIAL PRERUN CHECKLIST ON THIS CHAPTER THAT NEEDS TO BE FOLLOWED.
FAILURE TO DO SO MIGHT DAMAGE THE MACHINE BEYOND REPAIR OR EVEN FIRE.
READ ALL THE INSTRUCTIONS AND EXAMINE THE PHOTOS STEP BY STEP AT LEAST ONCE BEFORE PROCEEDING!
YOU WILL BE RESPONSIBLE FOR ANY DAMAGE CAUSED BY NOT FOLLOWING THE INSTRUCTIONS CAREFULLY!
PREPARE APPROXIMATELY 100GR OF DRIED RAW (VIRGIN) PLA PELLETS FOR CALIBRATION.
WE DO NOT RECOMMEND USING RECYCLED PLASTIC PELLETS FOR CALIBRATION PURPOSES.

Revision 1
  • There were some important updates during the preparation of this guide. There might some steps which you will encounter the older photos of the machine. Due to time it takes to shoot the photos we simply decided to keep the older versions as it is for now.
  • We added an voltage/current meter to measure how much power the stepper motor draws. This will also ensure if the motor is working within limits and make adjustments in realtime to the speed when needed during extrusion.

Revision 2
  • There were some important updates during the preparation of this guide. There might some steps which you will encounter the older photos of the machine. Due to time it takes to shoot the photos we simply decided to keep the older versions as it is for now.
  • We switched the stepper motor controller with a more advanced version.
  • A small opening added to top middle panel. The purpose of this opening is for inspect and adjusting the position of the shaft coupler spacing during first time startup. There is a small cover that covers it during the normal extrusion operation to avoid any plastic pieces or other foreign objects to fall inside.

Revision 3
  • There were some important updates during the preparation of this guide. There might some steps which you will encounter the older photos of the machine. Due to time it takes to shoot the photos we simply decided to keep the older versions as it is for now.
  • We switched the stepper motor driver with a more advanced version.

Step 1: Stepper driver current adjustment
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  • READ THE FOLLOWING INSTRUCTIONS CAREFULLY AND EXAMINE ALL THE PHOTOS FIRST TO LEARN HOW TO CONFIGURE THE MACHINE FIRST BEFORE PROCEEDING.
  • Open the panel PB2 to access stepper driver.
  • On the current settings table we will adjust the driver current settings to 2.84A peak and 2.03A RMS max current settings by adjusting the jumper selector.
  • On the Pulse/rev settings table we will adjust the driver pulse settings to 200 by adjusting the jumper selector.
  • Move the jumpers according to table below to following positions to set correct current and pulse settings;
    1: ON
    2: ON
    3: OFF
    4: OFF
    5: ON
    6: ON
    7: ON
    8: ON

Step 2: Thermocouple wiring polarity warning!
  • READ THE FOLLOWING INSTRUCTIONS CAREFULLY AND EXAMINE ALL THE PHOTOS FIRST TO LEARN HOW TO CONFIGURE THE MACHINE FIRST BEFORE PROCEEDING.
  • PLEASE NOTE THAT IF YOU ARE USING DIFFERENT BRAND OF PID CONTROLLERS THAN WHAT POLYSTRUDER XR3 IS USING, PLEASE REFER TO IT IS USER MANUAL TO ADJUST THE PROPER SETTINGS.
  • READ STEP 2 AND STEP 3 CAREFULLY FIRST BEFORE TURNING ON THE MACHINE AND PROCEED!
  • ON STEP 3 MACHINE WILL BE POWERED ON TO CHECK IF IT IS HEATING PROPERLY.
  • UNDER SOME RARE CASES DUE TO PRODUCTION VARIANCES WITH THERMOCOUPLE WIRING POLARITY, PID CONTROLLERS MIGHT THINK MACHINE IS COOLING AND KEEP THE HEATERS POWERED ON UNTIL FOREVER WHICH IS EXTREMELY DANGEROUS.
  • AS SOON AS THE MACHINE IS POWERED ON CHECK IF TEMPERATURE READING ON RED DISPLAY (PV) STARTS DROPPING AND SHOWS NEGATIVE (-) TEMPERATURES. IF THAT IS THE CASE POWER OFF THE MACHINE IMMEDIATELY! IT IS INSTRUCTED HOW TO CORRECT THIS ISSUE ON STEP 4 IF NECESSARY.
  • After turning on machine on step 3 check if red (PV) display indicates current temperature correctly when PID controller is on normal working mode. If it shows NEGATIVE (-) temperature on any or all PID controller POWER OFF THE MACHINE IMMEDIATELY BY HITTING EMERGENCY STOP BUTTON! That indicates polarity on thermocouple wiring needs to be switched.

Step 3: PID controller thermocouple polarity check
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  • READ THE FOLLOWING INSTRUCTIONS CAREFULLY AND EXAMINE ALL THE PHOTOS FIRST TO LEARN HOW TO CONFIGURE THE MACHINE FIRST BEFORE PROCEEDING.
  • PLEASE NOTE THAT IF YOU ARE USING DIFFERENT BRAND OF PID CONTROLLERS THAN WHAT POLYSTRUDER XR3 IS USING, PLEASE REFER TO IT IS USER MANUAL TO ADJUST THE PROPER SETTINGS.
  • READ STEP 2 AND STEP 3 CAREFULLY FIRST BEFORE TURNING ON THE MACHINE AND PROCEED!
  • ON THIS STEP MACHINE WILL BE POWERED ON TO CHECK IF IT IS HEATING PROPERLY.
  • UNDER RARE CIRCUMSTANCES DUE TO PRODUCTION VARIANCES WITH THERMOCOUPLE, PID CONTROLLERS MIGHT THINK MACHINE IS COOLING AND KEEP THE HEATERS POWERED ON UNTIL FOREVER WHICH IS EXTREMELY DANGEROUS.
  • AS SOON AS THE MACHINE IS POWERED ON CHECK IF REALTIME TEMPERATURE READING ON RED DISPLAY (PV) STARTS DROPPING AND SHOWS NEGATIVE (-) VALUES. IF THAT IS THE CASE POWER OFF THE MACHINE IMMEDIATELY TO CORRECT IT ON STEP 4.
  • IF THE HEATERS ARE REPORTING POSITIVE TEMPERATURES, POWER OFF THE MACHINE, SKIP STEP 4 AND PROCEED TO THE STEP 5.
  • Insert the power cable to the main power socket and turn on the safety power switch.
  • If emergency stop button is pressed, reset it by turning it to clockwise.
  • Emergency stop button should be now upwards and off position.
  • Turn on the main power switch.
  • Press the red power button to start the machine.
  • Wait around for 10 seconds until PID controllers fully boots up and reports back current working temperature on red display which should be around room temperature at first.
  • If the reported temperature starts dropping towards to zero degrees celcius instead of increasing and starts showing negative (-) values on red display POWER OFF THE MACHINE IMMEDIATELY BY PRESSING EMERGENCY STOP BUTTON AND CONTINUE TO STEP 4. Otherwise POWER OFF the machine and proceed to the STEP 5.

Step 4: PID controller thermocouple polarity fix
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  • READ THE FOLLOWING INSTRUCTIONS CAREFULLY AND EXAMINE ALL THE PHOTOS FIRST TO LEARN HOW TO CONFIGURE THE MACHINE FIRST BEFORE PROCEEDING.
  • ONLY COMPLETE THIS STEP IF ANY OF THE PID CONTROLLERS SHOWS NEGATIVE TEMPERATURE VALUES. OTHERWISE SKIP THIS STEP AND PROCEED TO STEP 5.
  • PLEASE NOTE THAT IF YOU ARE USING DIFFERENT BRAND OF PID CONTROLLERS THAN WHAT POLYSTRUDER XR3 IS USING, PLEASE REFER TO IT IS USER MANUAL TO ADJUST THE PROPER SETTINGS.
  • PLEASE TURN OFF AND UNPLUG THE MACHINE FROM POWER OUTLET BEFORE PROCEEDING.
  • Open PB1 panel to access PID controller wiring.
  • If leftmost PID controller shows negative temperature values switch TA01 and TA02 wiring positions to change polarity of thermocouple.
  • If middle PID controller shows negative temperature values switch TB01 and TB02 wiring positions to change polarity of thermocouple.
  • If rightmost PID controller shows negative temperature values switch TC01 and TC02 wiring positions to change polarity of thermocouple.

Step 5: PID controllers configuration - Preperation
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  • READ THE FOLLOWING INSTRUCTIONS CAREFULLY AND EXAMINE ALL THE PHOTOS FIRST TO LEARN HOW TO CONFIGURE THE MACHINE FIRST BEFORE PROCEEDING.
  • PLEASE NOTE THAT IF YOU ARE USING DIFFERENT BRAND OF PID CONTROLLERS THAN WHAT POLYSTRUDER XR3 IS USING, PLEASE REFER TO IT IS USER MANUAL TO ADJUST THE PROPER SETTINGS.
  • FOR THE NEXT COUPLE OF STEPS IT IS REQUIRED TO TEMPORARILY TURNING OFF ALL HEATERS BY SETTING THEM TO 0C.
  • PLEASE ACT QUICKLY DURING THIS STEP SINCE MACHINE MIGHT GET HOT IN SHORT AMOUNT OF TIME.
  • WHEN YOU ARE READY POWER ON THE MACHINE AGAIN AND PROCEED.
  • Once the machine is powered on again, wait around for 10 seconds until the PID controllers boots up. As soon as PID controllers reports back the currect temperature value, press SET button once to enter temperature set mode. Green display starts blinking rapidly. That indicates you can change the desired temperature value.
  • Switch to the leftmost decimal by pressing <R/S three times so decimal value switches to leftmost digit. Each time <R/S button is pressed decimal value will switch to left to allow a faster temperature adjustment. Current selected decimal value is displayed as solid digit instead of rapid blinking digits.
  • Press V button one time to reduce the temperature. This will quickly allows to reduce the temperature by 1000C in one press of button.
  • Press the SET button to save the desired temperature setting. Now the temperature should set to 0 on green display and heaters should be turned off. Repeat this step for all PID controllers.

Step 6: PID controller temperature limit configuration
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  • READ THE FOLLOWING INSTRUCTIONS CAREFULLY AND EXAMINE ALL THE PHOTOS FIRST TO LEARN HOW TO CONFIGURE THE MACHINE FIRST BEFORE PROCEEDING.
  • PLEASE NOTE THAT IF YOU ARE USING DIFFERENT BRAND OF PID CONTROLLERS THAN WHAT POLYSTRUDER XR3 IS USING, PLEASE REFER TO IT IS USER MANUAL TO ADJUST THE PROPER SETTINGS.
  • Press and hold SET for at least 3 seconds to enter settings menu.
  • Once inside the settings menu red display shows selected option, green display shows it is set value. To cycle between options press SET button once. To change the option value use V and Ʌ buttons. For detailed menu options please refer to the PID controller manual.
  • Press SET button several times to cycle between menu options until LCK option appears on red (PV) display. Green display now shows current value of the selected submenu option. If not set, press <R/S button 3 times to switch to the leftmost decimal and adjust it to 1000 by using V and Ʌ buttons. As soon as LCK value is set to 1000, press and hold SET and <R/S buttons simultaneously for couple of seconds until red display shows Cod option.
  • Set Cod value to 0001 by using V and Ʌ buttons. Aftewards press and hold SET button for several seconds. This allows us to enter Cod 0001 submenu which contains temperature limits of PID controllers.
  • Set the following parameters for each submenu options under Cod 0001 submenu by using V and Ʌ buttons. Also use <R/S button to switch between decimals to adjust to the desired value faster. You can cycle between submenu options by pressing SET each time once. Even though most of the settings are not applicable for polystruder XR3 it is best to set those values as indicated exactly below.
    SLH: "0300"     - Maximum temperature limit
    SLL: "0000"     - Minimum temperature limit
    oH: "2"     - Not used
    dF: "1"     - Not used
  • Once all the parameters are set wait around 30 seconds until PID controller returns back to the main status screen by itself. It will save these values automatically.

Step 7: PID controller thermocouple configuration
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  • READ THE FOLLOWING INSTRUCTIONS CAREFULLY AND EXAMINE ALL THE PHOTOS FIRST TO LEARN HOW TO CONFIGURE THE MACHINE FIRST BEFORE PROCEEDING.
  • PLEASE NOTE THAT IF YOU ARE USING DIFFERENT BRAND OF PID CONTROLLERS THAN WHAT POLYSTRUDER XR3 IS USING, PLEASE REFER TO IT IS USER MANUAL TO ADJUST THE PROPER SETTINGS.
  • Press and hold SET for at least 3 seconds to enter settings menu.
  • Once inside the settings menu red display shows selected option, green display shows it is set value. To cycle between options press SET button once. To change the option value use V and Ʌ buttons. For detailed menu options please refer to the PID controller manual.
  • Press SET button several times to cycle between menu options until LCK option appears on red (PV) display. Green display always shows current value of the selected submenu option. If not set, press <R/S button 3 times to switch to the leftmost decimal and adjust it to 1000 by using V and Ʌ buttons. As soon as LCK value is set to 1000, press and hold SET and <R/S buttons simultaneously for couple of seconds until red display shows Cod option.
  • Set Cod value to 0000 by using V and Ʌ buttons. Aftewards press and hold SET button for several seconds. This allows us to enter Cod 0000 submenu which contains thermocouple and alarm settings of PID controllers.
  • Set the following parameters for each submenu options under Cod 0000 submenu by using V and Ʌ buttons. Also use <R/S button to switch between decimals to adjust to the desired value faster. You can cycle between submenu options by pressing SET each time once. Even though most of the settings are not applicable for polystruder XR3 it is best to set those values as indicated exactly below.
    SL1: "0000" - K type thermistor selection
    SL2: "0000"     - Not used
    SL3: "0000"     - Not used
    SL4: "0000"     - Disable alarm 1
    SL5: "0000"     - Disable alarm 2
    SL6: "0001" - Heating mode
    SL7: "0000"     - Not used
    SL8: "0000"     - Not used
    SL9: "0000"     - Not used
    SL10: "0000"     - Not used
    SL11: "0000"     - Not used
  • Once all the parameters are set wait around 30 seconds until PID controller returns back to the main status screen by itself. It will save these values automatically.

Step 8: Stepper controller configuration
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  • READ THE FOLLOWING INSTRUCTIONS CAREFULLY AND EXAMINE ALL THE PHOTOS FIRST TO LEARN HOW TO CONFIGURE THE MACHINE FIRST BEFORE PROCEEDING.
  • Press and hold rotary knob for at least 3 seconds to enter settings menu on stepper controller.
  • Once inside the settings menu, top line of the display shows F-XX which indicates selected parameter. The second line indicates the value of the currently selected parameter. To change between different parameter options turn the rotary knob on either directions. There are total 13 different parameters.
  • To change the value of parameter press the rotary knob or RUN/STOP button one time. The first decimal from right on second line starts blinking. That indicates you can change that value. To change the value simply rotate the rotary knob. Each time the knob is pressed the indicator decimal will move towards left. Once the parameter is set press RUN/STOP button only once to save and exit from that parameter value settings.
  • Set the following values for each parameter options by using the rotary knob and RUN/STOP buttons. Even though most of the settings are not applicable for polystruder XR3 it is best to set those values as indicated exactly below. For more information about detailed parameter explanation please refer to the stepper controller manual.
    F-01: "P03" - Type of motion control
    F-02: "1    " - Not used in P03 mode
    F-03: "050.0"     - Forward screw speed
    F-04: "1"     - Not used in P03 mode
    F-05: "010.0"     - Reverse screw speed
    F-06: "----" - Not used in P03 mode
    F-07: "000.0" - Not used in P03 mode
    F-08: "000.0"     - Not used in P03 mode
    F-09: "10"     - Pulse per revolution
    F-10: "0"     - Unit display in RPM
    F-11: "0    " - Not used in P03 mode
    F-12: "001" - Not used in P03 mode
    F-13: "001" - Not used in P03 mode
  • Once all the parametes are set press and hold rotary knob button for at least 3 seconds to save and return to main status screen.

Step 9: Stepper driver startup
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  • READ THE FOLLOWING INSTRUCTIONS CAREFULLY AND EXAMINE ALL THE PHOTOS FIRST TO LEARN HOW TO CONFIGURE THE MACHINE FIRST BEFORE PROCEEDING.
  • MAKE SURE THAT THERE IS ABSOLUTELY NO POLYMER PELLETS OR FOREIGN OBJECTS PRESENT INSIDE THE FEEDER OR BARREL SECTION! CLEAN AND REMOVE ANY POLYMER PELLETS OR FOREIGN OBJECTS IF NEEDED!
  • When voltage is at 0.0 that indicates stepper driver powered off and does not supply any power to the motor even when stepper controller is powered on. This acts as a protection to avoid any accidental motor startup.
  • When current meter displays 0.00 it indicates motor is off. It should display 0.00 all the time unless motor is running.
  • Press the green push button to power up the stepper driver so it will be ready. MAKE SURE THAT CW AND CCW LIGHTS ON STEPPER CONTROLLER IS OFF BEFORE TURNING ON THE STEPPER DRIVER. THIS WILL ENSURE THAT MOTOR STAYS OFF WHEN STEPPER DRIVER IS TURNED ON.
  • Once green button is pressed one time voltage indicator on voltage/current meter should be around 48V. It indicates that stepper driver is on and ready to run the motor. It is ok if it displays between 46V to 50V. It is possible to calibrate the 48V PSU and voltage/current meter for 48V if you want to supply exact 48V to the stepper driver. It is purely optional and not needed.

Step 10: Shaft coupler calibration - Screw access check
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  • READ THE FOLLOWING INSTRUCTIONS CAREFULLY AND EXAMINE ALL THE PHOTOS FIRST TO LEARN HOW TO CONFIGURE THE MACHINE FIRST BEFORE PROCEEDING.
  • IT IS NECESSARY TO ADJUST THE SPACING BETWEEN SHAFT COUPLER COMPONENTS. THERE SHOULD BE APPROXIMATELY 2MM SPACING BETWEEN SHAFT COUPLER COMPONENTS TO AVOID ANY AXIAL PRESSURE TO THE GEARBOX. FAILURE TO ADJUST IT MIGHT CAUSES STEPPER MOTOR AND GEARBOX DAMAGE.
  • ON THIS STEP SOME OF THE PANELS WILL BE OPEN DURING IT IS POWERED ON! BE EXTRA CAREFUL NOT TO TOUCH ANY EXPOSED WIRES OR WIRE CONTACTS WITH BARE HANDS OR TOOLS DURING MACHINE IS POWERED ON.
  • MAKE SURE THAT THERE IS ABSOLUTELY NO POLYMER PELLETS OR FOREIGN OBJECTS PRESENT INSIDE THE FEEDER OR BARREL SECTION! CLEAN AND REMOVE ANY POLYMER PELLETS OR FOREIGN OBJECTS IF NEEDED!
  • Open panel PB4 and PTS4 to access shaft coupler mechanism. DO NOT UNPLUG OR TURN OFF THE MACHINE SINCE IT MIGHT BE NECESSARY TO TURN THE MOTOR SLIGHTLY TO ACCESS SHAFT COUPLER SCREWS.
  • Check if the motor side of the shaft coupler screw is accessible. If it is exposed and accessible, skip to step 10. If not we need to turn the motor slowly until it is exposed.
  • While on main status screen on stepper controller, turn the rotary knob to adjust the motor speed to 010.0 to set the motor speed approximately to 1 RPM.
  • Press the CW button once to start the motor. This will turn the motor to forward rotation and CW light indicator turns on. If the motor does not start or turns ultra slow it might be necessary to move the rotary knob one step to kickstart the motor as well. If that is the case turn the knob one step to any direction.
  • Wait until the motor side of the shaft coupler screw is exposed and accessible easily from side.
  • As soon as the motor shaft coupler screw is in correct position hit the RUN/STOP button to stop the motor.

Step 11: Shaft coupler calibration - Preperation
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  • READ THE FOLLOWING INSTRUCTIONS CAREFULLY AND EXAMINE ALL THE PHOTOS FIRST TO LEARN HOW TO CONFIGURE THE MACHINE FIRST BEFORE PROCEEDING.
  • IT IS NECESSARY TO ADJUST THE SPACING BETWEEN SHAFT COUPLER COMPONENTS. THERE SHOULD BE APPROXIMATELY 2MM SPACING BETWEEN SHAFT COUPLER COMPONENTS TO AVOID ANY AXIAL PRESSURE TO THE GEARBOX. FAILURE TO ADJUST IT MIGHT CAUSES STEPPER MOTOR AND GEARBOX DAMAGE.
  • ON THIS STEP SOME OF THE PANELS WILL BE OPEN DURING IT IS POWERED ON! BE EXTRA CAREFUL NOT TO TOUCH ANY EXPOSED WIRES OR WIRE CONTACTS WITH BARE HANDS OR TOOLS DURING MACHINE IS POWERED ON.
  • MAKE SURE THAT THERE IS ABSOLUTELY NO POLYMER PELLETS OR FOREIGN OBJECTS PRESENT INSIDE THE FEEDER OR BARREL SECTION! CLEAN AND REMOVE ANY POLYMER PELLETS OR FOREIGN OBJECTS IF NEEDED!
  • Use M3 allen key to loose the shaft coupler screw slightly. You may also need to use a extra torque by using a pliers to turn the allen key. DO NOT REMOVE THE SCREW COMPLETELY!
  • Keep loosen the screw until the shaft coupler is moving.
  • Try to move the shaft coupler towards to the motor with fingers.
  • If it is hard to move the coupler with fingers use a allen key to force move. There should be a enough spacing between motor coupler and middle coupling part.
  • Insert a 2mm thick allen key for M2 screws between the spacing.
  • Leave the allen key as shown in photo.

Step 12: Shaft coupler calibration - Spacing adjustment
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  • READ THE FOLLOWING INSTRUCTIONS CAREFULLY AND EXAMINE ALL THE PHOTOS FIRST TO LEARN HOW TO CONFIGURE THE MACHINE FIRST BEFORE PROCEEDING.
  • IT IS NECESSARY TO ADJUST THE SPACING BETWEEN SHAFT COUPLER COMPONENTS. THERE SHOULD BE APPROXIMATELY 2MM SPACING BETWEEN SHAFT COUPLER COMPONENTS TO AVOID ANY AXIAL PRESSURE TO THE GEARBOX. FAILURE TO ADJUST IT MIGHT CAUSES STEPPER MOTOR AND GEARBOX DAMAGE.
  • ON THIS STEP SOME OF THE PANELS WILL BE OPEN DURING IT IS POWERED ON! BE EXTRA CAREFUL NOT TO TOUCH ANY EXPOSED WIRES OR WIRE CONTACTS WITH BARE HANDS OR TOOLS DURING MACHINE IS POWERED ON.
  • MAKE SURE THAT THERE IS ABSOLUTELY NO POLYMER PELLETS OR FOREIGN OBJECTS PRESENT INSIDE THE FEEDER OR BARREL SECTION! CLEAN AND REMOVE ANY POLYMER PELLETS OR FOREIGN OBJECTS IF NEEDED!
  • Grab the motor shaft coupler and move it back to the middle coupling part. If it is hard to move with finger use allen key to force move it.
  • Make sure that motor shaft coupler is all the way back towards to middle coupling part and pressing firmly against the 2mm allen key to create a spacing between motor shaft coupler and middle coupling part.
  • Tighten the motor shaft coupler back in to place with only using allen key. DO NOT FULLY TIGHTEN IT YET!
  • Remove the 2mm allen key from shaft coupler.
  • Fully tighten the motor shaft coupler back using with allen key and pliers. Make sure that spacing between motor shaft coupler and middle coupling part is still present.
  • Close back all the open panels.

Step 13: Nickel anti-seize PTFE tape application
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  • READ THE FOLLOWING INSTRUCTIONS CAREFULLY AND EXAMINE ALL THE PHOTOS FIRST TO LEARN HOW TO CONFIGURE THE MACHINE FIRST BEFORE PROCEEDING.
  • TO AVOID ANY DAMAGE DUE TO PROLONGED HEATING AND COOLING IT IS NECESSARY TO APPLY NICKEL ANTI-SEIZE PTFE TAPE TO NOZZLE THREADS. IT PROTECTS AGAINST SEIZING, GALLING AND RUST. IT ALSO ALLOWS FOR EASIER INSTALLATION AND REMOVAL OF NOZZLE AND CREATES A TIGHT SEAL. KEEP IN MIND THAT IT IS REQUIRED TO APPLY A BRAND NEW TAPE EVERY TIME WHEN NOZZLE IS REMOVED AND INSTALLED. DO NOT USE A PREVIOUSLY APPLIED PTFE TAPE WHEN INSTALLING BACK THE NOZZLE.
  • WHEN NOZZLE IS INSTALLED FOR THE FIRST TIME IT IS OK TO DO THE PROCESS WHEN MACHINE IS COLD SINCE THERE IS NO MATERIAL IS PRESENT INSIDE THE BARREL. FOR THE FOLLOWING NOZZLE CHANGES ALWAYS HEAT THE MACHINE TO AT LEAST 200C AND WAIT FOR AT LEAST 15 MINUTES BEFORE PROCEEDING TO NOZZLE REMOVAL AND INSTALL BACK THE NOZZLE WHILE HEATERS ARE STILL RUNNING. THIS ALLOWS MUCH EASIER REMOVAL AND INSTALLATION PROCESS.
  • Remove the top front panel cover to reach the nozzle by loosening the 4 pieces of M3-6mm socket head screws.
  • Use an adjustable wrench to remove the nozzle.
  • Cut around 4 inches or 10cm length of Anti-seize nickel PTFE tape.
  • Wrap around the tape to the nozzle threads tightly.
  • Make sure that PTFE tape is firmly wrapped between threads. There should be no loose ends.
  • Install the nozzle back to the barrel using with adjustable wrench. STOP WHEN YOU CANNOT TURN IT ANYMORE EASILY. DO NOT OVERTIGHTEN OR FORCE IT! IT MIGHT BE VERY DIFFICULT TO REMOVE LATER.
  • Install back the front panel cover by tightening the 4 pieces of M3-6mm socket head screws.

Step 14: PID controller automatic temperature tunning calibration
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  • READ THE FOLLOWING INSTRUCTIONS CAREFULLY AND EXAMINE ALL THE PHOTOS FIRST TO LEARN HOW TO CONFIGURE THE MACHINE FIRST BEFORE PROCEEDING.
  • PLEASE NOTE THAT IF YOU REPLACED THE PID CONTROLLERS WITH DIFFERENT BRAND THAN POLYSTRUDER USES PLEASE REFER TO IT IS USER MANUAL TO ADJUST THE PROPER SETTINGS.
  • PID tunning calibration ensures that temperature controllers can adjust heaters precisely in realtime. This allows for stable extrusion. We recommend this process repeated when temperature drift is more than 3C between desired and realtime temperature during extrusion.
  • Set zone 1 and zone 2 temperatures to 200C.
  • Set zone 3 temperature to 190C.
  • Turn on zone 1 and zone 2 fans to minimum position.
  • Turn on zone 3 fan to maximum. WE ALWAYS RECOMMEND RUNNING THE ZONE 3 FAN TO MAXIMUM TO AVOID HEAT CREEP OVER TO THE FEEDER ZONE.
  • Wait for at least 15 minutes for the temperatures to settle all over the barrel before proceeding. This ensures for better calibration and extrusion process. After 15 minutes has passed, press and hold SET for at least 3 seconds to enter settings menu. Once inside the settings menu red display shows selected option, green display shows it is set value. To cycle between options press SET button once. To change the option value use V and Ʌ buttons. For detailed menu options please refer to the PID controller manual.
  • Set the following parameters for each menu parameters by using V and Ʌ buttons. Also use <R/S button to switch between decimals to adjust to the desired value faster. You can cycle between menu parameters by pressing SET each time once. Even though most of the settings are not applicable for polystruder XR3 it is best to set those values as indicated exactly below.
    Aru: "0001" - Turn on automatic PID calibration
    P:     Calculated by Aru - DO NOT CHANGE
    I:     Calculated by Aru - DO NOT CHANGE
    D:     Calculated by Aru - DO NOT CHANGE
    Ar:     Calculated by Aru - DO NOT CHANGE
    r: "0002" - Delay time between heating
    SC:     Skip - Not used
    LCK:     Skip - Not used
  • Once all the parameters are set AT (Automatic tuning) indicator light starts blinking for couple of minutes and PID controller temperature changes a few times for automatic temperature calibration. DO NOT PRESS ANY BUTTONS DURING AUTOMATIC TUNING IS IN PROGRESS. Wait until AT light goes off in a few minutes. Repeat this step one at a time for other temperature controllers as well. DO NOT RUN AUTOMATIC PID CALIBRATION ON ALL HEATERS SIMULTANEOUSLY AT THE SAME TIME. IT MIGHT CAUSE A INACCURATE TEMPERATURE CONTROL BETWEEN HEATERS. Once PID calibration is done for all controllers leave the heaters on and proceed to the next step.

Step 15: Shaft coupler rotation check
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  • READ THE FOLLOWING INSTRUCTIONS CAREFULLY AND EXAMINE ALL THE PHOTOS FIRST TO LEARN HOW TO CONFIGURE THE MACHINE FIRST BEFORE PROCEEDING.
  • IT IS NECESSARY TO CHECK IF STEPPER MOTOR IS ROTATING IN CORRECT DIRECTION. IF IT IS ROTATING FORWARD DIRECTION WHEN PRESSED CW BUTTON, SKIP STEP 16 AND PROCEED TO STEP 17. IF IT IS ROTATING TO BACKWARDS WHEN PRESSED CW BUTTON, STOP THE MOTOR AND PROCEED TO THE STEP 16.
  • MAKE SURE THAT THERE IS ABSOLUTELY NO POLYMER PELLETS OR FOREIGN OBJECTS PRESENT INSIDE THE FEEDER OR BARREL SECTION! CLEAN AND REMOVE ANY POLYMER PELLETS OR FOREIGN OBJECTS IF NEEDED!
  • Set the motor speed to 060.0 which is around 6RPM.
  • Press the CW button once and confirm CW light indicator turns on. This will start the motor to normal direction. If motor does not turn or turns ultra slow move the rotary knob one step to any direction. This will kickstart the motor.
  • Check the current meter value. It should be around 0.40 amps when motor is running empty and there is no material is present. It is ok if it shows slightly lower or higher value than 0.40 amps. That range can between anywhere in 0.30 to 0.50 amps.
  • Open the shaft inspection door and check if the shaft coupler is turning properly. Leave it open.
  • Look down inside the feeder chute and check if the screw is rotating in forward direction towards to the nozzle as shown on video. IF IT IS MOVING TO BACKWARDS TOWARDS TO THE MOTOR, POWER OFF THE MACHINE AND PROCEED TO STEP 16. OTHERWISE IF THE ROTATION DIRECTION IS FORWARDS TOWARDS TO THE NOZZLE SKIP STEP 16 AND PROCEED TO STEP 17.

Step 16: Stepper motor backwards rotation correction
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  • READ THE FOLLOWING INSTRUCTIONS CAREFULLY AND EXAMINE ALL THE PHOTOS FIRST TO LEARN HOW TO CONFIGURE THE MACHINE FIRST BEFORE PROCEEDING.
  • ONLY COMPLETE THIS STEP IF EXTRUSION SCREW ROTATING BACKWARDS TOWARDS MOTOR AS SHOWN ON STEP 15. OTHERWISE SKIP THIS STEP AND PROCEED TO STEP 17.
  • Power down the machine by switching off rotary button.
  • Open panel PB2 to access stepper driver.
  • Locate the SA1 on A+ and SA2 on A- on stepper driver and replace them to SA1 to A- and SA2 to A+. This will reverse the motor running direction. Once the switch is made, close back the PB2 panel and power on the machine again.

Step 17: Needle thrust bearing PTFE lubricant application
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Next
  • READ THE FOLLOWING INSTRUCTIONS CAREFULLY AND EXAMINE ALL THE PHOTOS FIRST TO LEARN HOW TO CONFIGURE THE MACHINE FIRST BEFORE PROCEEDING.
  • WE RECOMMEND TO REPEAT THIS PROCESS EVERY 3 MONTHS TO KEEP THE NEEDLE THRUST BEARING PROPERLY LUBRICATED.
  • Keep the motor running according to settings applied on step 15. Remove the panel PT2 by loosening the 6 screws marked on photo.
  • Locate the bearing lubricant chute between feeder cooler fan assembly and shaft assembly. It is a small wide opening that goes all the way down to the needle thrust bearing assembly.
  • Make sure that there is not any debris present inside the chute channel. Clean it if needed.
  • Start with applying a few drops of PTFE lubricant through the lubricant chute opening. Make sure that lubricant glides down all the way to the needle thrust bearing. Usually 10 to 15 drops of lubricant is sufficient. DO NOT OVERAPPLY THE LUBRICANT. IT MIGHT OVERFLOW AND DRIPS UNDER THROUGH THE MACHINE.
  • Wait and check for around one minute until the lubricant penetrating the needle thrust bearing while motor is running.
  • When finished turn off the motor by pressing RUN/STOP button on stepper controller. Put back the PT2 panel and tighten back all the screws to secure it in place.

Step 18: Shaft coupler calibration check - Preperation
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Next
  • READ THE FOLLOWING INSTRUCTIONS CAREFULLY AND EXAMINE ALL THE PHOTOS FIRST TO LEARN HOW TO CONFIGURE THE MACHINE FIRST BEFORE PROCEEDING.
  • Set the zone 1 temperature to 210C and fan settings to lowest.
  • Set the zone 2 temperature to 205C and fan settings to lowest.
  • Set the zone 3 temperature to 190C and fan settings to highest. Then wait for at least 15 minutes until the temperatures settles.
  • After temperatures are settled, set the motor speed to 060.0 and press CW button to start the motor. Do not forget to turn the knob slightly to either direction if the motor does not start when CW button is pressed.
  • Check the current meter value. It should be around 0.40 amps when motor is running empty and there is no material is present. It is ok if it shows slightly lower or higher value than 0.40 amps. That range can between anywhere in 0.30 to 0.50 amps.

Step 19: Shaft coupler calibration check - Extrusion test
Previous
Next
  • READ THE FOLLOWING INSTRUCTIONS CAREFULLY AND EXAMINE ALL THE PHOTOS FIRST TO LEARN HOW TO CONFIGURE THE MACHINE FIRST BEFORE PROCEEDING.
  • WE DO RECOMMEND USING DRIED RAW (VIRGIN) PLA PELLETS FOR THIS STEP. DRY THE PLA PELLETS WITH A PROPER DRYER MACHINE OR DEHYDRATOR FOR AT LEAST 2 HOURS AT 60C RIGHT BEFORE EXTRUSION. START EXTRUDING RIGHT AWAY SINCE IT CAN START COLLECTING MOISTURE AGAIN AS SOON AS DRYING IS COMPLETE.
  • PLEASE NOTE THAT EXTRUDED FILAMENT ON THIS STEP MIGHT LOOK ROUGH, UNDEREXTRUDED, NOT PROPERLY MELTED AND MIGHT CONTAIN ARTIFACTS. THIS IS NORMAL AND EXPECTED SINCE THE TEMPERATURE AND MOTOR SPEED SETTINGS THAT ARE PROVIDED IS ONLY FOR SHAFT COUPLER CALIBRATION PURPOSES AND NOT AIMED FOR PERFECTLY DIALED EXTRUSION SETTINGS.
  • EVERY PLASTIC TYPE REQUIRES DIFFERENT TEMPERATURE AND MOTOR SPEED SETTINGS. EVEN DIFFERENT BRAND OF PLA HAS COMPLETELY DIFFERENT EXTRUSION PARAMETERS. IT IS REQUIRED TO MAKE A LOT OF EXPERIMENTATION TO FIND OPTIMAL EXTRUSION SETTINGS. IT WILL BE EXPLAINED ON HOW TO PROPERLY EXTRUDE A FILAMENT ON UPCOMING "OPERATION AND EXTRUSION MANUAL" THAT IS CURRENTLY UNDER DEVELOPMENT.
  • When heaters are on and motor is turning fill the feeder port with PLA pellets as shown amount.
  • Check the current meter constantly. It should be around 0.50 amps to 0.80 amps range.
  • While checking the current meter also check the shaft coupler from inspection window constantly. The spacing between shaft coupler should stays same.
  • Wait until filament starts to come out from nozzle. KEEP CONSTANTLY CHECKING THE SHAFT COUPLER FROM INSPECTION WINDOW AND CURRENT METER UNTIL ALL THE PLASTIC IS EXTRUDED AND FEEDER IS EMPTY.
  • If shaft coupler spacing stays same after 10 minutes it is considered good calibration and no further action is necessary. If the gap between the shaft couplers stays same but current meter still keeps increasing, that indicates melt temperature is low. In that case stop the motor and increase the temperature of zone 1 and zone 2 heaters by 10C. Wait for at least 5 minutes and start the motor again.
  • If the current meter indicator starts increasing and approaches around 1.00 amps and more, inspect the shaft coupler to check if the gap is dangerously narrows. If that is the case shaft coupler parts might starts to touch each other and can push pressure on gearbox and possibly damage it. Stop the motor immediately by pressing RUN/STOP button on stepper controller. Keep the heaters on, empty the remaining plastic pellets from hopper with vacuum cleaner and go back to step 10 to repeat the shaft coupler calibration process.

Step 20: Finalization
Previous
Next
  • READ THE FOLLOWING INSTRUCTIONS CAREFULLY AND EXAMINE ALL THE PHOTOS FIRST TO LEARN HOW TO CONFIGURE THE MACHINE FIRST BEFORE PROCEEDING.
  • DO NOT LEAVE ANY PLASTIC PELLETS INSIDE THE FEEDER ZONE. EITHER WAIT UNTIL ALL THE PLASTIC IS EXTRUDED OR CLEAN IT WITH A VACUUM CLEANER.
  • Wait until all the plastic is extruded, no more pellets are present inside the feeder zone and no more filament is coming out of the nozzle.
  • Close back the inspection window cover.

First time startup is done!
  • Extrude time!

IMPORTANT OPERATIONAL RULES!

NEVER LEAVE THE MACHINE UNATTENDED DURING NORMAL OPERATION EVEN FOR A VERY SHORT PERIOD OF TIME!
NEVER RUN THE MOTOR IF THE HEATERS ARE TURNED OFF. IT MIGHT DAMAGE THE EXTRUSION SCREW.
AVOID RUNNING THE MOTOR FOR MORE THAN 5 MINUTES IF NO MATERIAL IS EXTRUDED. IT MIGHT WEAR OFF THE EXTRUSION SCREW UNNECESSARILY.
ALWAYS HEAT THE MACHINE TO EXTRUSION TEMPERATURE FIRST BEFORE RUNNING THE MOTOR.
WAIT 15 MINUTES MINIMUM UNTIL TEMPERATURE SETTLES INSIDE BARREL.
DO NOT STORE ANY HIGHLY FLAMMABLE MATERIALS AROUND THE MACHINE.
DO NOT ATTEMPT TO FEED/EXTRUDE ANY TYPE OF LIQUID OR LIQUID/SOLID MIXTURE OF MATERIAL INSIDE THE EXTRUSION BARREL.
MACHINE IS ONLY DESIGNED TO WORK WITH COMPATIBLE NON FLAMMABLE SOLID MATERIALS SUITABLE FOR EXTRUSION FOR UP TO 300C.
ALWAYS MONITOR THE OUTPUT TEMPERATURE FOR ANY ABNORMAL BEHAVIOUR.
ALWAYS OPERATE THE MACHINE INDOORS WITH ENOUGH VENTILATION.
ALWAYS HAVE A FIRE EXTINGUISHER NEARBY AS A PRECAUTION!

1.Frame

2.Electronics

3.Mechanical

4.Panels – Part 1

5.Panels – Part 2

6.Wiring

7.First Time Startup

7.First Time Startup

Previous Section - Wiring Assembly

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