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2PrintBeta Beta Prusa Basic, Assembly Instructions Manual

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Assembly Instructions Beta Prusa Minimal

30/05/13

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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 1.1.................................................................................................................................................................6

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 1.2.................................................................................................................................................................7

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 1.3.................................................................................................................................................................9

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 1.4 ..............................................................................................................................................................10

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 1.5 ..............................................................................................................................................................11

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 1.6 ..............................................................................................................................................................12

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 1.7...............................................................................................................................................................13

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 1.8...............................................................................................................................................................14

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 1.9...............................................................................................................................................................17

ASSEMBLY OF THE AXES................................................................................................................................18

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 2.1...............................................................................................................................................................19

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 2.2...............................................................................................................................................................21

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 2.3...............................................................................................................................................................24

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 2.4...............................................................................................................................................................26

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 2.5...............................................................................................................................................................28

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 2.6...............................................................................................................................................................30

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 2.7...............................................................................................................................................................32

ASSEMBLY OF THE EXTRUDER....................................................................................................................34

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 3.1...............................................................................................................................................................35

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 3.2...............................................................................................................................................................37

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 3.3...............................................................................................................................................................39

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 3.4...............................................................................................................................................................40

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 3.5...............................................................................................................................................................42

ASSEMBLY OF THE PRINT BED.....................................................................................................................43

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 4.1...............................................................................................................................................................44

ASSEMBLY OF THE ELECTRONICS..............................................................................................................45

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 5.1...............................................................................................................................................................46

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 5.2...............................................................................................................................................................48

 Page 3 / 57

Summary of Contents for Beta Prusa Basic

Page 1: ...Assembly Instructions Beta Prusa Minimal 30 05 13 Assembly Instructions Beta Prusa Basic 3D Printer Version 1 5 Date 30 05 13 Page 1 57 ...

Page 2: ...hings 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 ________...

Page 3: ...ols 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 43 ST...

Page 4: ...e 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 notes u...

Page 5: ...Assembly Instructions Beta Prusa Minimal 30 05 13 Chapter I Assembly of the Frame Page 5 57 ...

Page 6: ... 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 57 ...

Page 7: ...imal 30 05 13 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 57 ...

Page 8: ...at 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 57 ...

Page 9: ... 05 13 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 57 ...

Page 10: ...ut 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 Notice Place the bearing with the belt guide so that the protruding side of the belt guide points to the M8 nut Page 10 57 ...

Page 11: ...eeded 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 57 ...

Page 12: ...al 30 05 13 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 57 ...

Page 13: ...al 30 05 13 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 57 ...

Page 14: ...her 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 57 ...

Page 15: ...e 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 around 260 mm Assembly of a z motor holder Page 15 57 ...

Page 16: ... 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 16 57 ...

Page 17: ...s 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 57 ...

Page 18: ...Assembly Instructions Beta Prusa Minimal 30 05 13 Chapter II Assembly of the Axes Page 18 57 ...

Page 19: ...4x Bushing 1x Motor Nema17 with cable and plug 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 Push the smooth rods through the bar clamps on the frame and click the bushings onto the rods Do not fasten the nuts on the rod clamps yet Page 19 57 ...

Page 20: ... 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 57 ...

Page 21: ...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 Place the y carriage onto the bushings 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 clamps Page 21 57 ...

Page 22: ...clamps until the smooth rods can t be moved any more Now glue the bushings onto 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 Loop the belt around the belt guide around the gear on t...

Page 23: ...rom 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 horizont...

Page 24: ...re needed for this step 4x Bushings 2x Rod clamps 4x Washer M4 4x Nut M4 4x Screw M4 x 16 mm 2x Smooth rod 8mm x 350 mm 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 Click the bushing onto the smooth rods Page 24 57 ...

Page 25: ...r set the m4 nuts might be 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 fasten the bar clamps until the rods can t b...

Page 26: ... 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 57 ...

Page 27: ... 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 57 ...

Page 28: ...lder from the previous step 8x Screw M3 x 10 mm 4x Bushing 2x Smooth rod 8mm x 420 mm and the structure from the previous steps Assembly step 2 5 Push the four bushings onto the smooth rods and push them through both X end parts Insert the assembly into the 3D printer frame and push the X end parts onto the bushings on the vertical rods like it s shown in the picture above Page 28 57 ...

Page 29: ...e 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 glue on the vertical bushings onto the X end parts Page 29 57 ...

Page 30: ... Needed parts for step 2 6 The following parts are needed for this step 2x Z axis coupling 8x Screw M3 x 10 mm 2x Nut M8 2x Motor Nema17 with cable without plug 2x Threaded rod M8 x 210 mm and the structure from the previous steps Assembly step 2 6 Page 30 57 ...

Page 31: ... 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 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 rods of the frame also the X axis should be exactl...

Page 32: ...7 The following parts are needed for this step 1x X carriage 2x Belt clamp 1x Gear 1x Grub screw M3 x 8 mm 4x Nut M3 7x Washer M3 1x Belt 1x Motor Nema17 with cable and plug 4x Screw M3 x 20 mm 3x Screw M3 x 10 mm and the structure from the previous steps Assembly step 2 7 Page 32 57 ...

Page 33: ...e X carriage onto the bushings of the X axis and check if it can glide smoothly over the rods Glue the X carriage to the bushings Assembly detail step 2 7 Attach the belt clamps on the X carriage as shown in the picture above Both clamps are attached with two M3 x 20 mm screws and a washer and a nut Clamp the belt on the left side and loop it around the belt guide around the gear on the right side...

Page 34: ...Assembly Instructions Beta Prusa Minimal 30 05 13 Chapter III Assembly of the extruder Page 34 57 ...

Page 35: ...on 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 Before 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 Page 35 57 ...

Page 36: ... 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 Then push the thermistor into the sm...

Page 37: ...ep 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 thin 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 57 ...

Page 38: ...lly 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 NOTICE Make sure to place the screws exactly as shown in the picture or they might collide with the gear later Another way to mount the J head is by us...

Page 39: ...ed 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 Depending on your kit the nut might be already casted in Page 39 57 ...

Page 40: ...d 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 with cable and plug and all parts from the previous steps Assembly detail step 3 4 Page 40 57 ...

Page 41: ... 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 longer 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 ...

Page 42: ...lowing parts are needed for this step 2x Screw M4 x 20 mm 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 nuts onto the x carriage Page 42 57 ...

Page 43: ...Assembly Instructions Beta Prusa Minimal 30 05 13 Chapter IV Assembly of the print bed Page 43 57 ...

Page 44: ...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 into four parts 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 44 57 ...

Page 45: ...Assembly Instructions Beta Prusa Minimal 30 05 13 Chapter V Assembly of the Electronics Page 45 57 ...

Page 46: ... for this step 3x Optical end stop 2x curved end stop holder 1x straight end stop holder 2x Belt clamps without channel 3x Metal flags 5x Screw M3 x 20 mm 3x Screw M3 x 16 mm 1x Screw M3 x 10 mm 15x Washer M3 7x Nut M3 and the structure of the previous steps Assembly of the optical end stop on the Y axis Page 46 57 ...

Page 47: ...e 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 completely Assembly of the optic...

Page 48: ...eeded for this step 30x cable ties 3x Three wire cable with plugs 4x heatsinks 1x Heatsink glue 1x Thick two wire cable not included in this set ATX power supply not included in this set ATX Adapter not included in this set RAMPS Electronic and the structure from the previous steps Assembly step 5 3 Page 48 57 ...

Page 49: ...g 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 red cable is on the right side Page 49 57 ...

Page 50: ...lectronic 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 50 57 ...

Page 51: ...ighlighted cable above Again make sure that the red 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 51 57 ...

Page 52: ...n the image above Make sure the red cable is on the right side Connection of the extruder For connecting the Extruder guide the cables from the extruder motor the two red heater wires and the thin thermistor wire in a big loop to the side and along the diagonal rod down to the electronics Make sure the loop is big enough so the extruder can fully move to both sides even in the lowest setting Page ...

Page 53: ...hown above Here the colour coding doesn t matter The cables of the heater need to be connected to the lowest screw terminals on the electronics as shown above Here the colour coding also doesn t matter 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 and guide it in a small loop to the side of the printer and th...

Page 54: ... reverse connection So if the cable is plugging in the wrong directions you can easily correct it 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...

Page 55: ...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 alongside the middle rod to the electronic Connection of the y end stop to the electronic Connect the cable to the electronic as shown in the picture above Again make sure to use the correct pins for the plug Page 55 57 ...

Page 56: ... 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 56 57 ...

Page 57: ...e contacts 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...

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