Electron Beam Mealting

Arcam EBM System
Site requirements and

Pre-Installation Guide
Arcam EBM Pre-Installation Guide
Arcam AB
Krokslätts Fabriker 27A
SE-431 37 Mölndal
Sweden
Phone: +46 31 710 32 00

Fax: +46 31 710 32 01
E-mail: info@arcam.com
support@arcam.com
www.arcam.com
Changes regarding specification and details within this document might change without prior notification.
Arcam will not accept any claim regarding damage or loss caused by errors or omissions in this document.
1
1 Document Information
The purpose of this guide is to assist in preparing for the installation of the
Arcam EBM System. The recommendations made within this document are
for reference and any deviation can cause the system to malfunction.
Arcam does not supply all the equipment required for operation of the Arcam
EBM System and will not accept any responsible for the safety or functionality
of any customer-supplied equipment and sub-systems.
Arcam Staff will attend to site for installation connections and commissioning
of the EBM System.
For installation connections, operation and maintenance of the EBM System

please refer to other Arcam documents.
Arcam will not accept any kind of claims for damage or loss caused by errors
or omissions in this document.
2
Table of Contents:
1 DOCUMENT INFORMATION ................................................................................................................................... 2
2 SYSTEM COMPONENTS .......................................................................................................................................... 4
2.1 ARCAM SUPPLIED EQUIPMENT ................................................................................................................................................ 4
2.2 CUSTOMER SUPPLIED EQUIPMENT ........................................................................................................................................... 4
3 TRANSPORTATION................................................................................................................................................. 5
3.1 RECEIVING AND STORING ....................................................................................................................................................... 5
3.2 INSTALLATION ...................................................................................................................................................................... 6
3.3 RELOCATION ....................................................................................................................................................................... 6
4 FACILITY AND ROOM LAYOUT ................................................................................................................................ 7
4.1 ROOM SPECIFICATIONS AND DIMENSIONS:................................................................................................................................. 9
4.2 EQUIPMENT CLEARANCE ...................................................................................................................................................... 10
4.2.1 EBM System ......................................................................................................................................................... 10
4.2.2 PRS System........................................................................................................................................................... 10
4.2.3 Electric-Hydraulic Trolley ..................................................................................................................................... 11
4.2.4 Trolley Tool Stand ................................................................................................................................................ 11
4.2.5 Water Chiller........................................................................................................................................................ 11
5 AUXILIARY EQUIPMENT ........................................................................................................................................12
5.1 VACUUM CLEANER.............................................................................................................................................................. 12
5.2 CHILLER ............................................................................................................................................................................ 12
5.2.1 Cooling Water Circuit Specifications: ................................................................................................................... 12
5.2.2 Cooling Water Specifications: .............................................................................................................................. 13
5.3 COMPRESSED AIR ............................................................................................................................................................... 14
5.3.1 PRS System........................................................................................................................................................... 14
5.3.2 Pneumatic Powder Sieve...................................................................................................................................... 14
5.3.3 Vacuum cleaner ................................................................................................................................................... 14
6 ELECTRICAL SUPPLIES............................................................................................................................................15
6.1 EBM SYSTEM .................................................................................................................................................................... 15
6.1.1 Transformer (Not supplied by Arcam) ................................................................................................................. 16
6.1.2 Network connection............................................................................................................................................. 16
6.2 PRS SYSTEM ..................................................................................................................................................................... 16
6.3 WATER CHILLER ................................................................................................................................................................. 16
6.3.1 For EU and rest of world ...................................................................................................................................... 16
6.3.2 For US................................................................................................................................................................... 16
6.4 TROLLEY ........................................................................................................................................................................... 16
7 CUSTOMER-SUPPLIED AUXILIARY EQUIPMENT.......................................................................................................17
7.1 FIRE EXTINGUISHER ............................................................................................................................................................ 17
7.2 HELIUM REGULATOR/GAS ................................................................................................................................................... 17
7.3 FILE PREPARATION COMPUTER/SOFTWARE ............................................................................................................................. 17
7.4 STORAGE CABINET FOR A2 WIDE/TALL EQUIPMENT .................................................................................................................. 17
8 SITE REQUIREMENT CHECKLIST AND RETURN FORM...............................................................................................18
3
2 System components
Depending of usage of the machine and already existing equipment the list of required
equipment might vary.
e.g. for a second EBM Machine, no further PRS or Vacuum cleaner would be needed as
long as the EBM Machines runs with the same powder quality.
2.1 Arcam supplied equipment

 Control cabinet
 Vacuum chamber cabinet
 Tool cabinet (incl. basic tools for operation of EBM System)
 Start Pack for consumables
 Powder Recovery System (incl. cabinet, barrels, pneumatic sieve)
 Loading trolley (manual or electric-hydraulic)
 1st Vacuum cleaner* (explosion proof type for powder handling)
 2nd Vacuum cleaner* (explosion proof type for universal use)
 Water chiller*
* = Local supply acceptable if meeting Arcam EBM System demands.
2.2 Customer supplied equipment

Personal Protection Equipment (PPE).
Should meet the local laws and regulation, a minimum of
 Breathing mask with particle filter (Category P3).
 Safety goggles.
 Ear protection.
 Safety shoes (non-slip, steel toe) and protective clothing.
Compulsory
 Supply for compressed air (ISO 8573-1 Class 4)
 Helium gas (incl. pressure regulator)
 Fire extinguisher, Class D (Metal Powder)
 PC Workstation w. Magics RP software incl. support generation module.
For US, and other areas when needed

 Transformer (Local power to 3 phase 400 VAC, approximately 25 kW)
Optional
 Shelfs or cabinets for storing equipment
 Blasting cabinet (Post processing)
 Belt grinder (Post processing)
4
3 Transportation
3.1 Receiving and storing
The equipment will arrive to site on pallets and in crates, see dimension table below. Upon
arrival to site the crates have to be taken indoors and kept in a temperature controlled
storage facility until the time of installation.
In order to remove the EBM Machine cabinets from its shipping crates, a forklift with
cantilevered forks and a minimum capacity of 1020 kg (2250 lbs) is required.
It can be a manually-operated fork truck, or a warehouse type.
For positioning the cabinets in to their final position a manually-operated pallet jack is
required. It should have a minimum capacity of 1020 kg (2250 lbs).
Dimensions Weight
Specification:
(cm): (kg):
Electrical Cabinet Crate 130 x 113 x 223 400
Vacuum Chamber Cabinet Crate 130 x 113 x 223 1100
Start Pack EUR-pallet 120 x 80 x 95 200
HV Power Units 1/2-pallet 60 x 60 x 90 140
Powder Recovery System Crate 150 x 145 x 229 400
Electrical Trolley EUR-pallet 135 x 80 x 200 400
Stand for Trolley tools Crate 120 x 80 x 150 100
Barrel tool for Trolley (Optional) Crate 106 x 106 x 70 180
Vacuum cleaner 1/2-pallet 65 x 65 x 130 37
Extra build tank (A2 only) 1/2-pallet 60 x 80 x 75 70
Water Chiller (Rittal) ~1/2-pallet 70 x 70 x 85 150
Table 1: Typical dimensions for equipment during shipping.
5
Arcam EBM Pre-Installation
Installation Guide
3.2 Installation
During installation any door openings where the EBM
EBM System cabinets have to pass
through must have a minimum clearance of
 Height
o 215 cm (85 inch)
 Width
o EBM System100
System cm (39,5 inch)
o PRS System 130 cm (51 inch)
Handling equipment, such as fork lift and pallet jack, will not be supplied by Arcam and
have to be arranged by customer prior to arrival of Arcam staff.
staff
Caution !
Access route
es have to withstand the load from the
EBM System plus the load from transportation
equipment.
3.3 Relocation
Before any relocation of the EBM
E System please consult Arcam staff.
taff.
6
Installation Guide
4 Facility and room layout

The minimum floor space will depend on the amount of equipment and might vary due to
the room layoutout and access routes.
routes Typically a basic set up will require approx.
approx 30 m² (320
feet²). It is advisable to
o have a separate adjacent
jacent room for powder handling (powder
recycling and sifting). If more then one (1) EBM System is planned some of the required
space can be shared between the systems.
s
Each unit’s own requirements are described in detailed within this document.
document
It is recommended that air inlet to the EBM System room is filtered to avoid dust
contamination of powder.
Air quality should meet local laws and regulations for a safe workspace.
Particels, including oil mist, from surrounding equipment might contaminate the EBM
powder and interfere with final material specification.
 General health limits

limit for occurrence of particles smaller then 10µm:
o 24 hour period 50μg/m3
o Avg. 1 year period 30μg/m3
 Common health standard

standar limits for particles in air:
o Cobalt (Co) 0.05 mg/m3 air
o Crome (Cr) 0.005 mg/m3 air
o Titanium(Ti) 5 mg/m3 air
Reference AFS2005:17 2007

2007-05-24
To minimize the risk of contamination and hazardous environment it is advised that the
floor top is made of hard material allowing an
a easy cleaning.
EBM System room should be air conditioned to keep a stable temperature and to control
humidity. See Room specification below for details.
The water
ater chiller for the cooling liquid circuit is recommended to be placed outside of the
EBM System room to minimize
minimi the heat load in the room. If a central cooling water facility
is used a heat exchanger can be placed within the EBM System room.
It is advised that any post

ost processing equipment
equipment is placed in a separate room to avoid
contamination of EBM powder.
Caution !
In addition to the health hazard and contamination
risk there is a potential dust explosion hazard when
handling metal powder.
7
8 m (26’)
Sift and
powder
barrels
PRS
Arcam
EBM System
4 m (13’)
Trolley
Tools
Vacuum Vacuum
cleaner cleaner
Shelf
Shelf
Chiller
Picture 1: Typical room layout
With a sketch/drawing of the intended room for the EBM System Arcam staff can assist
you to find the best layout for a smooth operation.
8
4.1 Room specifications and dimensions:
 Ceiling height
o EBM System 2,9 m (9,5 feet)
o PRS area 2,4 m (7,9 feet)
 Floor
o Weight load
 EBM machine 1500 kg (3,300 lbs)
 Trolley up to 750 kg (1,700 lbs)
o Surface
 Hard surface for easy cleaning
o Level
 Maximum 0,5 % slope.
 Environmental
o Temperature 16-25 degC (60-78 degF)
o Humidity < 60% Relative, non-condensing.
o EMF < 0,2 µTesla (2 mGauss)
Typical sources of unacceptable electro-magnetic fields are electric motors,

high-current cables, distribution panels and transformers.
Please consult Arcam Service Dept. for advice if any of these are located near
the intended position of the EBM System.
 Doorway openings
o While operating the trolley it will demand a minimum of 80 cm (31,5 inch)

wide clearance between EBM and PRS.
o No threshold allowed.
 Illumination
o Sufficient general illumination is required to facilitate loading and unloading
of builds within the machine.
o Shielding and shading. It is desirable, but not necessary, to be able to dim
the lights and shield of any possible windows in the room to facilitate viewing
of the process through the observation window.
Please note that powerful overhead fluorescent lighting can cause electro-
magnetic interference problems.
If there is any doubt regarding the Room Specifications please consult Arcam Staff.
9
4.2 Equipment clearance

4.2.1 EBM System
Picture 2: EBM System minimum clearance.
4.2.2 PRS System
Picture 3: PRS System minimum clearance
10
4.2.3 Electric-Hydraulic Trolley
Picture 4: Electric-Hydraulic Trolley and optional barrel handling tool.
Manual trolley (delivered with EBM S12 system) demand less clearance.
4.2.4 Trolley Tool Stand

Only for Electric-Hydraulic Trolley.
Picture 5: Trolley tool stand minimum clearance
4.2.5 Water Chiller

It is highly recommended that the water chiller is placed outside of the room where the
EBM System is located to reduce the heat load for room Air Conditioning equipment.
A free airflow behind and in front of the chiller is required; please consult manufacturer’s
documentation for details. In general, a free space of 1 m (3’) would be needed around the
chiller to allow a free air flow. The space where the chiller is placed should be well
ventilated or cooled with a secondary system.
11
Installation Guide
5 Auxiliary Equipment
The
e following equipment is required operation of the system. Arcam AB / Arcam Inc. can
supply this if not bought form local supplier.
Caution !
Arcam takes no responsibility for any equipment
which has not been supplied by Arcam. Please note
that some of the auxiliary equipment is crucial for
the operation of the EBM System and any failure
might damage the EBM System or make make the
material specification deviate.
5.1 Vacuum cleaner

For a smooth operation of the EBM system yyou will need at least one “explosion-
protected” industrial vacuum cleaner for powder recovery. A second vacuum cleaner c to
use for cleaning the work areas, floor, etc. will be useful. If a second vacuum cleaner is
not ordered for cleaning the floor, a brush + dustpan should be available for the
installation. See section 5..3.3 for further details.
.
Caution !
The use of a standard vacuum cleaner might be
dangerous as the metal powder flowing in the hose
will generate static electricity and cause a potential
risk of fire/explosion.
explosion.
5.2 Chiller
The EBM system requires re-circulated
re circulated cooling water during operation to keep the vacuum
pumps, cabinets, and electron beam column at an acceptable temperature.
Arcam supplies two types of stand-alone
stand water chillers (Rittal 3334.600 for EU and
Temptech CF-1A for the US).
The EBM System can also be hooked up to a central cooling system via a heat exchanger.
5.2.1 Cooling Water Circuit

ircuit Specifications:
 Capacity: 4 kW (minimum)
 Water temperature: 25 degC (77degF) ±10%
Water temperature
re should be slightly higher tha
than room temperature to avoid
condensation on the internal machine components.
components
 Flow: 2 to 15 liters/min (0.5 to 4 gallons/minute)
 Nominal pressure: 2-5 bar (30-72 psi)
12
5.2.2 Cooling Water Specifications:

Arcam recommends Rittal RI-Frost as liquid for the internal cooling circuit.
Other Ethylene Glycol-based liquid could work as long as the general specifications below
are fulfilled.
Property Value
pH value (7) 7.5 – 8.5
Spec. el. Conductivity 200 – 1000 μS/cm
Residue on evaporation < 500 mg/dm³
Depositable substances < 3 mg/dm³
Hardness 3 – 8°dH
Ca + Mg 0.5 – 2 mmol/l
Hydrogen carbonate 1 – 5 mmol/dm³ (60 –300 mg/dm³)
Free CO² < 10 mg/dm³
Sulphide < 0.01 mg/dm³
Sulphate < 250 mg/dm³
Chloride < 50 mg/dm³
Nitrate < 25 mg/dm³
Nitrite < 0.1 mg/m³
COD < 7 mg/dm³
NH4 < 0.05 mg/dm³
FE < 0.1 mg/dm³
Mn < 0.1 mg/dm³
Cu < 0.1 mg/dm³
13
5.3 Compressed air

The Powder Recovery System and the pneumatic powder sieve require compressed air. A
post processing blasting cabinet could also need compressed air. Some types of vacuum
cleaner runs also on compressed air. The compressed air system has to be designed to fit
the needs for the intended equipment. In determining the size, it can be assumed that only
one piece of equipment will be operated at one time.
Air supply system (compressor and filter) has to meet the demands of
ISO 8573-1 Class 4, preferably Class 3.
Class 4 demands bulk liquid to be removed (air dryer)
5.3.1 PRS System

The PRS system is delivered with three air filters giving the required operational air quality,
any compressed air that comes in contact with metal powder has to meet ISO 8537-1
Class 1.
The filters life length and the risk of contamination of the powder are direct related to the
air supply quality.
Recommended supply pressure: 6 Bar (90 PSI)

The PRS System flow demand: 1200 liters/min (42 Feet³/min)
Customer connection point: ½” female connection with shutoff valve.
5.3.2 Pneumatic Powder Sieve

The pneumatic powder sieve supplied from Arcam has no direct connection between air
supply and metal powder. It can therefore be used directly on the main air supply without
additional filters.

Flow demand: 425 liters/min (15 Feet³/min)
Customer connection point: ½” female connection with shutoff valve.
5.3.3 Vacuum cleaner

The Vacuum cleaner used within the metal powder handling loop needs to be protected
against electrostatic charges. Arcam recommends and supplies Nilfisk A 15 ATEX, a non
electrical, compressed air vac which conforms to the Atex Zone 21-22 directives.

Air consumption: 980 liters/min (at 6 bar of pressure)
Customer connection point: ½” female connection with shutoff valve
14
6 Electrical supplies
All electrical connections and work shall be done according to local regulations and laws.
A qualified and licensed electrician should install and maintain any fixed electrical
equipment.
During normal operation of the EBM System there is no need for EX-approved electrical
installation within the area of Arcam EBM System installation.
Picture 6: Recommended positions for power outlets.

Socket standard might vary depending on installation country.
6.1 EBM System

The EBM requires 400 Volt 3-phase nominal power consumption at 7 kW.
However the phase load is uneven and the supply line demands 32 Amp fuse.
The connection is a 3-phase Y with Neutral and Protective Earth.
No potential difference is allowed between N and PE.
Voltage demands is +5V to -20 V.
Contact Arcam if you wish to run multiple machines connected to the same main power
supply.
The EBM System power comes with a 3 meter cable with a Euro 32A plug.
A suitable socket, or junction box, needs to be placed on the wall behind machine.
Alternatively an additional cable could be dropped from the ceiling via conduit.
Machine frame height is 2,1 m (7 feet)
15
6.1.1 Transformer (Not supplied by Arcam)

If the incoming power is not according the 6.1 a transformer has to be added to the power
supply line.
In US the incoming power will likely be either 480 Volt 3-phase or 208V 3-phase.
Depending on which type of power you have, you will need either a step-up or step-down
transformer. A transformer can be found at local supplier for electrical equipment. When
ordering a transformer, the supplier will need to know:
 Primary voltage (incoming power either 208volt, or 440/480volt)
Contact an electrician to check what is available
 Secondary voltage (output to EBM System, see 5.1.1)
 Capacity (Minimum 22kVA)
It is recommended to locate the transformer at least 10 m (about 30 ft) from the EBM
System to avoid influences from any electro-magnetic field created by the transformer. A
typical transformer has the dimensions of approximately a 0,5 meter (2 feet) metal cube
and weighing approximately 100-150 kg (200-300 pounds).
6.1.2 Network connection

In order to connect the EBM Machine to a local network there is a standard RJ-45
connection at the back of the EBM Machine.
6.2 PRS System

The Powder Recovery System ordered and delivered from Arcam demands a 220 volt,
single phase power supply. Nominal power consumption 850 W.
The PRS System comes with a 2 meter cable and with a grounded Euro plug
6.3 Water Chiller

Demands for water chillers supplied from Arcam:
6.3.1 For EU and rest of world

Rittal 3334.600. The Rittal water chiller requires a single power outlet. It comes with a
cable but no plug and should be provided prior to installation.
 400 V / 3 phase / 50 Hz, start-up current 15 A
6.3.2 For US
Temptech CF-1A with alternative voltages:
 115 V / 1 phase / 60 Hz, full load amperage 24 A
 220 V / 1 phase / 60 Hz, full load amperage 12 A
6.4 Trolley
The Electric-Hydraulic Trolley is battery operated but needs a single power outlet for its
charging equipment. Delivered as 115V / 60Hz or 230V / 50Hz version with nominal power
consumption not exceeding 250 W.
16
Installation Guide
The parking and charging

rging area has to meet local regulation for charging lead-acid
lead
batteries. (Well ventilated).
ventilated)
7 Customer-Supplied
Supplied Auxiliary Equipment
The following equipment is not available for purchase from Arcam but is required for
proper operation of the system.
7.1 Fire Extinguisher

Metal powder and its dust, especially if handled hot, is a potential risk.
risk
We recommend having at least one Class D fire extinguisher.
Please contact your company
ompany safety representative (or local fire marshal) for further
fu
advice.
7.2 Helium Regulator/Gas

The EBM process demands a Helium supply. The gas should be 99.996% pure helium
hel
(also known as Grade 4.6 or 4.7, or “high-purity”).
“high
Also, the cooling process after a build is completed demands Helium
elium gas.
Pressure output: 0,8 Bars (12 PSI) + 10%
Arcam recommends AirLiquid HD240-3-1

HD240 or similar.
Consumption:
Building process 1 liter / hour (0,25 Gallon / Hour)
Build cool down 50
50-75 liters / build cycle (13-20
20 Gallons / build cycle)
Caution !
Line pressure above 1 Bar (15 PSI) might damage
internal parts of the EBM System
7.3 File Preparation Computer/Software

Prior to running parts in the EBM Machine it is necessary to do some modelling and
preparation of the 3D model. A An office PC meeting the demands for a CAD Workstation
should be purchased. To create build supports and correct any STL errors the software
Magics, made by Materialise corporation (www.materialise.com),
( ), should be used.
Please consult Materialise for suggestions regarding detailed PC specifications.
7.4 Storage Cabinet for A2 wide/tall equipment

The extra A2 wide/tall spare build unit equipment should be stored in a cabinet.
The recommended storage cabinet dimensions are: h x w x d 1900x1030x500 mm
17
8 Site Requirement Checklist and return form

Please verify, sign and return the Checklist to Arcam Service and Support department
prior to installation visit.
Site transportation
□ Access routes, weight load and sufficient clearance.
□ Fork lift and pallet jacket available.
Room requirements
□ Floor space and floor surface.
□ Air quality.
□ EMF conditions.
Electrical connections
□ EBM System.
□ Water chiller.
□ PRS.
□ General sockets for vacuum cleaner and other equipment.
Sub system
□ Compressed air.
□ Cooling water system (not if supplied by Arcam).
□ Helium gas.
Auxiliary equipment
□ Fire extinguisher, Class D.
□ Personal Protection Equipment.
Date Customer signature
18
Arcam AB
Krokslätts Fabriker 27A
SE-431 37 Mölndal
Sweden
Phone: +46 31 710 32 00

Fax: +46 31 710 32 01
E-mail: info@arcam.com
support@arcam.com
www.arcam.com
19

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Arcam EBM System

Site requirements and

Phone: +46 31 710 32 00

For installation connections, operation and maintenance of the EBM System

2.1 Arcam supplied equipment

* = Local supply acceptable if meeting Arcam EBM System demands.

2.2 Customer supplied equipment

For US, and other areas when needed

Table 1: Typical dimensions for equipment during shipping.

4 Facility and room layout

 General health limits

 Common health standard

Reference AFS2005:17 2007

It is advised that any post

Picture 1: Typical room layout

4.1 Room specifications and dimensions:

Typical sources of unacceptable electro-magnetic fields are electric motors,

o While operating the trolley it will demand a minimum of 80 cm (31,5 inch)

4.2 Equipment clearance

Picture 2: EBM System minimum clearance.

4.2.2 PRS System

Picture 3: PRS System minimum clearance

4.2.3 Electric-Hydraulic Trolley

Picture 4: Electric-Hydraulic Trolley and optional barrel handling tool.

4.2.4 Trolley Tool Stand

Picture 5: Trolley tool stand minimum clearance

4.2.5 Water Chiller

5.1 Vacuum cleaner

5.2.1 Cooling Water Circuit

5.2.2 Cooling Water Specifications:

5.3 Compressed air

5.3.1 PRS System

Recommended supply pressure: 6 Bar (90 PSI)

5.3.2 Pneumatic Powder Sieve

Recommended supply pressure: 6 Bar (90 PSI)

5.3.3 Vacuum cleaner

Recommended supply pressure: 6 Bar (90 PSI)

Picture 6: Recommended positions for power outlets.

6.1 EBM System

6.1.1 Transformer (Not supplied by Arcam)

6.1.2 Network connection

6.2 PRS System

6.3 Water Chiller

6.3.1 For EU and rest of world

 400 V / 3 phase / 50 Hz, start-up current 15 A

The parking and charging

7.1 Fire Extinguisher

7.2 Helium Regulator/Gas

Pressure output: 0,8 Bars (12 PSI) + 10%

Arcam recommends AirLiquid HD240-3-1

7.3 File Preparation Computer/Software

7.4 Storage Cabinet for A2 wide/tall equipment

8 Site Requirement Checklist and return form

Date Customer signature

Phone: +46 31 710 32 00

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