robert.l38
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How to replace hot end heater cartridge?

Jan 17, 2019 8:48 pm

So I had a thermal runaway error pop up on my MK3 and I suspect it is the heater cartridge (or wiring). Thermistor seems to be working fine. I have a spare 24V 40W cartridge I bought awhile back in case this ever happened.

DId a google search and forum search and couldn't find instructions for heater cartridge replacement. Is it basically:
1) Remove cable wrap from around wires
2) Open circuit board box
3) Disconnect heater cartridge wiring from circuit board
4) Remove heater cartridge from hot end (How is that held in? The screw underneath the hot end by the nozzle? Is it an allen wrench needed?)
5) Reverse order of these steps to install new cartridge

Anything I'm missing?

Best Answer by joan.t » Jan 18, 2019 12:37 am
that is pretty much the process,
E3dV6 heatblock.png
there is a raised head screw clamping the heater capsule into the heatblock, it needs an Allen key (Hex wrench) to loosen it,(might need to heat the screw up, to get the Allen key into the hex socket)

you probably also need to gently pry the gap of the slot, open larger to release the heater capsule before sliding it out...

chances are that there is old charred and molten filament crusting this area up, so you may also need to heat the heat block up as well, to release the old heater capsule

Be careful not to burn yourself, and treat the thermistor wires with great respect, they are very fragile

when reassembling, pay particular attention to the alignment of the cables and cable ties, as the heads of the cable ties may prevent full movement of the X axis, if incorrectly aligned

regards Joan

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joan.t
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Re: How to replace hot end heater cartridge?

Jan 18, 2019 12:37 am

that is pretty much the process,
E3dV6 heatblock.png
E3dV6 heatblock.png (712.56 KiB) Viewed 127 times
there is a raised head screw clamping the heater capsule into the heatblock, it needs an Allen key (Hex wrench) to loosen it,(might need to heat the screw up, to get the Allen key into the hex socket)

you probably also need to gently pry the gap of the slot, open larger to release the heater capsule before sliding it out...

chances are that there is old charred and molten filament crusting this area up, so you may also need to heat the heat block up as well, to release the old heater capsule

Be careful not to burn yourself, and treat the thermistor wires with great respect, they are very fragile

when reassembling, pay particular attention to the alignment of the cables and cable ties, as the heads of the cable ties may prevent full movement of the X axis, if incorrectly aligned

regards Joan
I try to make suggestions that I believe to be well founded and safe,You should understand the context and ensure you are happy that they are safe before attempting to apply my suggestions,
what you do, is YOUR responsibility.

robert.l38
Posts: 3
Joined: Apr 08, 2018 5:37 am
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Re: How to replace hot end heater cartridge?

Jan 18, 2019 1:50 am

Thanks Joan,

Just fixed it. The heater cartridge wire had broken off right at the cartridge.

I think the failure itself was caused by repeated stress... the design isn't that great from a wire routing perspective. The wires come out at a sharp 90 degree angle, and the stiff shrink tubing is behind that. It seems that even with routing directly in the middle of the extruder wiring bundle, every time the print head moves to the extreme left side of the bed it will gently press up against the shrink tube (adding a little extra stress on the wires right at the cartridge). I have hundreds (maybe into the thousands?) of hours on the printer, so it gradually must have worn away.

Would like to see that design improved a bit... something to give a more gradual bend to the wires coming out of the heater cartridge (and the thermistor, too, for that matter).

For now, I'll make a mental note to avoid the far left side of the bed when slicing.

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randolph.l
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Re: How to replace hot end heater cartridge?

Jan 18, 2019 4:51 pm

Right angle wires at the cartridge are sold as special high heat items such as this one that costs $68 in either 12 or 24 volt form... I have no idea why someone is not selling a similar form factor in 24 volt 40 watt for the V6 hot end lines. perhaps someone is and I have just not seen it yet.
https://www.printedsolid.com/products/e ... -cartridge

Image
Heaters capable of operating up to 550°C for extended periods of time. For printing high temperature thermoplastics. Come with high ampage connectors and extension leads, the cartridge has the wires exiting at a 90° angle from the casing with a strain relief.

Voltage: 12V/24V

Power: Up to 65W

Max operating temp: 550°C.



Lead length: 2m

⚠️WARNINGS⚠️

- These heaters are more than capable of reaching temperatures that will soften the aluminium block shipped as standard with our heaters. These must only be used with a copper block. We also recommend coupling this with a copper nozzle, as the hardened nozzles will lose some hardness at these temperatures, and the copper will offer better thermal conductivity.

- For the 12V version, some printers' electronics are not able to withstand the current required by the heaters. If this is your case, or you don't want to risk blowing your board up, please purchase the MOSFET switch daughter board sold with the SuperVolcano

Read all about the cartridges in E3D's latest High Temperature blog post
https://e3d-online.com/blog/2018/10/22/ ... %EF%B8%8F/

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