13/11/12 Assembly Instructions Beta Prusa Standard & Deluxe 3D Printer Version 1.0 Date 13/11/12 Page 1 / 66
General data about the assembly instructions for an incomplete machine according to appendix VI of the EG machinery directive 2006/42/EG Manufacturer: Wenger & Krautwasser GbR - 2PrintBeta Scheffelstrasse 8 78462 Konstanz Description of the machine: Identification: Beta Prusa 3D printer Type: Standard with linear bearings Year: 2012 Conditions that must be met for the incomplete machine so that it can properly, and without compromising the safety and health of peoples, be assembled with other parts to form a complete machine: Condition 1: Let an expert check the electrical connections of the machine. Information over the undersigned: Name: Dominik Wenger Function: Shareholder Wenger & Krautwasser GbR 01.11.2012 Date, Signature This work is licensed under a Creative Commons Attribution-NonCommercial 3.0 Germany License. Page 2/ 66
Congratulations on purchasing a Beta Prusa 3D Printer! Please read the following assembly instructions carefully and keep the document on a safe place. Please follow carefully all instructions and lookout for the warning symbols. Table of Contents SAFETY INSTRUCTIONS...4 ASSEMBLY OF THE FRAME...5 STEP 1.1...6 STEP 1.2...7 STEP 1.3...9 STEP 1.4...10 STEP 1.5...11 STEP 1.6...12 STEP 1.7...13 STEP 1.8...14 STEP 1.9...17 ASSEMBLY OF THE AXES...18 STEP 2.1...19 STEP 2.2...21 STEP 2.3...24 STEP 2.4...26 STEP 2.5...28 STEP 2.6...30 STEP 2.7...32 ASSEMBLY OF THE EXTRUDER...34 STEP 3.1...35 STEP 3.2...37 STEP 3.3...39 STEP 3.4...40 STEP 3.5...42 ASSEMBLY OF THE PRINT BED AND EXTRAS...43 STEP 4.1...44 STEP 4.2...45 STEP 4.3...46 STEP 4.4...47 ASSEMBLY OF THE ELECTRONICS...50 STEP 5.1...51 STEP 5.2...54 STEP 5.3...56 Page 3/ 66
Safety Instructions Only assemble a Beta Prusa 3D printer according to the assembly instructions written here. Please take notice of the following Symbols and Notices. They are structured into danger levels according to ISO 3864-2. DANGER Refers to an imminent Danger. If the information is not followed, it can result in death or serious injury (invalidity). WARNING Indicates a possible dangerous situation. If the information is not followed, it can result in death or serious injury (invalidity). ATTENTION Indicates a potentially dangerous situation. If the information is not followed, damage to property or light to medium personal injuries are possible. NOTICE Indicates general notes, useful operator tips and operating recommendations which do not affect the safety and health of personnel. Page 4/ 66
Chapter I Assembly of the Frame Page 5 / 66
Step 1.1 Needed parts for step 1.1 The following parts are needed for this step: 2x Frame vertex with foot 1x Bar clamp 6x Washer M8 6x Nut M8 1x Threaded rod M8 x 370 mm Assembly Step 1.1 Assemble the bar clamp between two frame vertices like its shown in the picture above. Don't completely fasten the nuts yet. Page 6/ 66
Step 1.2 Needed parts for step 1.2 The following parts are needed for this step: 1x Pre-assembled part from step 1.1 1x Frame vertex without foot 8x Washer M8 8x Nut M8 2x Threaded rod M8 x 370 mm Assembly Step 1.2 Page 7/ 66
Connect the part from step 1.1 with the frame vertex and the rods to a triangle. Make sure that all sides of the triangle are exactly the same length. The distance between the outer edges of the plastic parts should be 291 mm. Repeat the previous two steps and build a second triangle. NOTICE Make sure all sides of both triangles are exactly the same length. Now fasten all nuts on the frame vertices. Assembly of step 1.2 repeated Page 8/ 66
Step 1.3 Needed parts for step 1.3 The following parts are needed for this step: 4x Washer M8 4x Nut M8 1x Threaded rod M8 x 294 mm Assembly Step 1.3 Position the nuts and washer on the threaded rod as shown in the picture above. Page 9/ 66
Step 1.4 Needed parts for step 1.4 The following parts are needed for this step: 1x Belt guide 2x Bar clamp 10x Washer M8 8x Nut M8 1x Bearing 608ZZ 1x Threaded rod M8 x 294 mm Bearing 608zz in belt guide Press the 608ZZ bearing into the belt guide until it's flush with one side of the guide. Assembly step 1.4 Position the parts on the threaded rod as shown in the picture above. Page 10/ 66
Step 1.5 Needed parts for step 1.5 The following parts are needed for this step: 2x Bar clamp 8x Washer M8 8x Nut M8 1x Belt guide 1x Bearing 608zz 1x Threaded rod M8 x 294 mm Assembly step 1.5 Position the parts on the threaded rod as shown in the picture above. Page 11/ 66
Step 1.6 Needed parts for step 1.6 The following parts are needed for this step: 2x Washer M8 2x Nut M8 1x Threaded rod M8 x 294 mm Assembly Step 1.6 Position the parts on the threaded rod as shown in the picture above. Page 12/ 66
Step 1.7 Needed parts for step 1.7 The following parts are needed for this step: 4x Nut M8 4x Washer M8 2x Threaded rod M8 x 440 mm Assembly Step 1.7 Position the parts on the threaded rod as shown in the picture above. Page 13/ 66
Step 1.8 Needed parts for step 1.8 The following parts are needed for this step: 1x Y motor holder 2x Z motor holder 20x Washer M8 16x Nut M8 and all previously assembled parts Assembly Step 1.8 Insert the two triangles from the outside into the prepared threaded rods and fix them together with a washer and a nut each. The longer threaded rods (440 mm) go into the frame vertices without feet, the shorter ones (294 mm) in the Frame vertexes without feet like it's shown in the picture above. Page 14/ 66
Distance between the frame triangles. Measure the distances between the triangles, as shown above, on all three sides of the frame. Position of the nuts on the outside of the frame. Now adjust the distance between the triangles by turning the nuts on the frame vertices until all distances are exactly the same. Make sure the triangles are as far out as possible, as shown above. The distance between the bolts should be 265 mm. Assembly of a z motor holder Now push the z motor holders, flat side down, onto the longer rods as shown above. Secure them with a washer and a nut each. Page 15/ 66
Assembly of the y motor holder At last, push the y motor holder onto the rods, besides the belt guide and secure it with the nuts on the threaded rods. Page 16/ 66
Step 1.9 Needed parts for step 1.9 The following parts are needed for this step: 2x Bar clamps 4x Washer M8 4x Nut M8 1x Threaded rod M8 x 440 mm and the structure from the previous step Assembly Step 1.9 Push the threaded rod through the two bar clamps at the bottom of the frame and attach the bar clamps on both sides with washers and nuts as shown in the picture above. Assembly detail Page 17/ 66
Chapter II Assembly of the Axes Page 18 / 66
Step 2.1 Needed parts for step 2.1 The following parts are needed for this step: 1x Gear 4x Linear bearing LM8UU 1x Motor Nema17 3x Washer M3 3x Screw M3 x 10 mm 1x Grub screw M3 x 8 mm 2x Smooth rod 8mm x 406 mm and the structure from the previous step Assembly Step 2.1 Page 19/ 66
Push the smooth rods through the bar clamps on the frame. Do not fasten the nuts on the rod clamps yet. NOTICE Grease the linear bearings before using them. Don't forget to add the linear bearings onto the smooth rods. Assembly of the Y Axis motor Before you attach the motor onto the holder, you should create a flat onto the motor shaft with a file so the gear has a good fit. Then push the gear onto the motor shaft and secure it with the 8mm grub screw. The gear has holes with integrated nuts for this. Now attach the motor to the y motor holder with three M3 screws and washers as shown in the picture above. Make sure the motor cables on the motor are pointing downwards. Page 20/ 66
Step 2.2 Needed parts for step 2.2 The following parts are needed for this step: 8x Cable ties 1x Belt clamp with channel 2x Belt clamp without channel 1x Y carriage 5x Nut M3 8x Washer M3 1x Belt 3x Screw M3 x 30 mm 2x Screw M3 x 25 mm and the structure from the previous step Assembly of the Y carriage Click the y carriage onto the linear bearings on the smooth rods and make sure the side with the additional hole is pointing to the y motor. Then adjust the smooth rods with the rod Page 21/ 66
clamps until the Y carriage sits exactly in the middle of the frame and can be moved without problems. The smooth rods should now be exactly parallel and should have the same distance to the threaded rods on both sides of the frame. Now carefully fasten the bar clamps until the smooth rods can't be moved any more. Now secure the linear bearings with cable ties to the Y carriage. Assembly of the belt Screw a belt clamp without channel with two M3 x 25 mm screws, washers and nuts onto one side of the Y carriage and use it to secure one side of the belt. Make sure the teeth of the belt are looking downwards. Assembly of the belt Page 22/ 66
Loop the belt around the belt guide, around the gear on the other side and over the other belt guide back to the carriage, as shown in the picture above. Assembly of the belt On the other side of the carriage, install two more belt clamps with the clamp with the channel on top and the one without channel on the bottom. Secure them with two M3 x 30 mm screws and the associated washers and nuts. Don't fasten the screws yet. Put a M3 nut into the pit on the inside of the carriage and screw, from the outside, a M3 x 30 mm screw into it. Depending on your model, the nut might be already casted in. Now pull the belt through the upper belt clamp to the inside of the carriage and through the lower belt clamp back to the outside of the carriage. Like it is shown in the picture above. Pull the belt tight and fasten the screws on the belt clamps. You can now adjust the belt tension with the horizontal screw. Cut off the surplus belt very near the belt clamp, it will be needed for the X axis. Check again that the y carriage can run smoothly on the smooth rods over its full range. Page 23/ 66
Step 2.3 Needed parts for step 2.3 The following parts are needed for this step: 4x Linear bearings LM8UU 2x Rod clamps 4x Washer M4 4x Nut M4 4x Screw M4 x 20 mm 2x Smooth rod 8mm x 350 mm and the structure from the previous steps Assembly step 2.3 Page 24/ 66
Put the smooth rods onto both sides of the frame as shown in the picture above. NOTICE Grease the linear bearings before using them. Don't forget to add the linear bearings onto the smooth rods. On the top the smooth rods are secured with rod clamps, M4 x 20 mm screws and associated washers and nuts. You can see how that is done on the following pictures. Assembly detail step 2.3 Justage step 2.3 Now adjust the two bar clamps, like its shown in the picture above, until the new smooth rods are exactly vertical. Use a plum line, which you can easily create yourself with a M8 nut and a thread, to make sure its really vertical. When you are satisfied with this, carefully fasten the bar clamps until the rods can't be moved any more. Page 25/ 66
Step 2.4 Needed parts for step 2.4 The following parts are needed for this step: 1x X end with motor holder 1x X end without motor holder 4x Screw M3 x 25 mm 4x Nut M3 8x Washer M3 1x Screw M8 x 50 mm 3x Washer M8 2x Nut M8 1x Bearing 608ZZ 1x Belt guide 2x X end add-on 608ZZ Bearing inside the belt guide Press the 608ZZ bearing into the belt guide until one side is flush with it's side. Belt guide on the x end part Page 26/ 66
Assembly the belt guide with the bearing and the M8 x 50 mm screw and associated washers and nuts on the x end part without motor holder like it is shown in the picture above. Assembly of x end add-on parts Place the two x end add-on parts onto the x end parts and screw them together with two M3 x 25 mm screws, washers on top and bottom, and nuts like its shown in the pictures above. Fasten the nuts good, so that they don't fall off when the parts are vibrating and moving. Page 27/ 66
Step 2.5 Needed parts for step 2.5 The following parts are needed for this step: 1x x end from the previous step 1x x end with motor holder from the previous step 8x Screw M3 x 10 mm 4x Linear bearings LM8UU 4x Cable ties 2x Smooth rod 8mm x 420 mm and the structure from the previous steps Assembly step 2.5 Slide the four linear bearings onto the smooth rods and push them through both x end parts. Insert the assembly into the 3D printer frame and click the x end parts onto the linear bearings on the vertical rods like its shown in the picture above. Page 28/ 66
NOTICE Grease the linear bearings before using them. Don't forget to add the linear bearings onto the smooth rods. Assembly detail step 2.5 Secure the smooth rods with four screws M3 x 10 mm on each x end part. Make sure the rods on the x end with motor holder don't stick out too much. NOTICE Don't tighten the screws for fixating the x smooth rods too tight. Check that the construction can smoothly go up and down on the vertical rods without any blocking. Let the z-axis slide down until it sits on the y carriage. Then secure the vertical linear bearings wit cable ties onto the x end parts. Page 29/ 66
Step 2.6 Needed parts for step 2.6 The following parts are needed for this step: 2x Z-axis coupling without nuts 2x Z-axis coupling with nuts 8x Screw M3 x 10 mm 2x Nut M8 8x Screw M3 x 20 mm 16x Washer M3 2x Motor Nema17 2x Threaded rod M8 x 210 mm and the structure from the previous steps Assembly step 2.6 Page 30/ 66
First push both motors onto the z-axis motor holders on top of the 3D printer and secure them with four screws M3 x 20 mm and associated washers each like it is shown in the picture above. Motor assembly Assembly of the z-axis drive rod Now push a M8 nut into the bottom of the x end parts and screw the threaded drive rods from the top through them. Then connect the drive rods with the motor shafts with the z-axis couplers. Use a z-axis coupler with nuts and one without on each rod and screw them together with four M3 x 20 mm screws and washers each. Use them to securely clamp together the drive rod and the motor shaft. Make sure the drive rods are exactly vertical and parallel to the smooth rods of the frame also the x-axis should be exactly horizontal. Now check again if the axis with the nut can turn easily and drive completely up and down without any problems. Page 31/ 66
Step 2.7 Needed parts for step 2.7 The following parts are needed for this step: 4x Cable ties 1x x carriage 2x Belt clamp without channel 1x Belt clamp with channel 1x Gear 1x Grub screw M3 x 8 mm 5x Nut M3 11x Washer M3 1x Belt 1x Motor Nema17 2x Screw M3 x 30 mm 2x Screw M3 x 25 mm 1x Screw M3 x 20 mm 3x Screw M3 x 10 mm and the structure from the previous steps Assembly step 2.7 Page 32/ 66
Motor assembly First you should file a flat onto the motor shaft, so that the gear has a good grip on it. Then push the gear onto the motor shaft like it is shown in the picture above and secure it with a M3 x 8 mm grub screw. Then attach the Motor to the x end with three screws M3 x 10 mm and fitting washers. Make sure the motor cable is pointing outwards. Click the x carriage onto the linear bearings of the x-axis and check if it can glide smoothly over the rods. Secure the bearings to the carriage with cable ties. Assembly detail step 2.7 Assemble the belt clamps onto the x carriage as shown in the picture above. On the left side mount a belt clamp without channel with two M3 x 25 mm screws and fitting washers and nuts. On the right side mount a belt clamp with channel on top and one without on the bottom. Secure both with two M3 x 30 mm screws, washers and nuts. Additionally put an M3 nut into the depression in the middle and screw a M3 x 20 mm screw horizontally through the part. Depending on your model the nut might be already casted in. Now clamp the belt onto the left side and loop it around the belt guide on the left side and around the gear on the right side and back to the carriage. Here the belt goes through the top belt clamp to the middle and back out through the bottom clamp. Tighten the belt a bit and clamp it with the screws on the belt clamps. You can now regulate the belt tension with the horizontal screw. Check again that the x carriage can be moved without problems and cut off the left over belt. Page 33/ 66
Chapter III Assembly of the extruder Page 34 / 66
Step 3.1 Needed parts for step 3.1 The following parts are needed for this step: 2x Teflon tube, 2 cm length 1x Thermistor 2x Ferrules 1x Heating element 1x Thin two-wire cable, 1m length 1x J-Head Assembly step 3.1 Page 35/ 66
Push the heating element into the big hole of the J-Head and secure it with the integrated grub screw. Next take the thermistor and carefully push a Teflon tube onto each pin of the thermistor. NOTICE Attention, the pins of the thermistor are very fragile and might break easily! Then take the cable and strip the isolation on both poles for about 1 cm. Push the ferrules onto the cables and insert a pin of the thermistor into each ferrule from the bottom. Position the ferrule and the Teflon tube so that everything is isolated and clamp everything together by using pliers on the ferrule. If needed apply a bit of isolating tape or heat shrink tube to isolate everything against a short. The push the thermistor into the small hole of the J-Head like it is shown in the picture above. Secure the thermistor cable and the cable of the heating element on the J-head with a piece of tape. Page 36/ 66
Step 3.2 Needed parts for step 3.2 The following parts are needed for this step: 4x Washer M3 2x Nut M3 2x Screw M3 x 35 mm 2x Spring 4x Washer M4 2x Nut M4 2x Screw M4 x 50 mm 1x Wades body 1x J-Head from the previous step Assembly step 3.2 Page 37/ 66
Put onto both M4 x 50 mm screws a M4 washer, a spring, and again a M4 washer. Then put two M4 nut into the top of the Wades body and screw the prepared screws into the body as shown in the picture above. Next carefully push the prepared J-Head into the hole on the bottom of the Wades body and secure it with two M3 x 35 mm screws and fitting washers and nuts. Make sure to place the screws exactly as shown in the picture, or they might collide with the gear later. Page 38/ 66
Step 3.3 Needed parts for step 3.3 The following parts are needed for this step: 1x Bearing 608ZZ 1x Nut M3 1x Bolt M8 x 20 mm 1x Wades Idler Assembly step 3.3 Push the bearing onto the short M8 bolt and click it into the Wades Idler. Put the M3 nut into the depression of the Idler as shown in the picture above. Page 39/ 66
Step 3.4 Needed parts for step 3.4 The following parts are needed for this step: 1x Big gear 2x Nut M8 1x Nut M8 Nyloc 3x Washer M8 1x Hyena drive screw 1x Grub screw M3 x 8 mm 3x Screw M3 x 12 mm 1x Screw M3 x 30 mm 1x Small gear 5x Washer M3 1x Nut M3 2x Bearing 608ZZ 1x Motor Nema17 and all parts from the previous steps Assembly detail step 3.4 Page 40/ 66
First you should file a flat onto the motor shaft so that the gear will have a good grip on it. Then secure the motor with three M3 x 12 mm screw and fitting washers onto the Wades body, but don't completely fasten the screws yet. Bolt the prepared Idler with a M3 x 30 mm screw and fitting washers and a nut onto the Wades Idler. Then fold the M4 screws with the springs over the Idler as shown in the picture above. Put a bearing into the depression on both sides of the Wades body. Assembly step 3.4 Put the M8 Nyloc nut into the big gear and screw it onto the shorter part of the Hyena drive screw. Also put two M8 washers onto the drive screw. Then put the small gear onto the motor shaft and secure it with a M3 x 8 mm grub screw and simultaneous put the drive screw with the big gear through the bearings on the wades body. Check that both gears can turn without problems and adjust the motor so that both gears mesh together and can turn without much play. Now secure the motor completely. As the last step secure the drive screw with a washer and two M8 nuts on the other side. Page 41/ 66
Step 3.5 Needed parts for step 3.5 The following parts are needed for this step: 2x Screw M4 x 20 mm 2x Washer M4 2x Nut M4 and the structures from the previous steps Assembly step 3.5 Put the extruder onto the x carriage like it is shown in the picture above. Then secure it in place with two M4 x 20 mm screws and fitting washers and nuts onto the x carriage. Page 42/ 66
Chapter IV Assembly of the Print bed and extras Page 43 / 66
Step 4.1 (Only available in the deluxe version) Needed parts for step 4.1 The following parts are needed for this step: 16x Cable ties 2x Left frame stabilizer 2x Right frame stabilizer and the structures from the previous steps Assembly step 4.1 Put the frame stabilizer onto each top corner of the frame and secure them with cable ties. Page 44/ 66
Step 4.2 (Only available in the deluxe version) Needed parts for step 4.2 The following parts are needed for this step: 2x Bearing holders 2x Bearing 608ZZ 2x Screw M3 x 25 mm 2x Nut M3 4x Washer M3 and the structures from the previous steps Assembly step 4.2 Press the bearings into the bearing holders and place them onto the lower end of both Z drive rods. Secure the holders with a M3 x 25 mm screw and a washer each. Page 45/ 66
Step 4.3 (Not available in the deluxe version) Needed parts for step 4.3 The following parts are needed for this step: 4x Spring 8x Washer M3 4x Nut M3 Nyloc 4x Screw M3 x 40 mm 1x Acrylic print bed and the structures from the previous steps Assembly step 4.1 Attach the acrylic print bed onto the y carriage with four screws M3 x 40 mm and springs, cut to length, and associated washers and nuts as shown in the pictures above The M3 Nyloc nut goes at the bottom. Make sure the print bed is exactly level, you can adjust the height position of it with the Nyloc nuts. Page 46/ 66
Step 4.4 (Only available in the deluxe version) Needed parts for step 4.4 The following parts are needed for this step: 1x Aluminium plate 225 mm x 225 mm 4x Spring 1x Thermistor 1x Thick two-wire cable, 50 cm length 1x Thin two-wire cable, 50 cm length 1x Kapton tape 16x Washer M3 4x Nut M3 Nyloc 4x Nut M3 4x Screw M3 x 40 mm 4x Screw M3 x 10 mm 1x Heated print bed and the structures from the previous steps Soldering of the heated print bed Page 47/ 66
Solder the thermistor onto the contacts in the middle of the heated print bed and secure it with a piece of Kapton tape. Then solder the thin two-wire cable onto the two inner contacts of the heated print bed and the thicker two-wire cable onto the outer two contacts as shown in the picture above. Secure all solder joints and the cables with a bit of Kapton tape. NOTICE Make sure to not cut the cables for the heated print bed to exactly 50 cm length. Securing of the through hole connections Secure the through hole connections on the sides of the heated print bed with Kapton tape to protect against possible shorts with the aluminium plate. After taping the print bed, you should pierce through the holes so its possible to put a screw into it later. Attaching the aluminium plate Page 48/ 66
Put the aluminium plate on top of the heated print bed with the coated side up and srew them together. Use four M3 x 10 mm screws and fitting washers and nuts on the four corners of the plates for this. Assembly step 4.4 Mount the heated print bed onto the y carriage with four M3 x 40 mm screw, springs, washers and nuts as shown in the picture above. The M3 Nyloc nut goes on the bottom in this assembly. The cables of the heated print bed should point away from the y axis motor. Make sure the print bed is exactly level, you can use the Nyloc nuts to adjust the height and position of it. Page 49/ 66
Chapter V Assembly of the Electronics Page 50 / 66
Step 5.1 Needed parts for step 5.1 The following parts are needed for this step: 3x Optical end-stop 2x curved end-stop holder 1x straight end-stop holder 2x Belt clamps without channel 1x Beverage can 5x Screw M3 x 20 mm 5x Screw M3 x 16 mm 1x Screw M3 x 10 mm 21x Washer M3 9x Nut M3 and the structure of the previous steps First you should open the beverage can and drink it's content. Then disassemble the can with pliers or scissors and create three metal strips with around 8 mm width and 60 mm length. Poke a hole into one side, wide enough for a m3 screw. Like it is shown in the following picture. Metal flags Page 51/ 66
Assembly of the optical end-stop on the Y-axis Attach the optical end-stop to the outer hole of a curved end-stop holder with a M3 x 16 screw, washers on both sides and a nut. Mount the end-stop holder on the outer rod of the 3d printer, in the direction of the y- motor, with a M3 x 20 mm screw and a washer as shown in the picture above. Attach the metal flag onto the y carriage with a M3 x 10 screw and fitting washers and a nut. Make sure the flag goes into the optical end-stop when the y-axis is driven completely to one side. If needed bend and cut the flag till it fits. Assembly of the optical end-stop for the Z-axis Mount the next optical end-stop on the second curved end-stop holder as shown in the picture above. Use two M3 x 16 mm screws and fitting washers and nuts for this. Attach the end-stop holder with a M3 x 20 mm screw and one washer onto the smooth rod below the x end part without motor. Attach a metal flag onto the outer screw at the bottom of the x end parts using an extra M3 nut and two washers. Then bend the flag down and adjust the flag and the end-stop until the flag goes into the endstop without problems when the z-axis drives down completely. Page 52/ 66
Assembly of the optical end-stop for the X-axis Attach an optical end-stop on the straight end-stop holder with two M3 x 16 mm screws and fitting washers and nuts. Mount the end-stop holder onto the smooth rod near the belt on the x-axis near the e end parts without motor. Secure it with a M3 x 20 mm screw and a washer. The attach two belt clamps to the belt near the x carriage with two M3 x 16 mm screws, washers on top and bottom and M3 nuts. Attach the metal flag onto the inner screw. Bend and cut the flag until it goes into the end-stop without any problems, when the x-axis is moved fully to one side. Page 53/ 66
Step 5.2 Needed parts for step 5.2 The following parts are needed for this step: 1x RAMPS electronic 1x RAMPS electronic holder 2x Rod clamps 1x Filament guide 1x 40mm Fan 2x Screw M3 x 16 mm 4x Screw M3 x 25 mm 2x Screw M3 x 35 mm 14x Washer M3 6x Nut M3 and the structure from the previous steps Assembly step 5.2 Page 54/ 66
Click the filament guide onto the rods on the top of the 3D printer. Screw the 40 mm fan onto the y carriage with two M3 x 16 mm screws and two washers as shown in the picture above. Assembly RAMPS Attach the RAMPS electronic holder onto the side of the 3D printer with two rod clamps and two M3 x 25 mm screw, washers and nuts, each. Put the RAMPS electronic onto the holder and secure it with two M3 x 35 mm screws, washer on top and bottom, and a M3 nut. Page 55/ 66
Step 5.3 (Partially available only in the deluxe version) Needed parts for step 5.3 The following parts are needed for this step: 30x cable ties 6x triple plug housing 2x double plug housing 4x quadruple plug housing 38x Crimp contacts 4x quadruple terminal block 1x eightfold terminal block 4x Heat sinks 1x thermal glue tube Four wire cable Three wire cable Thin two wire cable Thick two wire cable ATX power supply ATX Adapter and the structure from the previous steps Assembly step 5.3 Page 56/ 66
NOTICE Please make sure to not cut the cables too short. Always put the cables into the intended place to test the length before cutting it. If a cables ends in a plug on the pictures, you need to assemble the plugs first. Crimp contacts For this, strip a little bit of the isolation on the cables and clamp each wire into a crimp contact as shown in the picture above. Make sure the wire has good contact with the crimp contact and is properly secured. Then push the contacts into a fitting plug housing. Make sure to insert the contacts with the colour coding like it is shown in the pictures. On the backside of the crimp contacts there is a small tongue, this tongue needs to go into the hole on the side of the plug housing. If you insert it correctly, you should hear two soft clicks when the contact is inserted completely. We start with the z-axis motors. Place a four-way terminal block beneath both z-axis motors and connect the motor cables with them. Make sure to follow the colour coding shown in the pictures. Connection of the z motors Lay down a piece of four-wire cable between those terminal blocks and connect it with them. Make sure to respect the colour coding like it is shown in the picture below. Page 57/ 66
Colour coding on the z motor Attach another four-wire cable onto the terminal block on the left side and guide the cable down the left side of the frame as shown in the following picture. Cable management for the z motor Make sure to cut the cable so, that it can safely reach your electronics. Page 58/ 66
Connection of the z motors to the electronic Attach a quadruple plug to the lower end of the cable, like it is described above, and plug it into the electronic as is shown with the red marked cable in the picture above. Make sure the crimp contacts are fully inserted into the plug, as they have a very tight fit with the motor cables. Make sure to always respect the colour coding on the cable. Connection of the y motor Next put a four-way terminal block beneath the y-axis motor onto the lower rod and connect the motor cables with it. Attach a four-wire cable to it and guide to the side of the printer and from there to the electronics. Make sure to get the colour coding correct. Connection of the y motor onto the electronics Assemble a quadruple plug onto the new cable and plug it into the electronic as shown with the red cable above. Make sure to not mess up the colour coding. Page 59/ 66
Connection of the x motor To connect the x-axis motor, attach a four-way terminal block onto the middle of the diagonal threaded rod of the frame and connect the motor cables to it. Make sure the motor cables are loose enough so that the z-axis can move completely up and down. It is recommended to twist the motor cables together to prevent them getting stuck somewhere. Then connect a four-wire cable to the terminal block and guide the cable down the threaded rod, to the middle of the printer and along the middle rod to the electronic. Make sure to not mix up the colour coding of the cables. Connection of the x motor to the electronic Connect a quadruple plug to the cable and plug it into the electronic as shown with the red cable above. Make sure to get the colour coding correct when assembling the plug. Page 60/ 66
Connection of the extruder Place the eight-way terminal block, onto the extruder motor and connect the motor cables and the heater cables and the fan cables to it as shown in the picture above. Connect a four-wire cable for the motor, a thick two-wire cable for the heater and a thin twowire cable for the fan to the terminal block. Make sure to pay attention to the colour coding. Guide the motor cable, the heater cable, the fan cable and the already connected thermistor cable in a big loop to the top of the printer and from there down on the side of the printer to the electronic. Make sure loop of the cables is big enough, so that the extruder can move in x and z direction over its full range without getting in conflict with the cables. Connection of the extruder to the electronic Attach a quadruple plug onto the motor cable and plug it into the electronic as shown above. Make sure the colour coding is correct. The thermistor cable needs a double plug and gets plugged into the electronic as shown above. This time colour coding doesn't matter. The cables of the heater need to be connected to the lowest screw contacts on the electronics as shown above. Here the colour coding also doesn't matter. The fan cables go onto the middle screw terminal. Page 61/ 66
Connection of the x end-stop For the end-stops we take a three-wire cable and attach a triple plug with the colour coding as shown above. Plug the cable into the end-stop and guide it in small loop to the side of the printer and then down to the electronic. Make sure the cable has enough space, so the z-axis can move completely up and down. Connection of the x end-stop to the electronic On the other side of the cable we also attach a tripe plug and plug it into the electronic as shown above. Make sure to get the colour coding right. Page 62/ 66
Connection of the z end-stop Assemble another three-wire cable for the z end-stop and again make sure the get the color coding correct, as shown in the picture above. Guide the cable down the vertical rod and to plug it into the electronic like the red cable in the picture above. Connection of the y end-stop For the last end-stop we again prepare are three-wire cable with the correct colour coding and connect it to the end-stop. Guide the cable along the side of the printer till you get to the middle rod. From there guide it below the printer to the electronic. Connection of the y end-stop to the electronic Page 63/ 66
Connect the last triple plug to the cable and connect it to the electronic as shown in the picture above. Make sure to not mess up the colour coding. Connection of the heated print bed If you have the deluxe set, guide the cables of the heated print bed to the electronics as it is shown in the picture above. Make sure that the y-axis can still move over its full range without any problems and that the cables don't entangle with the belt. Connection of the heated print bed to the electronics The thermistor of the heated print bed needs a double plug and gets plugged into the electronics as shown above. The heating cables are connected to the upper screw terminal of the electronic like it is shown with the red cable in the picture above. For both cables the colour coding is not relevant. Page 64/ 66
Adding the heat sinks Take the 4 heat sinks and apply a bit of heat thermal glue to the bottom of them. Then place each heat sink onto one stepper drive and make sure to leave the potentiometers accessible. Connection of the power supply to the electronic Page 65/ 66
DANGER Make sure that the power supply is not connected to the life power while doing the following steps. Connect the ATX adapter with two thick two-wire cable with the right screw terminals on the electronic. Make sure the colour coding ist correct, and you don't connect plus with ground. At the ATX adapter the cables go to the contacts marked with 12V and GND. If you don't have a heated print bed it's enough to only connect one cable. In this case connect the cable to the terminals marked with 12V/5A. As a last step, secure all cables with cable ties to the rods of the 3D printer and check again if all axes can move freely over their full range. It is recommended to bundle all cables of the extruder to one big bundle to reduce the likelihood of entanglement with the cables. Grease all smooth rods and the z drive rods with machine grease or oil to allow the axes to run smoothly. Before you active the electronics, you should check again all cabling, preferably by an expert. To commission the machine and get started with printing, please read the general usage guidelines for 3D printers from 2PrintBeta. Page 66/ 66