ooznest Prusa i3 Assembly Instructions Manual

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Prusa i3
Assembly Instructions

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  • Page 1 Prusa i3 Assembly Instructions...
  • Page 2: Tools Required

    Overview The Prusa i3 is the third iteration in the series of printers designed Josef Prusa. Our kit uses his open- source design and adds many beneficial upgrades. Our kit includes all the parts required to build a Prusa i3, plus many extras that will help you get printing as quickly as possible.
  • Page 3 Y-Axis Idler Assembly Instructions A)* Insert a M4-Hex-Nut into the inset provided on the backside of the Y-Axis-Idler. Screw a M4-20mm-Bolt through the M4-Hex-Nut Nut until it is just about to come through the other side of the M4-Hex-Nut. B) Screw a M3-25mm-Bolt through 2 x 623zz-Flanged Bearings, as in the diagram, ensuring that two M3- Washers are included.
  • Page 4 Y-Axis Front Assembly Instructions A) Thread M8-Hex-Nuts, M8-Washers, Y-Axis-Idler & Y-Axis-Corners along the 2 x Threaded-Rods-8mm in the order as shown in the diagram. B) Finger tighten the M8-Hex-Nuts so the Y-Axis-Idler and Y-Axis-Corners are as shown in the left-hand image.
  • Page 5 Y-Axis Back Assembly Instructions Instructions A) Thread M8-Hex-Nuts, M8-Washers, Y-Axis-Motor & Y-Axis-Corners along the 2 x Threaded-Rod-8mm in the order as shown in the diagram. B) Finger tighten the M8-Hex-Nuts so the Y-Axis-Idler and Y-Axis-Corners are as shown in the left-hand image.
  • Page 6 Y-Axis Bed Assembly Instructions A)* Insert M3-Nyloc-Nuts into each of the hex insets on the 4 Heated-Bed-Spring-Traps. Push a Heated- Bed-Spring-Trap onto each corner of the Y-Axis-Bed-Plate B) Attach the Y-Axis-Belt-Holder to the Y-Axis-Bed-Plate using 2 x M3-16mm-Bolts & 2 x M3-Nyloc-Nuts. Ensure you place a M3-Washer in between each M3-16mm-Bolt head and the Y-Axis-Belt-Holder.
  • Page 7: Y-Axis Assembly

    Y-Axis Assembly Instructions A) Thread M10-Hex-Nuts, M10-Washers, M10-Penny-Washers, Y-Axis-Front & Y-Axis-Back onto both Threaded-Rods-10mm in the order as shown in the diagram. B) Insert 2 x Smooth-Rods-350mm through the LM8UU-Bearings of the previously assembled Y-Axis-Bed, and then insert the ends of the Smooth-Rod-350mm into the insets on the Y-Axis-Corners. Make sure the side on the Y-Axis-Bed with one LM8UU-Bearing is on the left-hand side of the assembly.
  • Page 8 X-Axis Tensioner Assembly Instructions A) Insert A M3-Hex-Nut into the inset provided on the backside of the X-Axis-Tensioner. Screw a M3- 20mm-Bolt through the M3-Hex-Nut until it is just about to come through the other side of the M3-Hex- Nut. B) Screw a M3-25mm-Bolt through 2 x 623zz-Flanged-Bearings, as in the diagram, ensuring that two M3- Washers are included.
  • Page 9 X-Axis Idler Assembly Instructions A) Insert the X-Axis-Tensioner through the horizontal slot in the X-Axis-Idler, as shown above. Screw a M4- 25mm-Bolt through the X-Axis-Idler & X-Axis-Tensioner, remembering to include the M4-Washers. Then attach a M4-Nyloc-Nut and finger tighten. This will be fully tightened later once the GT2-Belt has been connected.
  • Page 10 X-Axis Motor Assembly Instructions A)* Insert a M3-Hex-Nut into the slot provided on the right-hand side of the X-Axis-Motor. Screw a M3- 25mm-Bolt through a M3-Washer & Compression Spring. Once through the other side, attach a M3-Nyloc- Nut to the end. While holding the M3-Nyloc-Nut with a spanner, screw the M3-25mm-Bolt until it is flush with the bottom of the M3-Nyloc-Nut.
  • Page 11 X-Axis Carriage Assembly Instructions A) Insert 4 x LM8UU-Bearings into the bearing holders on the X-Axis-Carriage. Insert a 8mm-Smooth-Rod through each pair of LM8UU-Bearings, and securely attach each LM8UU-Bearing to the X-Axis-Carriage using cable ties through the provided slots. The 8mm-Smooth-Rods can now be removed. B)* Push 2 x M3-Nyloc-Nuts into the insets provided.
  • Page 12: X-Axis Assembly

    X-Axis Assembly Instructions A) Push a Smooth-Rod-370mm into each hole on the X-Axis-Motor. Ensure they are fully seated. Lightly tap with a mallet or hammer if needed. B) Slide the X-Axis-Carriage onto the 2 x Smooth-Rods-370mm. It should be oriented so the teeth on the back of the X-Axis-Carriage are pointing downwards.
  • Page 13 Attaching Z-Axis Frame Instructions A) Insert the Z-Axis-Frame between the M10-Penny-Washers on the Y-Axis. B) Adjust the Z-Axis-Frame so the distance between the front side of the Z-Axis-Frame and the end of the Smooth-Rod-350mm is 214mm on both sides. C) Strongly tighten the 4 x M10-Hex-Nuts that are holding the Z-Axis-Frame. Access to these nuts can be improved by removing the Y-Axis-Bed.
  • Page 14 Z-Axis Frame Brace Assembly - Part 1 Instructions A) Attach a Z-Axis-Framebrace on either side of the Z-Axis-Frame on top of the left-hand M10-Penny- Washers. This is done using 4 x M3-25mm-Bolts, 8 x M3-Washers & 4 x M3-Nylocs. The M3-25mm-Bolts go through both Z-Axis-Framebraces, with the M3-Nylocs attaching on the backside.
  • Page 15 Z-Axis Frame Brace Assembly - Part 2 Instructions A)* Insert a M3-Hex-Nut into each of the 2 slots provided on the Z-Axis-Framebrace. Due to a change to the kit, contrary to the image above, the slots are now found on the underside of the Z-Axis-Framebrace. B) Place the Z-Axis-Framebrace-Top over the Threaded-Rod-10mm, and tighten down into the inserted M3- Hex-Nut using 2 x M3-20mm-Bolts.
  • Page 16 Z-Axis Motor Mount Attachment Instructions A) Attach the Z-Axis-Motor-Left using 3 x M3-16mm-Bolts and 3 x M3-Nyloc-Nuts. B) Repeat the process for Z-Axis-Motor-Right. 16 of 62...
  • Page 17 Z-Axis Motor Attachment Instructions A) Attach a NEMA17-Stepper-Motor to the Z-Axis-Motor-Left using 3 x M3-10mm-Bolts and 3 x M3- Washers. Make sure that the connection terminal on the NEMA17-Stepper-Motor goes against the frame, and connect the wire that has been pre-inserted through the hole to this terminal. B) Repeat the process to attach the NEMA17-Stepper-Motor to the Z-Axis-Motor-Right.
  • Page 18 Z-Axis Nut Traps Assembly Instructions A)* Insert a Brass M5-Hex-Nut in both of the 2 slots on each Z-Axis-Nuttrap. The 2 x M5-Hex-Nuts need to be in sync for the Threaded-Rod-5mm to go through. This has already been completed by us. However, the procedure to get the 2 x M5-Hex-Nuts in sync is detailed in Appendix B.
  • Page 19 Attaching Threaded Rod to Motor Shaft Instructions Note Kit Change In the latest version of the kit 5x5mm-Flexible-Couplers are provided in place of the plastic printed ones. Ignore the above image and follow the new steps below: A) Loosen all grub screws on the 5x5mm-Flexible-Coupler, slide it over the left-hand side NEMA17-Stepper- Motor Shaft.
  • Page 20 Attaching X-Axis to Z-Axis Instructions Manual Amendment: Complete all steps on Page 22 before doing the steps on this page, and then continue as normal. A) Slide the previously assembled X-Axis over the 2 x Threaded-Rods-5mm so it sits on top of both Z-Axis- Nuttraps.
  • Page 21 Z-Axis Top Assembly Instructions A) Insert a 625zz-Bearing into the inset on the Z-Axis-Top-left until it is flush with the top, this may require a tap with a hammer. B) Attach the Z-Axis-Top-Left to the Z-Axis-Frame using 2 x M3-16mm-Bolt & 2 x M3-Nyloc-Nut, before tightening repeat the same procedure with the Z-Axis-Top-Right, then tighten them both fully.
  • Page 22 Attaching RAMPS 1.4 Instructions A) Attach a heat sink to each of the 4 x Stepper Drivers on the RAMPS-1.4 Board (red circles). Use a square of the provided Double-Sided Aluminium Conductive Sticker in between the heat sink and the Stepper Driver.
  • Page 23 Attaching X-Axis Motor Instructions A) Attach a NEMA17-Stepper-Motor to the X-Axis-Motor using 3 x M3-18mm-Bolts. Make sure the white connection terminal on the NEMA17-Stepper-Motor is pointing downwards. B) Push a GT2-Pulley onto the NEMA17-Stepper-Motor Shaft. Position it so the grooved section is in the middle of the horizontal gap, which goes through the X-Axis-Motor.
  • Page 24 Attaching X-Axis GT2 Belt Instructions A) Loop one metre of GT2-Belt around the GT2-Pulley on the X-Axis-Motor, then over to X-Axis-Idler, and loop it around the 623zz-Flanged-Bearings on the X-Axis Tensioner. Adjust the lengths so the two free ends of the GT2-Belt meet at the bottom of the X-Axis-Carriage. B) Loop one free end of the GT2-Belt around one of the grooved belt holders on the X-Axis-Carriage so it comes back on to itself with the teeth facing each other.
  • Page 25 Attaching Y-Axis Motor Instructions A) Attach a NEMA17-Stepper-Motor to the Y-Axis-Motor using 3 x M3-12mm-Bolts. Ensure the connection terminal on the NEMA17-Stepper-Motor is pointing towards the Z-Axis-Frame. B) Push a GT2-Pulley onto the NEMA17-Stepper-Motor Shaft. Position it so it is roughly 1.0mm from the motor casing.
  • Page 26 Attaching Y-Axis GT2 Belt Instructions A) Loop one metre of GT2-Belt around the GT2-Pulley on the Y-Axis-Motor, then over to Y-Axis-Idler, and loop it around the 623zz-Flanged-Bearings on the Y-Axis-Idler. Adjust the lengths so the two free ends of the GT2-Belt meet at the top of the Y-Axis- Belt-Holder.
  • Page 27 Attaching Heated Bed Instructions A) To attach the Heated-Bed to the Y-Axis-Bed, in each corner, use a M3-30mm-Bolt, M3-Washer, & a Compression-Spring. The Heated-Bed should be orientated so the plain aluminium side is facing upwards with the wire connections coming out at the back of the machine. The easiest way to attach the Heated- Bed is to first have the Heated-Bed resting on the Y-Axis-Bed with the Compressions-Springs in between and the M3-30mm-Bolt through the hole in each corner.
  • Page 28 Hotend Fan Assembly Instructions A)* Insert a M3-Nyloc-Nut into each slot provided on the left & right sides of the Hotend-Fan-Shroud. B) Attach the 25mm-Hotend-Fan to the Hotend-Fan-Shroud using 4 x M3-18mm-Bolts & 4 x M3-Nyloc- Nuts. The 25mm-Hotend-Fan should be orientated so the flat square side is against the Hotend-Fan- Shroud.
  • Page 29 Attaching Extruder Mount Instructions A) Attach the Extruder-Mount to the X-Axis-Carriage using 2 x M3-25mm-Bolts, which screw into 2 x M3- Nyloc-Nuts, that are on the back side of the X-Axis-Carriage. You will have to start off screwing the 2 x M3- 25mm-Bolts in at an angle.
  • Page 30 Attaching Extruder Instructions Manual Amendment: Complete Step A on Page 31 before doing the steps on this page, and then continue as normal. A) Attach the Extruder to the Extruder-Mount by first feeding the Thermistor & Cartridge Heater wires through the hole in the Extruder-Mount where the Hotend will sit. Next bring the Hotend downwards through the same hole so the extruder is sitting flat on the plastic.
  • Page 31 Attaching Extruder Fan & Extruder Wiring Instructions A) Attach the Extruder-Fan to the Extruder-Mount so the air flow opening on the Extruder-Fan is pointing towards the gap through the Extruder-Mount, which looks on to the Hotend. Secure it with the supplied Philips Screws.
  • Page 32 X & Y-Axis Endstop Holders Instructions A) Insert a Mechanical-Endstop into the X-Axis-Endstop-Holder, and attach it to the two Smooth-Rods- 370mm on the X-Axis. Use a cable tie going around the bottom Smooth-Rod-370mm and through the slot on X-Axis-Endstop-Holder to secure it roughly 15mm away from the X-Axis-Motor (this may need adjusting later).
  • Page 33 Attaching LCD Controller Instructions A) Attach the LCD-Controller to the 2 x Threaded-Rod-8mm on the front of the Y-Axis. B) Use 2 x M3-18mm-Bolts, 4 x M3-Washers & 2 x M3-Nylocs to secure it to the top Threaded-Rod-8mm. It is a good idea to leave this step until you are fully satisfied with the machine so you can easily get access to the Y-Axis-Idler if needed.
  • Page 34: Attaching Power Supply

    Attaching Power Supply Instructions A) Use 2 x M4-10mm-Bolts coming through the front of the Z-Axis-Frame to attach the Power-Supply in the orientation above. 34 of 62...
  • Page 35: Notes On Wiring

    Notes on Wiring Appendix C is a RAMPS 1.4 Wiring Diagram, which shows where every wire should be plugged into. The wires in the diagram are coloured the same as the wires supplied, so take care to follow which colour goes where so you get the correct orientation of each wire.
  • Page 36 Wiring - Part 2 A) If looking from the back, the left-hand Z-Axis & Y-Axis NEMA17-Stepper-Motor Wires can be routed along the back Threaded-Rod-8mm's along with the Y-Axis Mechanical-Endstop, Heated-Bed Power and Thermistor Wires. B) Route all the wires mentioned in Step A to the bottom of the RAMPS-1.4 and join them up with right- hand Z-Axis NEMA17-Stepper-Motor (If looking from the back).
  • Page 37 Wiring - Part 3 A) Route the wires from the X-Carriage behind the left-hand Threaded & Smooth Rod so they meet with the X & Z endstop wires and sit on top of the X-Axis-Motor. All these wires can now be cable tied to the anchor slot on the X-Axis-Motor (Green Circle).
  • Page 38 RAMPS Cooling Fans Assembly Instructions A) Attach 2 x 40mm-Fans (fan sticker downwards) to the RAMPS-Fans-Holder using 8 x M3-20mm-Bolts & 8 x M3-Nyloc-Nuts. Ensure the position where the leads attach to the 40mm-Fans is closest to the hinge. B)* Insert a M3-Nyloc into each of the two insets on the RAMPS-Fans-Bracket. C) Mate the hinges on the RAMPS-Fans-Holder to the hinges on the RAMPS-Fans-Bracket, and secure them together using 1 x M3-25mm-Bolt, 1 x M3-Nyloc-Nut &...
  • Page 39 RAMPS Cooling Fans Attachment Instructions A) Attach both 40mm-Fans to the D9 Terminals as in the RAMPS 1.4 Wiring Diagram. B) Attach the left side of the RAMPS-Fans to the RAMPS-1.4 using the already inserted M3-50mm-Bolt in the bottom-left corner of the RAMPS-1.4. Use a M3-8mm-Bolt through only the top board of the RAMPS- 1.4 stack to secure the the right side of the RAMPS-Fans.
  • Page 40 Testing & Commissioning - Part 1 Note the pre-configured firmware has been uploaded by us to the Arduino. However, Appendix D explains the procedure if it ever needs to be uploaded again. When first testing your Prusa, it is best to do so via a computer or laptop rather than the LCD Controller. The software used in the these instructions is PrintRun (Pronterface), which can be downloaded from: http://koti.kapsi.fi/~kliment/printrun/ Once extracted/installed, launch PrintRun.
  • Page 41 Testing & Commissioning - Part 2 The Z-Axis Mechanical-Endstop works the opposite way to the X & Y Mechanical- Endstops. When in normal motion, the red LED on the Mechanical- Endstop should be lit. When the Z-Axis travels down, towards its minimum position, the Hotend will rest on the Print Bed preventing it from going down any further.
  • Page 42 Testing & Commissioning - Part 3 Before starting the next step, attach the Borosilicate-Glass-Plate to the Heated-Bed using 4 x Bulldog-Clips. The Borosilicate-Glass-Plate should be orientated so the longest side is going from left to right and should sit in-between the front and back-row of bolt heads. Two Bulldog-Clips should be used on the right and left sides, roughly 2cm from the front and back of the Borosilicate-Glass-Plate.
  • Page 43 Testing & Commissioning - Part 4 To check that the 2 x 40mm-RAMPS-Fans work, enter M42 P9 S255 into the G-Code Viewer (S255 is the power of the fans and should range from 0–255). The 2 x 40mm-RAMPS-Fans should now work with the air flowing towards the electronics.
  • Page 44 Testing & Commissioning Part 5 To extrude some ABS Filament, set the Hotend temperature to 230°C. The Heated Bed can now be turned off. Place the filament on the Spool-Holder, as shown in the right-hand image. Cut some 5cm lengths of filament off the spool. These will be used later to make ABS juice.
  • Page 45: Levelling The Print Bed

    Levelling the Print Bed The Print Bed needs to be levelled, so as the nozzle moves from corner to corner it is always the same distance away. First, make sure the Z-Axis is sitting on both Z-Axis-Nuttraps and the X-Axis is level. To make sure the X-Axis is level, measure the distance from the bottom of the Z-Axis-Nuttraps to the top of the Smooth-Rods-320mm.
  • Page 46 Printing - Part 1 To print a model, it first needs to be in .stl file format. Then it is sliced and converted into G-Code, which can then be placed on to the SD Card and printed from the LCD Controller. For a slicer, we recommended using Cura from Ultimaker.
  • Page 47 We have created a pre-configured profile for Cura, which can be downloaded from the 'Documentation & Downloads' Tab on our product page: http://ooznest.co.uk/3D-Printer-Kits/Prusa-i3-Kit Load this profile into Cura by going to File > Open Profile, and select our profile you just downloaded. All the settings in Cura will now have been set to values that will work with our printer and the ABS filament supplied.
  • Page 48 Printing - Part 3 Advanced Nozzle Orifice: Should always be kept at 0.4mm. Bottom Layer Speed: Keep this really slow to increase adhesion to the print bed. Outer Shell Speed: Reducing this will increase the exterior quality of the prints. Enable Cooling Fan: This is initially disabled with ABS, because when ABS cools it shrinks.
  • Page 49 Printing - Part 4 With the Print Bed prepared, you are now ready to start your first print. Before starting the print, it is good practise to reset the printer. This is done by pressing the button below the RAMPS-Fan-Extender on the right-hand side of the RAMPS-1.4 (it is the blue/red button in the lower-right corner of the RAMPS-1.4 on the RAMPS 1.4 Wiring Diagram).
  • Page 50: Troubleshooting

    Troubleshooting The troubleshooting list below will be extended as we get feedback from users of our kit. Problem: When homing, the Z-Axis stops before reaching the Print Bed 1) Check by hand that the Z-Axis has a smooth up-and-down motion, and isn't catching at any points. 2) Ensure the M3-25mm-Bolt on the X-Axis-Motor is sufficiently pressing the Mechanical-Endstop on the Z-Axis- Nuttrap-Left.
  • Page 51: Appendix A - Parts List

    Appendix A – Parts List Electronic Parts 1 x RAMPS-1.4, 1 x RAMPS-Fan-Extender that Includes: with 2 Pin Wire. 2 x 40mm-RAMPS-Fans 1 x Arduino MEGA2560 (Bottom) 1 x RAMPS Shield (Top) 4 x A4988 Stepper Drivers 4 x Heatsinks 4 x Aluminium Stickers (These may already be attached to the heatsinks.)
  • Page 52: Mechanical Parts

    Appendix A – Parts List 2 x 4 Pin Motor-Wires 1 x Extruder-Fan 3 x 3 Pin Endstop-Wires 1 x 25mm-Hotend-Fan 2 x 0.5m RAMPS-Power-Wires 2 x 0.5m RAMPS-Power-Wires 1 x USB-Cable 1 x 3A-Plug 1 x 2m Mains-Cable Mechanical Parts 1 x Z-Axis-Frame with 2 x Smooth-Rod-320mm 2 x Inserted Motor wires...
  • Page 53: Nuts & Bolts

    Appendix A – Parts List 2 x 1m GT2-Belt 12 x LM8UU-Bearings (4 Labelled Z-Axis-LM8UU- Bearings) 4 x 623zz-Flanged-Bearings 5 x Compression-Spring 2 x 625zz-Bearings 1 x Filament-Feed-Tube Nuts & Bolts 15 x M3-Hex-Nut 60 x M3-Washer 1 x M4-Hex-Nut 2 x M4-Washer 22 x M8-Hex-Nut 22 x M8-Washer...
  • Page 54 Appendix A – Parts List 67 x M3-Nyloc-Nut 3 x M3-8mm-Bolt 1 x M4-Nyloc-Nut 6 x M3-12mm-Bolt 6 x M3-10mm-Bolt 15 x M3-16mm-Bolt 15 x M3-18mm-Bolt 20 x M3-20mm-Bolt 20 x M3-25mm-Bolt 15 x M3-30mm-Bolt 2 x M3-50mm-Bolt 2 x M4-10mm-Bolt 1 x M4-20mm-Bolt 1 x M4-25mm-Bolt Extras...
  • Page 55 Appendix A – Parts List 1 x 250ml Acetone 1 x Extruder-Cleaning-Kit Plastic Parts (in Order of Use) 1 x Y-Axis-Idler 4 x Y-Axis-Corner 1 x Inserted M4-Hex-Nut 1 x Y-Axis-Motor 4 x Heated-Bed-Spring-Trap 4 x Inserted M3-Nyloc-Nut 1 x Y-Axis-Belt-Holder 3 x Y-Axis-Bearing-Holder 55 of 62...
  • Page 56 Appendix A – Parts List 1 x X-Axis-Tensioner 1 x X-Axis-Idler 1 x Inserted M3-Hex-Nut 1 x X-Axis-Motor 1 x X-Axis-Carriage 1 x Inserted M3-Hex-Nut 2 x Inserted M3-Nyloc-Nut 4 x Z-Axis-Framebrace 4 x Z-Axis-Framebrace-Top 8 x Inserted M3-Hex-Nut 1 x Z-Axis-Motor-Left 1 x Z-Axis-Nuttrap-Left 1 x Z-Axis-Motor-Right 2 x Inserted Brass...
  • Page 57 Appendix A – Parts List 1 x Z-Axis-Nuttrap-Right No Longer Included from 2 x Inserted Brass 27/4/16 Onwards. M5-Hex-Nut Replaced with: 2 x 5x5mm-Flexible Coupler No Longer Included from 1 x Z-Axis-Top-Left 27/5/16 Onwards. Replaced with: 2 x 5x5mm-Flexible Coupler 1 x Z-Axis-Top-Right 1 x Hotend-Fan-Shroud 2 x Inserted M3-Nyloc-Nut...
  • Page 58 Appendix A – Parts List 1 x Y-Axis-Endstop-Holder 1 x RAMPS-Holder 1 x RAMPS-Fans-Holder 1 x RAMPS-Fans-Bracket 2 x Inserted M3-Nyloc-Nut 1 x Power-Supply-Cover 1 x Spool-Holder 58 of 62...
  • Page 59: Appendix B - Z-Axis Nuttraps

    Appendix B – Z-Axis Nuttraps On the Z-Axis-Nuttraps, the two Brass M5-Hex-Nuts have to be in sync. Otherwise, the Threaded-Rod-5mm will not go through both of them. The method to achieve this is trial and error. First, insert a M5-Hex-Nut into one of the slots. This will be the fixed nut.
  • Page 60: Appendix C - Ramps 1.4 Wiring Diagram

    Appendix C - RAMPS 1.4 Wiring Diagram 60 of 62...
  • Page 61: Appendix D - Uploading Firmware

    To upload the firmware, download and install the latest Arduino Software Version: https://www.arduino.cc/en/Main/Software Also, download and extract the firmware from the downloads section of our product page: http://ooznest.co.uk/Prusa-i3-Kit With the printer plugged in via USB, disconnected in PrintRun and switched off at the power socket, open up the Arduino software.
  • Page 62: Appendix E - Lcd Controller Menu Tree

    Appendix E – LCD Controller Menu Tree 62 of 62...

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