# Pulsar™ Atom Precision Pellet Extruder

# Revision

Date Revision Modifications
2023-11-28 R001 Initial Release

# Specifications

See product specification here. (opens new window)

# General

# What’s Included

Item Quantity
Pulsar™ Atom Precision Pellet Extruder 1
Mounting Hardware (4* M4 x 10 Low Profile Cap Screw 1

# Available accessories with your Pulsar™ Atom Extruder

Item Quantity
25A 660VAC Solid State Relay (SSR) 2
Stepper Driver:
- Dyze Design’s Digital Stepper Motor Driver
- Ethernet/IP Stepper Driver (STF06)
1
Cable Harness (5m long)
- Hotzone
- Coldzone
- Power harnesses
1
PT100 Amplifier Boards
- Dyze Design’s PT100 Amplifier Boards
- Duet PT100 Daughter Boards
2
PID Temperature Controller (NOVUS N1040) 1
Dyze Design’s Liquid Cooling System 1
Dyze Design’s Pellet Feeding System 1
Liquid Cooling Fitting Kit
- 4* M8 x 1.00 Elbow
- 2* M8 x 1.00 Plug
- 2 * Water Cooling Blocks
- Required Fasteners
1
High Temperature Liquid Cooling Tubing Sold by the meter
High Temperature Pellet Sensor 1
Part Cooling Kit
- Axial Fan Assembly
- 2* Part Cooling Bracket
- Required Fasteners
1

* If you need any of these items, contact sales.

# What’s required

  • 24VDC Power Supply
    • Required for the Pulsar™ Atom cooling fan
    • Required for the pellet sensor
    • Required for the Part Cooling Add-On
    • Required for the Water Cooling Add-On (if using Dyze Design liquid cooling)
  • 24-50VDC Power Supply
    • For driving the stepper driver
  • AC supply 50 or 60 Hz required for the heating elements totaling 400W
Heater Nominal Tension (V) Lower range (V) Higher range (V)
110V Heatcore 100 130
220V Heatcore 200 240

Note : Power is sized based on nominal tension value. Power will be reduced or increased depending on supplied voltage according to Ohm’s Law

  • 2 x PT100 Amplifier circuits.
    • Dyze Design amplifier
    • RTD Amplifier for Duet & RepRapFirmware
    • Any other equivalent
  • Any open-source, firmware available, 3D Printer Controller Board
    • Open Source types:
      • Duet3D
      • BTT SKR
      • BTT Octopus
      • MKS
      • SmoothieBoard
      • Rambo
    • CNC Type
      • 4th axis
      • Temperature control
    • Robotic Arm
      • Dyze Design Robotic Arm Controller
  • Liquid Cooling System (if using Water Cooling Add-on)
    • Dyze Design can offer a custom liquid cooling system tailored for 3D printing as an add-on with your extrusion system

# Safety Notice

Pulsar Atom Heat Hazard and Electrical Hazard

Heat Hazard

This product generates heat and can cause burns. When performing maintenance, ensure it has cooled down completely before touching any heated parts.

Electrical Hazard

During maintenance, exercise extreme caution to prevent electric shock. Ensure the product is disconnected from the power source before performing any maintenance tasks. Do not touch exposed wires or components. Prioritize safety at all times

# Critical Don'ts

# Do not insert pellets larger than 2.75mm

This product is engineered for peak performance with pellets under 2.75mm in size. Although pellets ranging from 2.75-3mm may function in certain scenarios, stability cannot be assured. Pellets exceeding 3mm in size will be unable to access the extrusion screw, thereby impeding the process.

# Use with proper product cooling (Air or Water)

Insufficient cooling on the feeding section can lead to overheating and malfunctioning of the product. In such cases, you may need to remove the heatzone for maintenance to clear any clogs.

# Never drill any parts from the product

Some parts are hardened, others have a specific surface roughness. The drill could damage or get broken and stuck inside the unit.

# Avoid prolonged idle periods

Avoid operating the product for prolonged durations without extrusion: In some instances, this may cause polymer degradation, leading to system clogs.

# Prevent extended exposure to acidic materials, even during downtime

Make sure not to leave acidic materials in the barrel. It's essential to consistently purge such materials to prevent any degradation of the material. Some PLA and polymer blends have the potential to induce material degradation.

# Be cautious of excessive retraction

Refer to the retraction section for guidelines. Retracting beyond half a turn can lead to molten polymer traveling upward in the system, causing clogging issues.

# Watch out for overcurrent on the motor

Overcurrent can cause the motor to overheat, increasing the temperature in the feeding section. This may result in malfunction and clogging.

WARNING

Motors damaged by overcurrent are not covered under our warranty policy.

# Unboxing and Initial Assembly

# Intended Use

The Pulsar™ Atom is a precision-engineered 3D printing solution optimized for industrial use. Its versatility extends to compatibility with a broad spectrum of thermoplastics commonly found in industrial settings. Designed to boost production efficiency, this innovation embodies our commitment to advancing industrial manufacturing processes.

WARNING

It is of critical importance that you carry out an inspection upon unboxing your Pulsar™ Atom Extruder. In the unlikely event that there’s damage or any issue. Get in touch with Dyze Design’s support team.

Dyze Design is not responsible for the Atom's control, integration to the 3D printer or robotic arm (summarized as motion system) and firmware.

Safe control and operation of the Atom requires the motion system to have a proper firmware with enabled safety features compiled by qualified personnel as well as a physical emergency button which cuts power to the Atom.

Safe maintenance requires the Motion System to be powered off and for the Atom and the motion system to have cooled down. Safe maintenance is to be done by qualified personnel familiar with this user manual.

Contact our support team if you require assistance.

INFO

Training and specialized support could also be offered on demand as part of our service plans. (Contact sales for more information)

# Installation / Mounting

The Pulsar Atom is mounted from the front using 4 X M4 thru holes.

Check out our drawing page to get the 3D STEP file. Design your bracket according to the available mounting options.

On the CAD file, consider the following references:

  • 4.20mm holes are clearance for M4 screws

Pulsar Atom Mounting

# Water Cooling Add-On

The Pulsar™ Atom comes with an air cooling system, engineered to operate effectively at ambient temperatures not exceeding 50°C. To enhance operating temperature, we offer the choice of incorporating water cooling blocks, allowing for sustained functionality at temperatures of up to 150°C. The two available blocks are:

  • Motor Cooling Block
  • Fan Replacement Block

Pulsar Atom Water Cooling Add-On

Recommended Tubing : Ø6.35 mm (1/4") ID x Ø9.53mm (3/8") OD

# Part Cooling Add-On

If your polymers require active cooling, you can opt to install an additional part cooling accessory.

To install it, follow these steps:

  1. Loosen the M3 screws found at the bottom of the Hotzone shield on one side.
  2. Secure the bracket in place using the provided M3X0.5 X 8 screws.
  3. Repeat the same process on the opposite side.
  4. Connect the fans to the connector situated beneath the motor, located at the rear of the hotzone.

Pulsar Atom Water Cooling Add-On

These steps ensure the proper installation of the part cooling add-on, enhancing the cooling capabilities of your system for optimal performance with specific polymers.

# Wiring

It is possible to order custom length harnesses designed to connect the Atom to your printer. The diagrams below provide additional details regarding the electrical connections:

Pulsar Atom Electrical Connections

Pulsar Atom Wiring Scheme

# Emergency Stop

The Pulsar Atom Extruder does not have an emergency stop feature. An emergency stop loop is a must to operate the Extruder safely. The emergency stop must cut the power to the heating elements and the power supply of the motor. This feature can be implemented in your 3d printer firmware and control interface or physically in your control cabinet.

# Heaters

Each heater has its own SSR. Two SSR can be provided with the Atom.

The fuse is optional but strongly suggested. Each fuse should be rated according to the power rating:

  • Top heater, 250 Watts, 2.5A for 120VAC and 1.25A for 240VAC systems
  • Bottom heater, 150 Watts, 1.5A for 120VAC and 0.75A for 240VAC systems

Many pins can be used as the temperature output control. Your 3D Printer Controller (or motion controller) pins can be as below:

The standard extruder output (E0, E1, E2, etc). These are usually rated at the same voltage as your main power supply (12VDC or 24VDC). Any available expansion pins. These can be determined by checking the 3D Printer Controller specification pins.

Please refer to the above diagram for wiring the Atom.

# Stepper Driver

# Using your own stepper driver

It’s possible to use your own stepper driver. However, make sure it can drive the motor with the specifications below, especially the current. We won’t be able to offer adequate support if an insufficient stepper driver is used.

Drive Voltage 24-48VDC
Motor Current 1.68A
Frame size NEMA17

# Using Dyze Design's Stepper Driver

If you're using our Dyze Stepper Driver, you can refer to our Pulsar Atom Quick Start Guide here..

# 3D Printer Guideline

# General

Printing without cooling is only possible with large parts. Thick and large layers take time to cool down, thus requiring you to reduce speed for small parts.

# Use Z lift

Raising the Z axis between each fast-travel is required. It will prevent any collision with the printed part. See the Slicer section for more info.

# Width line and layer height

Layer height and width are contingent on the nozzle size. Below, you'll find a table that outlines the minimum, maximum, and advisable configurations. For additional details, please consult our informative article. (opens new window)

Nozzle Size (mm) Min. Max. Line Width (mm) Recommended Line Width (mm) Min. Max. Layer Height (mm) Recommended Layer Height (mm)
0.40 0.24-0.80 0.60 0.10-0.32 0.20
0.60 0.36-1.20 0.90 0.15-0.48 0.30
0.90 0.54-1.80 1.35 0.23-0.72 0.45
1.20 0.72-2.40 1.80 0.30-0.96 0.60
1.80 1.08-3.96 2.70 0.45-1.44 0.90
2.50 1.50-5.20 3.75 0.63-2.00 1.25

# Consider thermal expansion

It’s critical to consider the heat cylinder thermal expansion when doing the bed leveling.

For instance, when leveling at room temperature, the printing head will be 0.25mm lower. Therefore, exercise great care when conducting Z homing due to this thermal expansion effect.

For bed leveling with a cold extruder (20°C), make sure you compensate the thermal expansion:

Temperature (°C) Extra length (mm)
200 0.37
300 0.57
400 0.77

# Robotic Arm Guideline

If you plan on installing the Atom on a robotic Arm, you'll need to get some extra hardware to get the same features as a 3D printer controller. These items are the following:

  • A motion planner capable of outputting STEP / DIR pulses for the stepper driver.
  • Two (2) PT100 temperature sensor inputs.
  • Two (2) digital outputs to drive the SSRs.

TIP

Dyze Design is now offering an ethernet/ip controller to enable sync between your robot/robot controller and the Atom extruder (motor & flow control, heating elements, etc). Contact sales for more information.

# Firmware

# Marlin Firmware

2.0.x

# Configuration.h

Set number of extruders:

#define EXTRUDERS 2

Set the correct temperature sensor values. Please refer to Marlin thermal settings (opens new window) to find the correct value based on your amplifier circuit or your actual setup.

#define TEMP_SENSOR_0 68 //could also be 20 or 21. Check the Marlin thermal settings.
#define TEMP_SENSOR_1 68 //could also be 20 or 21. Check the Marlin thermal settings.

Set temperature min temp:

#define HEATER_0_MINTEMP 19
#define HEATER_1_MINTEMP 19

Set temperature max temp:

#define HEATER_0_MAXTEMP 500
#define HEATER_1_MAXTEMP 500

The heaters are very powerful, which is required for engineering and advanced polymers. If you are planning on printing low temperature, reduce the bang_max from 255 to 127.

Set temperature bang_max:

#define BANG_MAX 127

Increase the PID_functional_range:

#define PID_FUNCTIONAL_RANGE 40

Set the base PID values:

 #define DEFAULT_Kp 2.85
 #define DEFAULT_Ki 0.07
 #define DEFAULT_Kd 27.57

Set the extruder steps per mm:

TIP

{X Axis, Y Axis, Z Axis, E Axis} The value of the XYZ axis may vary and are shown as XXX.XX. The value of 818.1 serves as an initial reference point. Calibration will be necessary to optimize it for your specific configuration. You can find instructions for this calibration process in the "Calibrating the flow" section.

#define DEFAULT_AXIS_STEPS_PER_UNIT   { XXX.XX, XXX.XX, XXX.XX, 818.1 }

Set the max feed rate:

TIP

{X Axis, Y Axis, Z Axis, E Axis} The value of the XYZ axis may vary and are shown as XXX.XX

#define DEFAULT_MAX_FEEDRATE          { XXX, XXX, XXX, 200 }

Switch enable logic for the extruder motor:

#define E_ENABLE_ON 1

# Configuration_adv.h

Configure the external stepper driver

#define MINIMUM_STEPPER_POST_DIR_DELAY 500
#define MINIMUM_STEPPER_PRE_DIR_DELAY 500
#define MINIMUM_STEPPER_PULSE 3
#define MAXIMUM_STEPPER_RATE 200000

# PID tuning

Each heater needs to be tuned separately, use the M303 command in the console to run the tuning cycle as detailed here: https://marlinfw.org/docs/gcode/M303.html (opens new window) Run the PID tuning without any material inside the barrel or only set a PID target temperature within your material range to avoid clogs.

Example:

M303 E0 S300		;tune heater 0 with a target temperature of 300C

Once the tuning cycle is completed, save the new heater 0 values by entering the M500 command in the console (only works if EEPROM_SETTINGS is enabled in your firmware).

Repeat the process for the second heater. Example:

M303 E1 S300 		;tune heater 1 with a target temperature of 300C

# RepRap Firmware

TIP

In your configuration file, you should find values similar to the ones below. However, we do recommend that you use the online ReRap Firmware configurator tool (opens new window).

WARNING

The following information is based on Duet 2 and RepRap Firmware 3.x. We strongly suggest that you also read the official Duet/RepRap documentation (opens new window) to make sure you correctly connected and configured your Duet board, PT100 (RTD) amplifier board and RepRap firmware version.

# Config.g

Set the correct temperature sensor values. Please refer to Duet documentation to find the correct value based on your amplifier circuit.

TIP

For the Duet 3 MB6HC, pins spi.cs1 and spi.cs2 should be replaced with spi.cs0 and spi.cs1.

M308 S1 P"spi.cs1" Y"rtd-max31865"    		 	; configure sensor 1 as PT100 on pin e0temp
M308 S2 P"spi.cs2" Y"rtd-max31865"             ; configure sensor 2 as PT100 on pin e1temp

Set temperature max temp:

M143 H0 S500
M143 H1 S500

Set the extruder steps per mm:

M92 XXXX.X YXXX.X ZXXX.X E818.1

TIP

The value of 818.1 serves as an initial reference point. Calibration will be necessary to optimize it for your specific configuration. You can find instructions for this calibration process in the "Calibrating the flow" section.

Set the max feed rate:

M203 XXXXX YXXXX ZXXXX E3000

Assign heaters 1 and 2 to the same tool:

M563 P0 D0 H1:2 S"PulsarAtom"

Configure external stepper drivers (only if using the external stepper driver):

M569 PXXX SXXX R1 T2

# PID tuning

The two heaters need to be tuned separately as it is not yet possible in RepRap to tune both at the same time.

Run the PID tuning without any material inside the barrel or only set a PID target temperature within your material range to avoid clogs.

Using the M303 command in the Duet console, run the PID tuning for each heater as explained here: https://docs.duet3d.com/User_manual/Reference/Gcodes#m303-run-heater-tuning (opens new window).

Example:

M303 H1 S300		;tune heater 1 with a target temperature of 300C

Once the tuning cycle is done for heater 1, copy the generated M307 command and replace them in your config.g file to the appropriate line.

Then, we tune heater 2 following the same procedure.

Example:

M303 H2 S300		;tune heater 2 with a target temperature of 300C

Copy the generated M307 command for heater 2 and replace it in the config.g file.

The heaters are very powerful, which is required for engineering and advanced polymers. If you are planning on printing low temperature, reduce the maximum PWM by 50%.

If you encounter an overshooting error when trying to heat up the two heaters at the same time, try lowering the PWN value of the problematic heater even more.

Set maximum PWM (Change HX by H0, H1, H2, etc. based on your heater configuration):

M307 H1 S0.50	;the S parameter will depend on your setup
M307 H2 S0.40	;the S parameter will depend on your setup

# Repetier Firmware

TIP

In your configuration file, you should find values similar to the ones below. However, we do recommend that you use the online Repetier Firmware configurator tool (opens new window).

# Configuration.h

Set the correct temperature sensor values. Please refer to Repetier configurator tool (opens new window) to find the correct value based on your PT100 amplifier circuit.

#define EXT0_TEMPSENSOR_TYPE 13
#define EXT1_TEMPSENSOR_TYPE 13

Set temperature min temp:

#define MIN_DEFECT_TEMPERATURE 20

Set temperature max temp:

#define MAXTEMP 500
#define MAX_DEFECT_TEMPERATURE 505

The heaters are very powerful, which is required for engineering and advanced polymers. If you are planning on printing low temperature, reduce the bang_max from 255 to 127.

Set maximum power output:

#define EXT0_PID_MAX 127
#define EXT1_PID_MAX 127

Set the extruder steps per mm:

#define EXT0_STEPS_PER_MM 818.1

TIP

The value of 818.1 serves as an initial reference point. Calibration will be necessary to optimize it for your specific configuration. You can find instructions for this calibration process in the "Calibrating the flow" section.

Set the max feed rate:

#define EXT0_MAX_FEEDRATE 200

Switch enable logic for the extruder motor:

#define EXT0_ENABLE_ON 1

# Configuration_adv.h

Configure the external stepper driver (if using the external stepper driver):

#define STEPPER_HIGH_DELAY 2
#define DIRECTION_DELAY 2

# PID tuning

Each heater needs to be tuned separately, use the M303 command in the console to run the tuning cycle as detailed here: https://github.com/repetier/Repetier-Firmware/blob/master/src/ArduinoAVR/Repetier/Repetier.ino#L191C3-L194C40 (opens new window)

Run the PID tuning without any material inside the barrel or only set a PID target temperature within your material range to avoid clogs.

Example for heater 0:

M303 P0 S300 X0 R4 C0 ;tune heater 0 with target temperature of 300C, saves result in EEPROM, 4 cycles, classic method

Once the first heater is tuned, run the tuning for the second heater with M303 again.

Example for heater 1:

M303 P1 S300 X0 R4 C0 ;tune heater 1 with target temperature of 300C, saves result in EEPROM, 4 cycles, classic method

# Using the Pulsar™ Atom extruder

# Requirements for “Mini” Pellets

Given the product's scale, this extruder is tailored for smaller pellets with a maximum dimension of 2.75mm.

The image below illustrates exemplary pellets.

Note that employing standard 5mm pellets with this extruder will lead to extrusion failure. Such pellets are unable to enter the extrusion screw due to their size, thereby thwarting the extrusion process. It is imperative to use solely the specified mini pellets to ensure correct operation.

Mini Pellets (Micro Pellets)

If sourcing smaller pellets poses a challenge, reach out to our sales team. Dyze Design can currently supply mini pellets for the following materials:

  • PLA
  • PETG
  • rPETG

*Our range of materials is continuously expanding.

# Powering on the unit

Once the unit is mounted, the software is configured and electrical connections are finished. The next step is to power the unit.

While the unit is empty perform the following verification :

  • Make sure the cooling system is in functional condition, may it be air or watercooled
  • Low speed extrusion command (5RPM)
    • Confirm that the screw rotation is counterclockwise when inspecting the screw from the feeding section. Removing the hopper assembly is necessary to inspect the screw.
  • Setpoint to a low temperature (50-75°C) on the top heater
  • Make sure the matching sensor reads
  • Setpoint to a low temperature (50-75°C) on the bottom heater
  • Make sure the matching sensor reads

# Pellet Feeding

Pellet feeding into the extruder can be achieved via three distinct methods:

  • Automated Pellet Feeding
    • Utilizing Dyze's Automatic Pellet Feeding System
    • Custom-Made Solutions
  • Gravity Feeding
  • On-Board Hopper

Each method presents its own set of advantages and drawbacks. This product is chiefly engineered to excel with an automatic pellet feeding system, enriched by its integrated pellet sensor. Nonetheless, when employing gravity feeding, the sensor transitions into a pellet runout detector, broadening its utility.

# Slicer and Print Settings

  • Set vertical lift to at least your layer thickness. For layers of 1.00mm, lift 1.00mm. Slicers aren’t yet optimized for large prints. Many over-extruded sections will be noticeable. Lifting the head will prevent any collision with the printed part.

  • Wipe nozzle to at least the line width. For a line width of 3.50mm, wipe 3.50mm or greater.

  • Set the heating to both heaters to the required temperature in the start Gcode script. Make sure to refer to your slicer documentation for variable names.

M109 T0 S[first_layer_temperature]
M109 T1 S[first_layer_temperature]
  • Set end script to turn off both extruders:
M104 T0 S0 ; turn off extruder
M104 T1 S0 ; turn off extruder
  • Output flow and pressure greatly changed depending on the printing speed. To get the best result, keep the output flow steady by keeping the same speed everywhere.

# Calibrating the flow

The extrusion throughput depends on various factors, including temperatures, polymer type, nozzle size, pellet geometry, and more. For achieving the best results, we recommend calibrating the flow pourcentage whenever there is a change in a variable that could impact the flow.

To perform this calibration, you can use a basic single wall thickness cube. The flow percentage can be adjusted using the following formula:

New Flow Rate Formula

As an example, let's say we print a 1.5mm wall thickness cube using a 1.2mm nozzle, and initially, the flow percentage is set at 100%. After measuring, we find that the actual wall thickness is 1.69mm.

To calculate the new flow percentage, you would use the formula as follows:

New Flow Rate Formula Example

Therefore, the new flow percentage should be set to approximately 88.76 for optimal calibration in this scenario.

Achieving precise calibration often requires multiple iterations.

Calibrating 2-3 times in a row can help fine-tune the extrusion process and ensure more accurate and consistent results.

# Using retraction

To mitigate oozing and globbing, since there's no inherent anti-oozing feature, retraction can be utilized. Yet, exercising caution during retraction is imperative. In operation, the screw of the pellet extruder should never rotate clockwise beyond half a turn.

Overzealous clockwise retraction could propel melted material into unwanted regions, posing a risk of flow obstructions.

A half turn equates to 9974 steps (given a 3200 steps/revolution setting). If a conversion to millimeters (mm) is necessary, employ the formula below:

Retraction Formula

# Non Planar/Angled Printing

The clearance angle around the nozzle is depicted in the accompanying image. The addition of the Part Cooling Add-On decreases the 44° clearance to 9°.

Pulsar Atom Angled Printing

Gravity exerts a significant influence on the flow of pellets, causing a decreased flow rate for the Atom when it is inclined. To ensure optimal performance when inclining the product, please take note of the following recommendations:

  • Minimize forward inclinations.
  • When possible, favor backward angles over lateral angles.

Pulsar Atom Possible Angles

# High Temperature Use

The Pulsar™ Atom, along with its various add-ons, is designed to operate within an environmental temperature range of up to 50°C. Certain components have temperature limitations as follows:

  • The product cooling fan and part cooling fans can both function effectively up to 60°C.
  • The pellet sensor has a higher temperature threshold of up to 70°C

If you intend to use this product in an environment with temperatures as high as 150°C, you should take the following factors into account:

  • Implement the Water Cooling Add-on.
  • Consider our Dyze Design’s Liquid Cooling System, should the need arise.
  • Opt for High Temperature Liquid Cooling Tubing.
  • Replace the included pellet sensor with a high-temperature version.
  • Ensure that the pellet convey tubing is resistant to high temperatures.
  • Ensure that the cable harnesses are resistant to high temperatures.
  • Do not use the Part Cooling Add-on in high-temperature environments.

INFO

We can assist you in acquiring any necessary upgrades or custom components required for high-temperature environments. If you need any of these items or questions, contact sales.

# Maintenance & Troubleshooting

# Safety Notice Reminder

Pulsar Atom Heat Hazard and Electrical Hazard

Heat Hazard

This product generates heat and can cause burns. When performing maintenance, ensure it has cooled down completely before touching any heated parts.

Electrical Hazard

During maintenance, exercise extreme caution to prevent electric shock. Ensure the product is disconnected from the power source before performing any maintenance tasks. Do not touch exposed wires or components. Prioritize safety at all times

# Clogged Nozzle

# Causes

Clogging can be caused by a few factors. Make sure you understand which one is causing the issue and solve it before attempting a new print.

  1. Bad slicer settings
  • Too high retraction. Make sure you are not pulling the molten polymer too high. Refer to the retraction section
  • Too high volumetric flow. Make sure you aren't asking too much of the Pulsar Atom. Thick and wide lines are misleading since a slow printing speed can still represent a high volumetric throughput.
  1. Bad pellet conditions
  • Pellets are not dry. Pellets containing a lot of moisture will foam at the entry and greatly increase the friction. The print quality will also greatly suffer.
  • Wrong temperatures. Usually, because of the very long melting zone, lower temperature can lead to better results.
  1. Overheating in the feeding section
  • Try reducing the feed top heater temperature by 10°C
  • Make sure the cooling system (water or air) is running properly
  • Check the motor current which might be overheating

# Solution

  1. Temporary extrude hotter
  • Raise the temperature by steps of 10°C.
  • Wait until the setpoint is reached.
  • Send a slow extrusion command such as the one below.
G0 F60 E25
  • Repeat until the extruder is unclogged or the temperature is too high.

# Gears

Maintaining adequate lubrication of the gears is vital for ensuring the product's longevity and seamless operation. Access to the grease ports is achievable by removing the hotzone shield. As you turn the motor, administer white lithium grease into these ports.

It's notable that the Pulsar Atom is pre-lubricated with white lithium grease of ISO Viscosity Grade 150. For a streamlined grease application, employing a compact grease gun, such as the Astro Mini Grease Gun, could prove beneficial.

Pulsar Atom Grease Ports

# Periodic Inspection

For prolonged durability of the gearbox and its components, we advocate for routine thorough inspections and maintenance. It's prudent to regularly examine all gears and the housing.

To facilitate this, detach the top cover from above to unveil the gears. Utilize towels to clear away the majority of the aged grease. Substitute any gears exhibiting significant wear marks or with diminished teeth.

# Hopper Vent Plate

Utilizing the automatic pellet system entails the propulsion of pellets and dust through the system via compressed air. Over a period, polymer dust may accumulate within the vents, potentially causing an exhaust blockage.

Such blockages can subsequently impair the feeding system. To prevent this, it's advisable to clean both sides of the hopper vent plate periodically. This can be done by disassembling the coldzone shield and inlet plate.

Pulsar Atom Hopper Vent Plate Maintenance

# Emptying the Hopper

Once pellets are lodged within the hopper, emptying it without spillage becomes a non-trivial task.

The alternatives at your disposal include either extruding the pellets until the hopper is entirely vacant, or employing a vacuum to extract the pellets through the inlet tube.

# Hotzone Removal

The hotzone can be removed for maintenance or troubleshooting purposes. To do this, you will need the following tools:

  1. 2.5mm allen key
  2. Heat Protection Gloves

Hotzone Removal

Follow these steps for hotzone removal:

  1. Move the Z-axis upwards until the nozzle is at least 150mm away from the bed.
  2. Heat the hotzone to extrusion temperatures.
  3. Ensure the product is entirely free of any polymer by extruding it.
  4. Power off the product and disconnect both the power and hotzone connectors.
  5. While the hotzone is still hot enough to contain molten polymer, unscrew the four M4 screws that join the coldzone and hotzone.
  6. Be prepared to hold the hotzone using heat protection gloves.
  7. You may need to gently pull on the heatzone to separate it from the extrusion screw.

# Hotzone Installation

To install a heatcore, you will require the following tools:

  • 2.5mm allen key
  • Heat Protection Gloves
  • Mild steel tweezers
  • Heat gun

To perform the installation, follow these steps:

  1. Use a heat gun to heat the extrusion screw until the polymer becomes somewhat soft.
  2. Employ mild steel tweezers to remove any excess polymer that may protrude from the screw's flights, as this can hinder the screw from entering the barrel.
  3. Raise the Z-axis until the tip of the screw is at least 150mm above the bed.
  4. Connect the power and hotzone connectors.
  5. Position the heatzone over the bed and start heating it to extrusion temperatures.
  6. While heating, use mild steel tweezers to eliminate any polymer film that may have formed at the entrance of the barrel.
  7. Power off the product and disconnect both the power and hotzone connectors.
  8. While the hotzone is still hot enough to contain molten polymer, put on heat protection gloves and gently press the heatzone onto the extrusion screw. Be cautious, as polymer may extrude from the nozzle during this process.
  9. Once the heatzone is completely affixed to the screw, secure it in place using the four M4 screws.

# Screw Change

You can remove the extrusion screw for replacement or maintenance. Here are the tools you'll need:

  • 2.0mm allen key
  • 2.5mm allen key
  • 4.0mm allen key
  • Heat Protection Gloves
  • Mild steel tweezers
  • Heat gun
  • 8mm wrench

Pulsar Atom Screw Change

To accomplish this, please adhere to the subsequent steps:

  1. Follow the guidelines outlined in the "Heatzone Removal" section to detach the heatzone.
  2. Remove the coldzone shield and the threaded plug from the top cover.
  3. Hold the screw flats with a 8mm wrench by passing it through the feed.
  4. Unscrew the M3 screw that secures the extrusion screw in place.
  5. Carefully remove the screw.
  6. When installing the new screw, ensure it is correctly inserted into the shaft coupler before tightening the M3 screw.
  7. Follow the instructions provided in the "Heatzone Installation" section to reattach the heatzone.

# Nozzle Change

The nozzle of the Pulsar Atom can be readily removed when needed. To achieve this, please follow these steps:

  • Torque wrench
  • 20mm hex socket

Pulsar Atom Nozzle Change

To do so you need to:

  1. Heat the product to the extrusion temperature.
  2. Power off the product.
  3. Carefully unscrew the nozzle, and be sure to recover the crush washer.
  4. Thoroughly clean both the top and bottom surfaces of the crush washer.
  5. Remove any excess polymer from the barrel, the screw and the nozzle.
  6. Place the crush washer onto the new nozzle.
  7. Install the new nozzle by applying a torque of 8Nm.

# Purging

Purging Compound consists of inert material used to clean the extruder.

General purpose is used in low temperature applications to switch between resins, remove corrosive materials for regular downtime & lightly clean the extrusion screw & barrel.

High temperature is used to clean and flush out engineering material. It’s also useful as a step up to engineering material from low temperature resins or step down from engineering material.

Heavy Scrubbing is used for a deep clean of the extruder. It’s useful to flush burnt or carbonized material to an extent. This needs to be paired with a common purge afterwards.

Here are the steps to follow to purge the hotzone:

  1. Empty the Pulsar’s hopper
  2. Flush the barrel using the extrusion command
  3. Fill the hopper with 50-100 grams of purge
  4. Bring the Pulsar’s to purging temperature (Warning : make sure it’s compatible with the previous resins temperature range)
  5. Extrude until there’s no previous material mixed in the purge

For material change, you might follow the following steps:

  1. Empty the bulk and Pulsar’s hopper
  2. Flush the barrel using the extrusion command
  3. Fill the Bulk hopper with new material
  4. Bring the Pulsar to set temperature (Warning : make sure it’s compatible with the previous resins temperature range)
  5. Extrude until there’s no previous material mixed

# Pellet Sensor Calibration Procedure

Tools Needed :

  • 12mm wrench

Steps to follow:

  1. Fill the hopper with pellets to the desired carrying capacity.
  2. Turn on the pellet feeding controller to power up the sensor.
  3. Unscrew the sensor counterclockwise until the LED turns off.
  4. Screw the sensor a quarter turn clockwise at a time until the red LED turns on.
  5. Lock in the sensor’s position with its nut.
Last Updated: 2/1/2024, 1:19:42 PM