ELECTRONICS Check List ..................................59 Software ......................................60 Connect to the Printer & Loading Firmware ............................60 Verify the Endstops ..................................... 62 Verify Motor Direction and Homing ..............................65 Adjusting Z Height ....................................66 Folger Tech Kossel Rev B User Manual V2 Page 1...
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Appendix ........................................87 1) Diagnal Rod Assembly ..................................87 2) 2004 LCD Screen ....................................90 3) Printing from an SD Card ................................. 92 Step-by-step Process ................................... 92 4) Ramps 1.4 ......................................93 Folger Tech Kossel Rev B User Manual V2 Page 2...
DAMAGES and assumes no responsibility or liability for any loss or damage suffered by any person as a result of the use or misuse of any of the information or product. FOLGER TECHNOLOGIES LLC assumes or undertakes NO LIABILITY for any loss or damage suffered as a result of the use, misuse or reliance on the information and or product.
Red 22 AWG Wire Belt Holder 3’ Black 22 AWG Wire Roller Carriages Long Motor Wire Effector Short Motor Wire Sensor Mount 3 pin connector pigtail GT2 Belt Kapton Tape Injection Molded Block Folger Tech Kossel Rev B User Manual V2 Page 4...
F623zz Bearing M3x20 Screw Belt Tensioner M3x25 Screw Black Zip Tie M3x30 Screw Nylon Roller M3x45 Screw Wire Wrap 3. 300mm 2020 Beam 4. 700mm 2020 Beam 37. 2020 Insert Folger Tech Kossel Rev B User Manual V2 Page 5...
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1. AL Bottom Corner 2. AL Top Corner 7. Carbon Fiber Arm 21. AL Effector (optional add-on feature not included with stock kit) 35. 40mm Fan 10. All Metal Hot end Folger Tech Kossel Rev B User Manual V2 Page 6...
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11. 2mm Push Fit 15. Stepper Driver 16. Endstop 14. MKS Base Board (MKS board is an add-on feature not included in stock kit) Stepper Motor Ramps 1.4 Board Arduino Mega Folger Tech Kossel Rev B User Manual V2 Page 7...
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12. Round Hot Bed 13. 100k NTC Thermisor 22. Sensor Mount 19. Belt Holder 20. Roller Carriages Printed Effector 18. 360W Power Supply Folger Tech Kossel Rev B User Manual V2 Page 8...
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36. AC Cord V. Wire Wrap 23. GT2 Belt 45. 3 Pin Connector 39-40. 14 AWG Wire 25. Inductance Probe 41-42. 22 AWG Wire 26-27. Resistors Folger Tech Kossel Rev B User Manual V2 Page 9...
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Hardware Kit 8. 1.75 Teflon Tube 46. Kapton Tape 33. Endstop Mount 31. Extruder Mount 32 Power Supply Mount 28. Bed Mount Spacer 30. Electronic Mount Folger Tech Kossel Rev B User Manual V2 Page 10...
The figure below shows the features of the Folger Tech Kossel 3D printer. You can reference this graphic for clarification of printer parts mentioned in this manual. Extruder Filament Spool Carriage Tower Bowden Tube Effector (Hot end & Nozzle) Belt Inductance Power Supply sensor Printer Folger Tech Kossel Rev B User Manual V2 Page 11...
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The Bowden Tube is the small tube that runs from the extruder to the hot end. Nozzle The nozzle is the brass fitting below the heater block that the plastic extrudes from. Folger Tech Kossel Rev B User Manual V2 Page 12...
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The effector holds the hot end and moves about the printing area. It is connected to the three carriages by the support arms. Power Supply The power supply is what takes the 120 AC from the wall and converts it into 12v DC. Folger Tech Kossel Rev B User Manual V2 Page 13...
Attach Carbon Fiber Rods Assembly The Extruder Mount the Extruder, Endstops, and Top Mounting Belts Assemble and Mount Electronics Wiring the Inductance Sensor Wiring the Heated Bed Wiring the Printer Odds and Ends Folger Tech Kossel Rev B User Manual V2 Page 14...
There should be a 2mm gap between the tip of the motor shaft and the end of the pulley. Once the pulley is positioned correctly, tighten both set screws. Folger Tech Kossel Rev B User Manual V2 Page 15...
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7 holes (see picture for locations). Make sure the taped edged side of the T-nut faces away from the corner. Repeat steps 1- 3 for the other two corners. Folger Tech Kossel Rev B User Manual V2 Page 16...
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2020 beams are tight into the other corners. Make sure the T-nuts are slotted into their respective beam. Tighten the screws and lock the T-nuts into place. Folger Tech Kossel Rev B User Manual V2 Page 17...
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Double check all of the screws to make sure they are tight and that the base is locked tightly together. Folger Tech Kossel Rev B User Manual V2 Page 18...
1. Insert a M4x10mm screw into one of the side holes on the aluminum corner and screw a M4 T-nut onto the other end. Repeat this for the three holes on the corner piece. Folger Tech Kossel Rev B User Manual V2 Page 19...
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T-nuts (left of the hex hole on one of the sides or the corner). Tighten the screw to lock in the 2020 beam. Repeat steps 1-4 on the other two corners. Folger Tech Kossel Rev B User Manual V2 Page 20...
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2020 beams into place. At each corner, insert a M4x8mm screw through the corner and thread a M4 T-nut onto the end. The T-nut should be loose and be able to rotate freely. Folger Tech Kossel Rev B User Manual V2 Page 21...
Put a M4 T-nut on the M4 screw (the T-nut will be inside the square hole on the corner). Repeat this for the remaining five corners on the base. Folger Tech Kossel Rev B User Manual V2 Page 22...
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The end of the 2020 beam should touch the table. Tighten the M4 screws so that the 2020 beam is locked into place. Repeat step 2 for the remaining two corners. Folger Tech Kossel Rev B User Manual V2 Page 23...
M5 Nylock Nut M3x20mm Screw M3 Nut Take the 3D printed carriage and insert the M5x25mm screws into the face of the carriage (the screw should not protrude out the face). Folger Tech Kossel Rev B User Manual V2 Page 24...
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Thread the screw into the nut. This will act as the tensioner when the slide is located on the 2020 beam. Repeat steps 1-3 for the remaining two carriages. Folger Tech Kossel Rev B User Manual V2 Page 25...
M3x20mm screws into the top two holes of the belt holder and one M3x16mm screw into the bottom left hole. Finally, tighten the three screws. Repeat steps 1-2 for the remaining two carriages. Folger Tech Kossel Rev B User Manual V2 Page 26...
Take the hot end mount and dry fit it onto the All metal hot end. It should be a tight fit and you may need to sand it to get it to fit onto the collar. Folger Tech Kossel Rev B User Manual V2 Page 27...
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Secure this with 4 M3 Nylock nuts. Mount the 40mm fan using two M3x12mm screws. The wires of the fan should be located at the top of the effector. Folger Tech Kossel Rev B User Manual V2 Page 28...
The screw should be tight enough that there is no movement on the carbon fiber arm. Repeat step 1 on the remaining 5 mounting locations on the effector. Folger Tech Kossel Rev B User Manual V2 Page 29...
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Tighten this down on the nylock nut. Repeat this for the other carbon fiber arms that mounts to the carriage. Repeat step 3 on the other two carriages. Folger Tech Kossel Rev B User Manual V2 Page 30...
Install the brass drive gear on the shaft of the motor. Secure it in place using the setscrew located on the drive gear. The drive gear should be just above the face of the stepper motor. Folger Tech Kossel Rev B User Manual V2 Page 31...
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M3x8mm screw. Install the arm of the MK9 and secure it down with a M3x16mm screw. The spring should be put in place while tightening it down the screw. Folger Tech Kossel Rev B User Manual V2 Page 32...
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Mount the stepper motor to the laser cut extruder mount using two M3x45mm screws. The slots of the mounting plate should be on the same side as the quick disconnect fitting. Folger Tech Kossel Rev B User Manual V2 Page 33...
Tighten the tensioning screws on the carriages. This will lock them onto the 2020 beams. Sensor Mount Folger Tech Kossel Rev B User Manual V2 Page 34...
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Place an endstop on top of a laser cut endstop mount. Line up the two holes on the endstop with two of the holes on the end stop mount. Insert three M3x12mm screws through the three holes. Folger Tech Kossel Rev B User Manual V2 Page 35...
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Repeat step 7 on the remaining two endstops. Try to keep them equal distance from the base, this will be important when calibrating the printer. As this determines the level of the bed and Z height. Folger Tech Kossel Rev B User Manual V2 Page 36...
2 inches of the belt end. Use a zip tie to secure the loop and cut away excess zip tie material. The teeth of the belt should be inward. Folger Tech Kossel Rev B User Manual V2 Page 37...
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Place the loop around the bottom square mounting stub of the plastic belt holder. Feed the other end of the GT2 belt down and around the pulley that is mounted to the stepper motor. Folger Tech Kossel Rev B User Manual V2 Page 38...
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Ensure that the end of the zip tie is facing away from the other belt as shown in the image. Install a belt tensioner above the last loop. This will ensure the belt is always tight. Folger Tech Kossel Rev B User Manual V2 Page 39...
M3x12mm Screw M3 Nylock M3 T-nut M4x10mm Screw Remove a stepper driver from its packaging and stick the aluminum heatsink on top of the chip on the stepper driver. Trim Pot Folger Tech Kossel Rev B User Manual V2 Page 40...
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Flip the electronics mount over and Mount the MKS board using four M3x16mm screws and four M3 nylocks. The t-nuts and the board should be on the same side of the controller mount. Folger Tech Kossel Rev B User Manual V2 Page 41...
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On the remaining four holes on the power supply mounts, insert a M3x12mm screw into each hole and thread on a M3 T-nut. The T-nut should be on the same side as the back of the power supply. Folger Tech Kossel Rev B User Manual V2 Page 42...
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Line the power supply so the fan hole is facing away from the frame. Slide the T-nuts into the top 2020 beam on the X-Z side and lock it into place by tightening the M3 screws. Folger Tech Kossel Rev B User Manual V2 Page 43...
Take the inductance sensor and remove 4 inches of the black shielding. Take the brown wire and curl it back. This is the 12v supply line and nothing has to happen to it. Folger Tech Kossel Rev B User Manual V2 Page 44...
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Solder the other end of the 10k resistor to the blue wire from the inductance sensor and the black wire from the pigtail end of the three wire connector. Folger Tech Kossel Rev B User Manual V2 Page 45...
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Wrap everything in kapton or electrical tape to prevent any damage to the sensor and the MKS board. Make sure all of the exposed wires are wrapped and there is no interference between lines. Folger Tech Kossel Rev B User Manual V2 Page 46...
3 and 2. Place the tip of the thermistor on the center of the hot bed. Using Kapton tape, tape the thermistor and the 14 AWG wires down to the hotbed. Folger Tech Kossel Rev B User Manual V2 Page 47...
Run the cable across the top to the tower the connector on the motor is pointing towards. The cable should run down the outside of the machine and down into the base. Folger Tech Kossel Rev B User Manual V2 Page 48...
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Repeat step 2 for the remaining two endstop. With the 3D printer on its side, plug the board side of the extruder motor cable into the fourth stepper driver plug on the MKS board. Folger Tech Kossel Rev B User Manual V2 Page 49...
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Plug the board end of the cable into the first stepper plug. Take the endstop cable that is located at the same beam as the stepper motor from the previous step. Plug the board end into the X-Max plug. Folger Tech Kossel Rev B User Manual V2 Page 50...
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Z tower. Using a small screw driver, loosen the two set screws on the top green connector. Insert the red wires into the connector and tighten the set screws back down. Folger Tech Kossel Rev B User Manual V2 Page 51...
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12. Cut and strip a ½ off the two wires from the hot end fan. Cut the 22 AWG wire in half, and strip both end ½ inch. Twist and solder them together and seal them using kapton tape. Folger Tech Kossel Rev B User Manual V2 Page 52...
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13. Take the wire wrap and start wrapping all the wires running to the hot end into one bundle. Folger Tech Kossel Rev B User Manual V2 Page 53...
Through two hotbed spacer and into one of the holes on the electronic mount. Finish the screw off with a washer and a M3 nylock nut. Folger Tech Kossel Rev B User Manual V2 Page 54...
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Using a small screw driver, loosen the two set screws on the heated bed power plug on the MKS board. Insert the 14 AWG wires from the hot bed into the power plug (black over Red). Folger Tech Kossel Rev B User Manual V2 Page 55...
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Take a zip two zip ties and zip tie all of the wires together. Then zip tie the power cable to the frame. This will relieve any stress on the wires from normal use. Folger Tech Kossel Rev B User Manual V2 Page 56...
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Tighten down the screw. Twist the brown wire from the inductance sensor and the red wire from the hot end fan. Insert this into the slot with the red wire form the power supply. Folger Tech Kossel Rev B User Manual V2 Page 57...
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Using a zip tie, connect the hot end bundle to the Bowden tube. 11. Plug the other end of the Bowden tube into the quick disconnect fitting on the extruder. Folger Tech Kossel Rev B User Manual V2 Page 58...
2. The thermistor wires should be plugged into the 1 and 3 connector. The top one should be the hot end and the bottom should be the heated bed. Folger Tech Kossel Rev B User Manual V2 Page 59...
Rotate the printer on its side, so that it is resting on the X and Z towers, and plug the USB cable into Arduino, which is the control board shown in the image below. Folger Tech Kossel Rev B User Manual V2 Page 60...
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Open the Marlin.ino firmware using the Arduino IDE. Press the compile and load button and wait for it to say done uploading. Leave this open because we will be coming back to calibrate the printer. Folger Tech Kossel Rev B User Manual V2 Page 61...
Then click the “Connect” button to the right of the port pulldown. If the computer is connected to the printer correctly, then you should see “the printer is now online” on the right. Folger Tech Kossel Rev B User Manual V2 Page 62...
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Lower the hotend down to the printer bed so the nozzle is touching the center of the bed. Adjust the inductance sensor by loosening the top nut. Lower the inductance sensor until it is just above the bed and the led on top has gone off. Folger Tech Kossel Rev B User Manual V2 Page 63...
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Lift the hot end away form the printer bed. Type in the “m119” command, the z-min should read OPEN. Move the hotend back down to the printer bed so that the inductance sensor trips (red led comes on). Type in the “m119” command and the Z-min should read TRIGGERED. Folger Tech Kossel Rev B User Manual V2 Page 64...
Note that at any time durring this step be ready to turn off the printer in case the carriages are moving downwards during the homing process. Folger Tech Kossel Rev B User Manual V2 Page 65...
This number is your Z height. This number is just a general value, when printing the z-probe will accurately capture the z-height. Folger Tech Kossel Rev B User Manual V2 Page 66...
Once the printer bed has reached temp and maintained it for a few minutes, press the off button. Before turning off the hot end, proceed to the next step “Verify the Extruder”. Folger Tech Kossel Rev B User Manual V2 Page 67...
170°C. Now the drive gear should turn in a counter-clockwise direction. Turn off the hot end by clicking the “Off” button next to “Heat” on Pronterface. CALIBRATE INDUCTANCE PROBE Folger Tech Kossel Rev B User Manual V2 Page 68...
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Configuration.h tab, change the Z_PROBE_OFFSET_FROM_EXTRUDER value. This value can be adjusting later to get the first layer just right. Lower will increase the first layer height, Higher will decrease first layer height. Z_PROBE_OFFSET (X, Y, Z, E) Folger Tech Kossel Rev B User Manual V2 Page 69...
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If the machine was assembled right, the inductance probe should line up with the nozzle along the X axis. If not, move both the Y and the X using pronterface until the inductance probe is under the crosshair. Folger Tech Kossel Rev B User Manual V2 Page 70...
Download and install Cura at https://software.ultimaker.com/ Launch the Cura program from your computer’s start menu or desktop icon To setup your printer, select Machine > Add new Machine Click Next on the Configuration Wizard. Folger Tech Kossel Rev B User Manual V2 Page 71...
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Under “Select your machine,” choose Other (Ex: RepRap, MakerBot, Witbox). Then click Next. Under “Other machine information,” select Custom and click Next. Folger Tech Kossel Rev B User Manual V2 Page 72...
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Input the following values into the RepRap custom settings. Machine height was calculated in a previous section. Go to Machine > Machine Setting Folger Tech Kossel Rev B User Manual V2 Page 73...
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Verify the following values in the table under Machine settings and click Ok. Folger Tech Kossel Rev B User Manual V2 Page 74...
The parameters that are frequently adjusted to obtain the desire results for an individual part are found under the Basic Setting tab in Cura. The figure below shows the typical Basic tab settings for most prints. A detailed explanation of each parameter can be found below in the figure. Folger Tech Kossel Rev B User Manual V2 Page 75...
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Bed Temperature (°C): This is the temperature of the heated bed. ABS should be set too 100 °C and PLA should be set to 70 °C. Although PLA can be printed without the heated bed turned on. Folger Tech Kossel Rev B User Manual V2 Page 76...
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2) Raft, which is a support structure under a print that helps secure it to the bed. A skirt is the initial pass that outlines a part to prepare the hot end for printing. Folger Tech Kossel Rev B User Manual V2 Page 77...
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The Advanced tab parameters are printer specific and most will only need to be adjusted once. The figure below shows the typical advanced tab settings for your Kossel printer. A detailed explanation of each parameter can be found below in the figure. Folger Tech Kossel Rev B User Manual V2 Page 78...
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To enact auto leveling, the proper gcode has to be added to the starting gcode. Add “G29” and “G1 X0 Y0 Z10” to the starting gcode. This will execute the auto leveling command before each print. Folger Tech Kossel Rev B User Manual V2 Page 79...
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Select the axis of rotation by selecting and holding the desired circle around the part. Drag the circle to change the orientation of the part. Folger Tech Kossel Rev B User Manual V2 Page 80...
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Mirror – This function allows you to mirror the part about an axis. Click on the mirror icon in the lower left corner to activate this function. Select the desired axis to mirror part about. Folger Tech Kossel Rev B User Manual V2 Page 81...
1. Verify that Kossel is selected under the Machine tab. 2. Load the desired model file (typically STL but CURA does accept other formats) by clicking on the Load icon in the top left of the print window. Folger Tech Kossel Rev B User Manual V2 Page 82...
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Note: Hovering the mouse over a setting will bring up a description of how the setting will affect the print. 5. Plug the printer into the computer into your computer. Click the print icon in the top left of the print window to connect Cura to your printer. Folger Tech Kossel Rev B User Manual V2 Page 83...
3. Continue to feed the filament through the extruder and the Bowden Tube until it flushes out the old filament from the nozzle. Release the extruder lever and you are now ready to get back to printing! Push Down Extruder Lever Folger Tech Kossel Rev B User Manual V2 Page 84...
(optional). If printing with ABS, apply a layer of glue (normal glue stick) over the area to be printed on. Allow this layer to dry before printing. Folger Tech Kossel Rev B User Manual V2 Page 85...
Next, verify Plastic is not extruding from the nozzle. the nozzle temperature is correctly set between 210 °C for PLA and 230 C for ABS. Folger Tech Kossel Rev B User Manual V2 Page 86...
4. Using a piece of extruded aluminum as a guide, measure the carbon fiber rod length from the end. Lock in the M3-T nut at the end, this will act as a stop for the carbon fiber rod. Folger Tech Kossel Rev B User Manual V2 Page 87...
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7. Ensure all of the tie rod ends are aligned properly (the faces should be parallel to each other). Use what is left of the M3 threaded rod as a guide. Folger Tech Kossel Rev B User Manual V2 Page 88...
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M3 insert of each tie rod. Repeat this for the other side. 9. It is important these dry properly, so set these aside and let them dry. Folger Tech Kossel Rev B User Manual V2 Page 89...
Prepare – Option to setup a print (preheat hot end, auto home, cool down, etc) Control – Change printer firmware settings (temperature, motion, and restore failsafe) Print From SD – Select a file to be printed Folger Tech Kossel Rev B User Manual V2 Page 90...
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Prepare: You can reach this from the Main Menu. The two common features that will be used on this screen are: Auto Home – Zeros the machine and returns the effector to the home position Preheat PLA – Sets the hot end temperature to 200 °C Folger Tech Kossel Rev B User Manual V2 Page 91...
Once printing is completed the effector will return to the home position. 8. Allow the hot end to reach room temperature. Then remove your finished masterpiece. Folger Tech Kossel Rev B User Manual V2 Page 92...
Mega. Make sure all the pins line up nicely, then push the two together. Insert three jumpers per stepper motor plug. This tells the board that 1/16 micro steps will be used. Folger Tech Kossel Rev B User Manual V2 Page 93...
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1.4 board. The trim pot should be away from the power supply plug. Secure the ramps assembly to the electronics mount using three M3x25mm screws and two M3 nylock nuts. Folger Tech Kossel Rev B User Manual V2 Page 94...
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Plug in the four stepper motors. Make sure the red wire is on the right side. Extruder motor (top left), X tower (bottom left), Y tower (bottom middle), and Z-tower (bottom right). Folger Tech Kossel Rev B User Manual V2 Page 95...
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(left). 10. Wire in the hot end heater wire into the top two connectors on the blue plug. Then wire in the hotbed wire into the bottom two connectors. Folger Tech Kossel Rev B User Manual V2 Page 96...
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11. Wire in the four wires from the power supply. Make sure the order is black-red-black-red, as seen in the picture. Folger Tech Kossel Rev B User Manual V2 Page 97...
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Take the hot end mount and dry fit it onto the All metal hot end. It should be a tight fit and you may need to sand it to get it to fit onto the collar. Folger Tech Kossel Rev B User Manual V2 Page 98...
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The wires of the fan should be located at the top of the effector. Insert a M3 nylock nut into the hex hole located on the 3D printed effector. Folger Tech Kossel Rev B User Manual V2 Page 99...
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Insert a M3x25mm screw through the ball joint of the tie rod end, through the 3D printed effector and thread it into the Nylock nut. Repeat this step for the remaining five carbon fiber arms. Folger Tech Kossel Rev B User Manual V2 Page 100...
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Strip ¼ from one of the ends on each wire. With the hotbed lying top down on the table (red up), solder the red and black wire onto the back of the hot bed. Folger Tech Kossel Rev B User Manual V2 Page 101...
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Place the tip of the thermistor on the center of the hot bed. Using Kapton tape, tape the thermistor and the 14 AWG wires down to the hotbed. Folger Tech Kossel Rev B User Manual V2 Page 102...
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