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Assembly Instructions Beta Prusa V2 Deluxe - EasyBuild

12/10/12

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

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TEP

 1.1

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6

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 1.2

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7

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TEP

 1.3 

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8

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TEP

 1.8

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TEP

 1.5

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12

ASSEMBLY OF THE AXES................................................................................................................................13

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TEP

 2.1

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14

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TEP

 2.2

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16

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TEP

 2.3

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18

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TEP

 2.4

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20

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TEP

 2.5

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 2.6

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ASSEMBLY OF THE EXTRUDER....................................................................................................................26

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TEP

 3.1

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27

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 3.2

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ASSEMBLY OF THE PRINT BED AND EXTRAS..........................................................................................31

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 4.1

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32

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TEP

 4.2

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33

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 4.3

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34

ASSEMBLY OF THE ELECTRONICS..............................................................................................................36

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 5.1

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37

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 5.2

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40

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 5.3

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 Page 3/ 53

Summary of Contents for Beta Prusa V2 Deluxe

Page 1: ...Assembly Instructions Beta Prusa V2 Deluxe EasyBuild 17 01 14 Assembly Instructions Beta Prusa V2 Deluxe EasyBuild 3D Printer Version 2 2 Date 17 01 14 Page 1 53 ...

Page 2: ... V2 EasyBuild Year 2013 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 10 09 2013 ...

Page 3: ...nd 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 8 STEP 1 8 9 STEP 1 5 12 ASSEMBLY OF THE AXES 13 STEP 2 1 14 STEP 2 2 16 STEP 2 3 18 STEP 2 4 20 STEP 2 5 22 STEP 2 6 24 ASSEMBLY OF THE EXTRUDER 26 STEP 3 1 27 STEP 3 2 29 ASSEMBLY OF THE PRINT BED AND EXTRAS 31 STEP 4 1 32 STEP 4 2 33 STEP 4 3 34 ASSEMBLY OF THE ELECT...

Page 4: ... If the information is not followed it can result in death or serious injury invalidity 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 n...

Page 5: ...Assembly Instructions Beta Prusa V2 Deluxe EasyBuild 12 10 12 Chapter I Assembly of the Frame Page 5 53 ...

Page 6: ...ild 12 10 12 Step 1 1 Needed parts for step 1 1 The following parts are needed for this step 4x Washer M8 4x Nut M8 1x Threaded rod M8 x 294 mm Assembly Step 1 1 Position the nuts and washer on the threaded rod as shown in the picture above Page 6 53 ...

Page 7: ...asyBuild 12 10 12 Step 1 2 Needed parts for step 1 2 The following parts are needed for this step 2x Washer M8 2x Nut M8 1x Threaded rod M8 x 294 mm Assembly Step 1 2 Position the parts on the threaded rod as shown in the picture above Page 7 53 ...

Page 8: ...asyBuild 12 10 12 Step 1 3 Needed parts for step 1 3 The following parts are needed for this step 4x Nut M8 4x Washer M8 2x Threaded rod M8 x 440 mm Assembly Step 1 3 Position the parts on the threaded rod as shown in the picture above Page 8 53 ...

Page 9: ... parts for step 1 8 The following parts are needed for this step 1x Y motor holder 2x Z motor holder 24x Washer M8 16x Nut M8 2x pre assembled triangles and all previously assembled parts as well as the pre assembled 294mm threaded rods with bearings Assembly Step 1 8 Page 9 53 ...

Page 10: ...ame vertexes without feet like it s shown in the picture 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 ou...

Page 11: ...older 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 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 11 53 ...

Page 12: ...or 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 5 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 12 53 ...

Page 13: ...Assembly Instructions Beta Prusa V2 Deluxe EasyBuild 12 10 12 Chapter II Assembly of the Axes Page 13 53 ...

Page 14: ...x 10 mm 2x Smooth rod 8mm x 406 mm and the structure from the previous step Push the smooth rods through the bar clamps on the frame and slide on the linear bearings Do not fasten the nuts on the rod clamps yet Make sure that the pre mounted endstopflag is positioned on the side of the y motor NOTICE Grease the linear bearings before using them Make sure that the pre mounted endstopflag is positio...

Page 15: ...ke sure the motor cables on the motor are pointing downwards Assembly of the Y Axis motor Then adjust the smooth rods with the rod 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 un...

Page 16: ...re needed for this step 1x Belt and the structure from the previous step Assembly of the belt Secure the belt on the thin belt clamp and 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 Page 16 53 ...

Page 17: ...e Like it is shown in the pictures above Pull the belt tight and fasten the screws on the belt clamp 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 17 53 ...

Page 18: ... needed for this step 2x Rod clamps 4x Washer M4 4x Screw M4 x 16 mm 2x Smooth rod 8mm x 350 mm 2x pre assembled X ends and the structure from the previous steps Assembly step 2 3 Put the smooth rods onto both sides of the frame as shown in the picture above Slide the X ends onto the rods before fixating them Page 18 53 ...

Page 19: ...ou can see how that is done on the following pictures The M4 nuts are already casted in 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 f...

Page 20: ...he following parts are needed for this step 1x pre assembled X carriage 2x Smooth rod 8mm x 420 mm and the structure from the previous steps Assembly step 2 4 Slide the pre assembled x carriage onto the smooth rods and push them through both x end parts like its shown in the picture above Page 20 53 ...

Page 21: ...nd part Make sure the rods are centred Check that the construction can smoothly go up and down on the vertical rods without any blocking If necessary vary the tension of the screws on the linear bearings until the construction slides easily Let the z axis slide down until it sits on the y carriage Also check if the X carriage can slide smoothly on the horizontal rods and secure the screws on the l...

Page 22: ... 5 Needed parts for step 2 5 The following parts are needed for this step 2x Z axis coupling 8x Screw M3 x 10 mm 8x M3 washer 2x Nut M8 2x Motor Nema17 with cable and plug 2x Threaded rod M8 x 210 mm and the structure from the previous steps Assembly step 2 6 Page 22 53 ...

Page 23: ...ds from the top through them If the M8 nut sits too loose wrap it with a few layers of tape until it fits perfectly Then connect the drive rods with the motor shafts with the z axis couplers Use a z axis coupler on each rod use them to securely clamp together the drive rod and the motor shaft with the integrated grub screws Make sure the drive rods are exactly vertical and parallel to the smooth r...

Page 24: ...Beta Prusa V2 Deluxe EasyBuild 12 10 12 Step 2 6 Needed parts for step 2 6 The following parts are needed for this step 1x Belt 1x Pulley and the structure from the previous steps Assembly step 2 7 Pulley assembly Page 24 53 ...

Page 25: ... 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 over the belt clamp to the middle and back out under the 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 carriag...

Page 26: ...Assembly Instructions Beta Prusa V2 Deluxe EasyBuild 12 10 12 Chapter III Assembly of the extruder Page 26 53 ...

Page 27: ...efore installing the hotend you should make sure that the nozzle is screwed into the holder to the very end If there is a gap between the holder and the inner part of the nozzle the hotend might block Therefore put a toothpick into the hotend and check if you can feel a significant gap inside the hotend Push the heating element into the big hole of the J Head and secure it with the integrated grub...

Page 28: ...y The push the thermistor into the small hole of the J Head like it is shown in the picture above Fixate the thermistor at the nozzle with a small piece of heat resistant tape or glue You should make sure it cannot drop out the nozzle Secure the thermistor cable and the cable of the heating element on the J head with a piece of tape Page 28 53 ...

Page 29: ...luxe EasyBuild 12 10 12 Step 3 2 Needed parts for step 3 2 The following parts are needed for this step 2x Screw M4 x 20 mm 2x Washer M4 1x pre assembled Extruder 1x Hotend clamp 1x J Head from the previous step Assembly step 3 2 Page 29 53 ...

Page 30: ... needed use pliers Place the hotend with it s clamp onto the x carriage and the pre assembled extruder on top of it Make sure cables from the hotend are on the extruder side without gears Use two M4x20 mm screws and fitting washers to secure the extruder to the x carriage It is also possible to mount the extruder turned 180 Page 30 53 ...

Page 31: ...Assembly Instructions Beta Prusa V2 Deluxe EasyBuild 12 10 12 Chapter IV Assembly of the Print bed and extras Page 31 53 ...

Page 32: ...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 32 53 ...

Page 33: ...ed 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 33 53 ...

Page 34: ...te 200 mm x 200 mm 4x thick Spring 8mm 1x Kapton tape 8x Washer M3 4x Nut M3 Nyloc 4x Screw M3 x 30 mm 1x pre assembled Heated print bed 4x Foldback clamps Assembly step 4 3 Mount the heated print bed onto the y carriage with four M3 x 30 mm screw the spring which was cut into 4 parts washers and nuts as shown in the picture above The M3 Nyloc Page 34 53 ...

Page 35: ...s between the PCB of the heated bet and the springs 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 Place the mirror plate onto the heated printbed and secure it with the four foldback clamps Page 35 53 ...

Page 36: ...Assembly Instructions Beta Prusa V2 Deluxe EasyBuild 12 10 12 Chapter V Assembly of the Electronics Page 36 53 ...

Page 37: ... holder 1x straight end stop holder 1x flag 3x Screw M3 x 20 mm 3x Screw M3 x 16 mm 8x Washer M3 4x Nut M3 and the structure of the previous steps 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 Page 37 53 ...

Page 38: ... 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 end stop without problems when the z axis drives down complete...

Page 39: ...tions Beta Prusa V2 Deluxe EasyBuild 12 10 12 Bend and cut the flag on the x carriage until it goes into the end stop without any problems when the x axis is moved fully to one side Position of the endstops Page 39 53 ...

Page 40: ...re needed for this step 1x RAMPS electronic 1x RAMPS electronic holder 4x Rod clamps 1x Filament guide 1x 40mm Fan 1x Fan director 1x metal Strip 2x Screw M3 x 20 mm 4x Screw M3 x 30 mm 3x Screw M3 x 25 mm 2x Screw M3 x 10 mm 16x Washer M3 8x Nut M3 and the structure from the previous steps Assembly step 5 2 Page 40 53 ...

Page 41: ...o the fan with two M3 x 10 mm screws Then attach the strips to a screw of the x carriage and bend them so that the fan blows at the black part of the hotend Assembly RAMPS Attach the RAMPS electronic holder onto the side of the 3D printer with four rod clamps and two M3 x 30 mm screw washers and nuts each Put the RAMPS electronic onto the holder and secure it with three M3 x 25 mm screws washer on...

Page 42: ... following parts are needed for this step 30x cable ties 1x twofold terminal block 4x Heat sinks 1x thermal glue tube 3x Three wire cable with plugs 1x Thick two wire cable 1x Thin two wire cable 1x ATX power supply 1x ATX Adapter and the structure from the previous steps Assembly step 5 3 Page 42 53 ...

Page 43: ...utting it We start with the Z axis motors Move both cables to the side where the electronic is and run the cables down the rod on this side to the electronics Connection of the z motors Cable management for the z motor The highlighted cable in this picture are the Z motor cables Plug both cables in like it is shown the pictures below Make sure the blue cable is on the right side Page 43 53 ...

Page 44: ... the electronic Put the electronic on the left side of your 3d printer like it is shown in the first picture Connection of the y motor Next run the cable of the Y axis motor alongside the rods to the electronics board Like it is shown in the picture above with the highlighted cable Page 44 53 ...

Page 45: ...the highlighted cable above Again make sure that the blue cable is on the right side Connection of the x motor To connect the x axis motor guide the motor cable in a loose curve onto the diagonal rod and from there on downwards Make sure the is enough cable that the Z axis can move fully up and down Guide the cable below the printbed along the middle rod to the electronics Page 45 53 ...

Page 46: ... motors to the electronic Connection of the x motor to the electronic Plug the cable into the right most motor connector on the electronics as is shown with the highlighted cable in the image above Make sure the blue cable is on the right side Connection of the extruder Page 46 53 ...

Page 47: ...to the colour coding Cable management of the Extruder 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 wit...

Page 48: ...n the electronics as shown above Here the colour coding also doesn t matter The fan cables go onto the middle screw terminal Connection of the x end stop For the end stops we take a three wire cable with the plugs on both sides Plug the cable into the end stop with the marked side pointing to the front and guide it in a small loop to the side of the printer and then down to the electronic Make sur...

Page 49: ... later Connection of the z end stop Connect another three wire cable to the z end stop and guide the cable down the vertical rod and plug it into the electronic like the red cable shown in the picture above Make sure to plug it into the correct socket There is always on free row of pins between the end stop plugs Again make sure the marked side of the cable points to the front of the endstop and o...

Page 50: ...a three wire cable and connect it to the end stop Make sure the marked side points to the front of 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 alongside the middle rod to the electronic Connection of the y end stop to the electronic Page 50 53 ...

Page 51: ...e plug and that the marked side of the cable points to the USB plug 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 e...

Page 52: ...ew 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 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 52 5...

Page 53: ... and connect the black cables to GND and the yellow ones to plus It is recommended to connect at least two cables each to make good contact Also make sure that the unused red cables stay isolated good and can not make any shorts 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 bundl...

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