CCF (Carbon Chamber Filter)

CCF (Carbon Chamber Filter) 

Slicer settings 

Filament: ASA 
Nozzle: 0.4mm 
Layer height: .2mm 
Infill type: Gyroid, Honeycomb, Triangle or Cubic
Infill percentage: 30% 
Wall count: 3 
Top/Bottom layer: 5 
No support/brim required

Slicer settings (TPU Seal) 

Filament: TPU 
Nozzle: 0.4mm 
Layer height: .2mm 
Wall count: 3 
Top/Bottom layer: 3 
No support/brim required.

Required tools 

• Soldering iron
• Heat set insert tip

Suggested tools 

•  11/64 drill bit 
• Magnet Installation Tool 6x3. Click the link for details

CCF - Required hardware 

• 16 M3 Heat set inserts (M3x5x4)
• 16 M3x6 SHCS 
• 2 4028 24v fans 
• 1 JST-XH 2 pin female connector, pre-crimped 
• Super glue
• Acid free carbon pellets
• HEPA Filter for ILIFE Robot Vacuum (80mmx40mmx15mm)
• 3M VHB tape 

Additional hardware

• The Creality K1-K1C specific fan ducts will require 2 M4x10 BHCS and 2 printed M4 Tapered spacers for mounting in the enclosure

External power source - Required hardware 

• 24V DC Power adapter
• 5.5mm x 2.5mm female barrel plug adapter
• 2 M3 Heat set inserts (M3x5x4)
• 2 M3x6 SHCS
• 1 JST-XH 2 pin male connector
• 22 AWG 2 conductor silicon wire

Suggested hardware

• 5.5mm x 2.5mm male to female extension cable with On/Off switch

Note: You can substitute the JST-XH connectors for WAGO Connectors.

Optional  power source 

• Auxiliary fan splitter switch (MTS-203 Housing DPDT ON/OFF/ON mini toggle switch)
   

Printed parts

•  Fan Module
•  Carbon Cartridge
•  Carbon Cartridge Magnet Plate

• Intake
• Fan Duct 
• TPU Seal 

Magnet installation

 
Install four 6x3 magnets into the Carbon Cartridge Magnets Plate. I suggest using the optional magnet installation tool to insure the correct orientation. Place one of the magnets on the tool with the plus sign facing upward, then apply a small dab of super glue before pressing the magnet into the 6mm pocket. CAUTION!!! DO NOT INSTALL THE MAGNENTS INTO THE COUNTERBORES MEANT FOR THE M3 SHCS!!! Repeat the process for the three other magnets.

Next install four 6x3 magnets into the Fan Module. This time when using the magnet installation tool, place the magnet on the side opposite the plus sign, ensuring the magnets will be attracted to one another when the parts are assembled.

Heat set insert installation

 
Install four M3 heat set inserts into the Fan Duct.

Install eight M3 Heat set insets into the Carbon Cartridge.

4028 Fans

When the fans are installed, we want the air to be pulled through the filter. Many fans will have arrows on the side indicating the rotation, and air flow direction. Make sure the fans are oriented correctly when installing the threaded inserts. 

The holes in the fans will be under size. I recommend drilling out a few millimeters of clearance with an 11/64 drill bit. You want just enough of a counterbore to help guide the threaded insert square and concentric with the existing hole. Carefully twist the drill bit by hand.

Fan mounting and soldering

Mount the fans to the Fan Module using four M3x6 SHCS. 

Insert the JST-XH 2 pin female connector (wires pre-crimped) into the square hole, then apply a small dab of super glue before installing permanently.

Cut and strip the wires to an appropriate length, then apply heat shrink before soldering the connection.

Alternatively WAGO connectors can be used to wire the unit.

Final assembly

Mount the Fan Module sub assembly to the Fan Duct with four M3x6 SHCS.

Mount the Carbon Cartridge Magnet Plate to the Carbon Cartridge with four M3x6 SHCS.

Fill the reservoir with carbon pellets to the top of the cylinders.

Install the Intake with four M3x6 SHCS.

Install the HEPA filter and TPU seal.

Installation

Apply 3M VHB tape to the bottom of the Fan Duct then install into your enclosure.

If you are installing one of the K1-K1C specific fan ducts, remove two of the screws located on the floor of the enclosure. Either the two in the back or the two on the left depending on your build.

Insert two printed M4 Tapered Spacers into the countersunk holes.

Note: You may need to remove the bottom panel to support the power supply when installing the new screws.

Secure the Fan Duct with two M4X10 BHCS.

I suggest changing the carbon pellets and HEPA filter every 50 hours or every 30 days.  

External power source 

There are many ways to power the unit. The simplest option would be with a 24v DC power adapter.

For this configuration you will also need a 5.5mm x 2.5mm female barrel plug adapter.

An extension cable with On/Off switch is also recommended. 

Printed parts

• Barrel plug adapter housing top
• Barrel plug adapter housing base  

Install two M3 heat set inserts into the Barrel plug adapter housing base.

Insert the barrel plug adapter into the Barrel plug adapter housing base and apply 3M VHB tape.

Crimp or solder a JST-XH 2 pin male connector to one end of 22 AWG 2 conductor wire. Run the cable from the CCF out of the enclosure. Secure he barrel plug adapter housing to enclosure and connect the wires.  

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