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Build the base completely (Y assembly pages 29-31) before attaching it to the printer later. (Hardware Label #11)
If you're not using REPRAPGURU filament, make sure you pick a good quality 1.75mm filament for good prints.
The endstop switches use a 3 wire connector, if you put one on backwards you will short out your controller!
(The green wire should face the nearest edge of the board; Page 62)
If you study each picture closely, they will have the orientation of all the parts and your build will be perfect.
You should have 2 large bearings and a bag of spare nuts and bolts when finished. (Hardware bag #10)
If you're using a LCD controller to control your 3d printer, please keep in mind there is a programming flaw in
the Marlin software when using the preheat function, both heaters start at the same time causing the ramps
board connections (green connector) to overheat and melt. It's best to use the SD card function, load your
file and the heatup will start like it should.
The 2 Z-axis acrylic frame assemblies are not interchangeable (page 16). The power supply side does not have
the "wire feeding slot" at the top and goes on the left side (looking from the front; page 17)
Make sure you change the power supply to the proper voltage (115 volts for USA)
Remove all protective paper from the acrylic pieces before building.
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PARTS LIST
1. What is in the shipping box.
Hardware Box 1
Hardware Box 2
PRUSA i3 Frame Kit (Acrylic Hardware)
Metal rods
2. Box 1
PCB
PCB and USB cable
3 cable sets
5 PCB and 5 heat sinks
4 clips - 15 cable ties - 4 belts
7 cables, bearings and pulleys
10 bags of hardware
3. Bags of hardware (All washers are flat) (nuts are 5.5mm)
#1 Metal Frame = 38)M3 bolts - 38)M3 nuts - 40)washers
#2 Acrylic Frames = 24)M3x16mm bolts - 24)flat nuts - 24)washers
#3 Z motor and Y motor = 10)M3x10mm bolts - 8)washers
#4 X Plastic End (motor and end stop bolts) = 4)m3x20mm bolts - 4)washers - 1)m5 bolt - 5)M5 nuts
#5 Ramps and Power supply = 3)m3x30mm bolts - 3)washers - 3)spacers - 3)M4x8mm bolts
#6 Belts and Pulleys = 2)m3x26m bolts - 2)lock nuts - 4)washers
#7 End Stops = 3)M3x20mm bolts - 6)M3x10mm bolts - 9)M3 nuts - 9)washers
#8 Heat Bed Plastics (Y Plastics) = 12)m3x5mm bolts - 4)3M nuts - 9)3M lock nuts - 23)washers
#9 Hot Bed = 4)M3x20mm bolts - 4)thumb nuts - 4)12mm springs
#10 Extra
4. Hardware
#11 Y Axis Rods = 3)210mm threaded rods - 1)27mm threaded rod - 2)455 threaded rods - 1)395mm smooth rod
#12 Z Axis Rods = 2)5mmx310mm threaded rods - 2)320mm smooth rods
#13 X Axis Rods =2)365mm smooth rods
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Prusa i3 Build Manual
Tools/Supplies Required:
. 13mm open end wrench (2 if possible, if not, a small adjustable crescent wrench will do)
. Cutting pliers (if you want to trim wires, zip ties and power supply wire)
. Phillips screwdriver #1 (mount motors and acrylics)
. A small jewelers screwdriver (Set drivers boards)
. Volt meter (to calibrate the 5 driver boards)
. Metric calipers or measuring device
. Not required, an Infrared thermometer (comes in handy to check your hot end and heated bed)
Using one of the pulleys in your plastic parts bag and the part shown below, insert the pulley as
shown. Use a M3 26mm bolt, 2x M3 Washers and M3 nylon locking nut to secure. Dont overtighten as
the pulley must move freely. (Hardware Bag #6). The M3 nuts are 5.5mm.
Using 3 of the linear bearings (small steel cylindrical pieces); slide them into the 3 plastic bearing holders as
shown below.
Using the three Y bearing holders in step 5 and the acrylic bed frame (which will hold the heater and glass
printing plate later), attach the bearing holders to the frame as shown and set aside for later. (Hardware Bag #8)
Bolt heads are on the top of the Y carriage.
(Acrylic has paper on for better pictures, you will remove all paper before starting these steps)
Tip: Use one of the smooth steel rods to align the bearings.
(X Bed Frame design may change from pictured below, But steps are the same)
Using 3 linear bearings, 6 zip ties and the X carriage, place the zip-ties through the
carriage as shown. Note the direction of the zip ties closely.
Using 4 linear bearings, insert the bearings in each end of the two Z carriages.
Using the other pulley and one of the Z carriages from step 8, insert the pulley as shown below. Use a M3
26mm bolt, M3 Washers and M3 nylon locking nut to secure. Dont over tighten as the pulley
must move freely. If it is binding, loosen bolt. (Hardware Bag #6)
Repeat the process for the left side mount making sure the hole noted above is on the left side.
(Hardware Bag #3) (Acrylic has paper on for better pictures, you will remove all paper before starting these steps)
(Acrylic has paper on for better pictures, you will remove all paper before starting these steps)
Mount the motor to the right side of the X motor mount as shown. (Hardware bag #4)
No washer are to be used here and do not over tighten.
(You will have to set the pulley upside down so the teeth are inline with the belt opening)
Insert the long smooth rods as shown, dont put them all the way in yet, just enough to hold together is fine.
(Hardware #13)
Grab the X carriage we built earlier, slide it gently on to the 2 rails in the orientation shown.
Note: The distance between the two end pieces (inside to inside) is 305mm or less(very close to 12 inches).
The holes are .323 inches, or 5/16th of an inch, in diameter if you need to drill out any obstruction.
Once this piece is installed later, there should be no lateral play in the rods.
Using the parts below, mount the end stop circuit board to the end stop holder. (Hardware Bag #7)
Do not install the long bolt until the next step.
Note: The end stop will not contact the carriage; it will contact the extruder motor.
Step 18: Insert Smooth Rods Into The Z Bearings On The X Assembly
Using the shortest smooth rods, insert them into the Z bearings on the X assembly. Do this slowly to
make sure the bearings align themselves properly. (Hardware #12)
Loosen the set screws so the threaded rods go about 10mm into the motor couplers.
To assemble the Z axis end stop you can follow the same steps in step 16, however, attach the end stop
circuit board to the opposite side (hump side) of the end stop holder. Mount it on the right side Z axis
smooth rod shown below where the spring lines up with the end stop bolt. (Hardware bag #7)
Take the 2 long threaded rods and 4 nuts and 4 washers and thread as shown.
Add the 4 black end pieces to the rods and 4 more nuts and 4 washers:
Insert the ends of the rods into the Y frame corners; repeat this for all 4 corners.
Carefully adjust Y frame corners so rods drop straight down into frame.
Shorten the distance between the front and the back from the back side of the frame, this will look
much cleaner when its done.
Use the Y carriage to adjust the width between the 2 rods at the end. It is important to do this on a flat
surface as we want the frame to be level and square. Tighten the nuts on the corners as you make your
adjustments. We want the Y carriage to slide smoothly back and forth without binding. When everything is
tight, insert zip ties as shown and tighten.
Step 26: Assemble & Mount The Y Axis Belt Block To The Carriage
Mount the Y belt block to the underside of the Y carriage with 2 or 3x M3 16mm bolts
and Nyloc nuts. (Hardware Bag #8)
Note: You will not be able to fit a washer on the single side underneath hole of the older design
*** NEW design will use the same hardware bag and steps but you will have extra washers, bolt and nut
Place the pulley on the motor. Orient the pulley as shown and align the end of the pulley flat with the end of
the motors shaft. Tighten with a 2mm or 1/16 hex key.
Mount the motor to the frame as shown below, use 2 M3 10mm bolts. Make sure the
motors connection is pointing towards the front of the machine. (Hardware bag #4)
OR
Run the belt through the idler pulley at the front of the assembly.
Now back into the block. The belt should be taught, but not super tight.
Note: Cut extra belt length off (leave 1 inch).
Older Design
New Design
OR
Align the motor and front idler pulley so that the belt is straight by adjusting the nuts on the threaded rods, then
tighten nuts.
Set the assembly down ensuring the 1 washer and 1 nut on the longer rods of the Y assembly are on both
sides of the acrylic frame.
Measure and tighten the nuts that are on both sides of the acrylic frame. The corners of the Y assembly should
be 70mm from the acrylic frame. Gently tighten the nuts on the acrylic frame, DO NOT OVER TIGHTEN, the
frame will crack, snug is just fine. Do not tighten the left and right(Z), until squared up in the next step.
Install a washer and nut on each side of the threaded rod that slides into the vertical acrylic support. Make
sure the vertical supports are at a 90 degree angle to the acrylic frame. Now you can tighten the left and right
Y and Z nuts. Also the ends on the smooth Y-rod holders. Lift up on the rear Y frame while tightening to vertical Z .
NOTE: If you prefer, you can square up the 90 degree angles on the outside rather the inside of the frame.
This is similar to the belt installation on the Y axis except the X carriage is the belt block. From the back, install
the belt into the right side of the X carriage. Time to cut the tie-wrap ends if you have not already.
Thread the belt through the idler on the right side (from the back of the printer then around the motor pulley
on the left side.
Insert the belt (pulling it taught, but not super tight into the X carriage belt block. Join the ends with a zip tie
and trim the excess belt. Note: Cut extra belt length off (leave 1 inch).
Mount the heated bed to the acrylic Y carriage. Mount the bed with the wires towards the back and
the solder connections down. The thumb screws will allow for bed leveling later. (Hardware Bag #9)
Step 37: Build Arduino Electronics With RAMPS Board And Stepper Drivers
This is the brain of the printer, it's composed of an Arduino Mega 2560 board (programmable controller)
and a RAMPS shield board. This provides all the necessary connections for the motors, sensors, hot
end, heated bed and the stepper drivers that control the power and signals to the stepper motors.
This enables 16X micro-stepping for the stepper drivers, which is where the precision is derived from.
Your 5 stepper drivers need heat sinks. Peel off the tape from the back of each heat sink and apply the
heat sink to the each chip on each driver board.
Align the small stepper drivers boards (could green or red) as shown with the small potentiometer
(looks like a philips screw) towards the top of the board and press them down on to the board ensuring
that the pins are in the connectors.
Press the RAMPS shield with stepper drivers installed on to the Arduino board.
Make sure the power supply is set correctly for your Country. 115 for USA
Lets start by attaching the Green ground wire to the G/ground screw down terminal. Depending on the
country code, the Neutral (N terminal) will be either white/blue and the Load (L terminal) will be
brown/red/black.
(If using Green/White/Black cord, Green is Ground, White is Neutral and Black is Hot).
The 1 inch wire will be removed later. We will use it for a gound to calibrate the VREF on the 5 driver boards later
Step 42: Connect Fan, Hot End And Heated Bed Wires To RAMPS Board
Connect the Fan wires to the blue screw terminals marked D9 on the RAMPS board. Make sure the red
wire from the fan goes to the positive terminal on the D9 terminal. NOTE: Again be careful not to have any
loose or fraid wires that can short.
Now, connect the hot end wires (woven red fabric wires) to the screw terminals marked D10. Polarity is not
important.
Finally, connect the heated bed wires to the RAMPS board. If trimming the wires, make sure you have
enough slack for the bed to move to the front of the machine (D8).
Step 43: Connect Hot End And Heated Bed Thermistors To RAMPS Board
Connect the hot end thermistor (thin 2 pin connector from the extruder) to T0 and the heat bed
thermistor (thin 2 pin connector from the heat bed) to T1 on the RAMPS board. No polarity on
either.
Please follow the pictures for the proper wire orientation. If a motor
moves the in the opposite direction, simply rotate the connector 180
degrees and plug back in to the board.
Note: The E1 port is not used. This is usually for a second extruder,
in this case, it is a spare stepper driver in case you have a failure.
Using a ruler, measure the distance between the top of the acrylic motor mounts to the bottom of each side
of the X carriage. There is no set distance, but they should be the same distance from the mounts. To adjust
the height, turn the threaded rods on either side. NOTE: Make sure the Z axis nuts are seated inside the X carriage.
Using a ruler, measure the distance between the right side Y front frame and the end stop. Set it at 60mm to
start.
Note: We have supplied 2 flanged bearings to hold the M5 threaded rod in place. Just insert in the hole openings on top of these rod
keepers.
Before proceeding:
X 0.550V
Y 0.550V
Z 0.550V
E 0.550V
Picture shown is for reference; yours should already be installed on your printer and wired. If you're up on your electronics,
connect your meter ground probe to the 1 inch
1. Attach your ribbon cables from the LCD to the RAMPS 1.4 adapter board (small board to connect the RAMPS later).
2. Attach the RAMPS 1.4 adapter board to the RAMPS 1.4 board
3. Adjust the contrast on the LCD display with a small phillips screw driver.