kijenzi printer user manual revised

Kijenzi Delta Kijenzi Delta Mod Printer

User Manual

Titles you can't find anywhere else

Try Scribd FREE for 30 days to access over 125 million titles without ads or interruptions! Start Free Trial Cancel Anytime.









1

Table of Contents 1. Quick-Start Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1.1. Setting up the printer 1.2. Connecting to a computer 1.3. Loading a file 1.4. Managing a print 2. Printer Components Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2.1. ABG towers 2.1.1. Motor and belt assembly 2.1.2. Carriage and travel rods 2.1.3. End-stop 2.2. End effector assembly 2.2.1. End effector mount 2.2.2. Hot end assembly 2.2.2.1. Aluminum heat sink 2.2.2.2. Thermistor 2.2.2.3. Current-carrying element 2.2.2.4. Hot end 2.3. Extruder assembly 2.4. Control box 2.4.1. Power supply 2.4.2. Control board 2.5. Supporting features 3. Electronics Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 3.1. CAT 6B connection point maps 4. Computer Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 4.1. CAD programs 4.2. Slicing models 4.3. Pronterface 4.3.1. G-code shortcuts 5. Calibration Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 5.1. Full calibration instructions









2

1. Quick-Start Guide 1.1 Setting up the printer Find a flat, stable space to set up the printer, control box, and accompanying laptop, with access to a consistent source of power. Place the three Alpha Beta Gamma (ABG) towers in a counter-clockwise orientation, arranging in order X, Y, Z, starting with the X tower, as labeled on the towers. Secure all aluminum support bars in place with screws and nuts. •

Be sure to align ABG motor ethernet cables at an easy point of access, running all three under one aluminum frame bar at the base.

Secure print-bed holders and print bed to tower assembly base, and make sure the bed is level and firmly held in place. Place magnetic arm rods into upper carriage sockets, letting them hang. Place the extruder and end effector assembly onto one of the aluminum frame bars at the top of the th e printer, with the end effector assembly inside the printer frame. •

•

Secure magnetic arm rods into magnetic end effector sockets, with the flat sides of the end effector mount facing the towers, not the corners. Ensure that th at each pair of rod arms are a re parallel. Rotate the end effector before mounting to provide sufficient tension in the Teflon tube and cable leading up, as to assure there is no interference with end-stops.

Place the filament holder on top of the frame and feed the filament tip into the extruder mechanism. Plug ABG motor ethernet cables into corresponding CAT 6 outlets in the control box. Plug the extruder and hot end cables into the EXT ports in the control box.

1.2 Connecting to a Computer









3 On the computer, open Pronterface, and connect to the COM port corresponding with the printer.

Input g-code or select the appropriate option to test the printer’s printer’s basic functions (see section 4.3): Homing: G28 Run fan: M106 Heat: turn hot end ON Test calibration: G0Z10, lower manually to satisfactory level. If this differs from the existing calibration, reset zero with M306 and return to home. • • • •

If all functions are satisfactory, home the end effector. If the test calibration is significantly off, the printer may require a full calibration (see section 5.1). If any tests do not function as expected, check the troubleshooting section for a solution (section 6).

1.3 Loading a file In Pronterface, click ‘load file’ and select the select the desired g-code file (.gcode). Wait for the file to load completely and carefully review the preview image to ensure it has loaded fully before clicking ‘print.’ Depending on the settings the g-code was sliced with, the print should start by itself once the hot end reaches the requisite temperature.

1.4 Managing a print As the print begins, there will be several things to watch out for: Calibration errors If the calibration is too loose, the filament will not adhere properly to the print bed. The first layer will not stick, and instead drag the filament along behind, or the









4 If the calibration is too tight, the first layer will appear thin, faint or non-existent on the print bed, as little to no filament will be able to extrude. This can be acceptable if there is at least some material on the first layer, and the print will be able to be successfully removed removed from the bed on completion. If the calibration is unacceptably tight, the hot end will drive into the board, and the extruder motor will click as a s it attempts to extrude filament, requiring an adjustment to the G0Z0 setting. Fan errors If the fan is continually turning tu rning off, there is an error with your slicer settings (see section 4.2). If the print had been progressing normally, and the fan shuts off, a clog can occur. This will be noticeable n oticeable in the print, as the filament will stop extruding. Pause the print, and remove the clog (see section 6.2). Motor clicking If there is audible clicking coming from the ABG motors, and the print begins to look distorted, check the temperature of the motors by carefully touching them. If they are too hot, this can cause skipping and other errors. This can cause configuration errors and can take some time to fix (see section 6.2).

The duration of a print can also increase the likelihood of errors. Once the print is successfully completed, completed, make sure the fan is turned on, let the hot end cool, and remove the print from the board with a scraper.









5

2. Components 2.1 ABG towers The Alpha Beta Gamma (ABG) towers are three identical towers responsible for the motion of the end effector. They also form the structural frame supporting the end effector, extruder assembly, a ssembly, and print bed. Each tower holds a motor, a belt, and two vertical steel rods, which move the carriage. The moving carriages house two neodymium magnets connect to arm rods from each of the ABG towers and provide multiaxial movement movement to the end effector assembly. At the top of each tower is an end-stop that indicates to the control box when a carriage is ‘home.’ 2.1.1 ABG motor and belt assembly The ABG motors are biphasic stepper motors, which move at .8 degrees per step. They are attached to the towers with 4 screws, and have an operating current is .5 amps. The motor connects to a belt, which moves on a frictionless bearing at the base of the ABG tower. The belt assembly is attached with a zip-tie, which should be tensioned by hand so the belt can be plucked like a string. 2.1.2 Carriage and travel rods The carriage travel rods are polished steel, and require greasing for operation. Always use lithium grease, not WD40 or other greases, as they can cause irreparable damage. The carriage rides on the travel rods with a frictionless bearing. The carriage has two sockets with neodymium magnets, with attach to the arm rods. These sockets should also be greased with lithium grease to prevent friction.











6 If an end-stop end-stop is reading ‘1’ and the respective carriage is not home, it is malfunctioning malfunctioning (see section 6.1).

2.2 End effector assembly 2.2.1 End effector mount The PLA plastic mount for the end effector includes six neodymium magnet sockets for arm rods, a mounting location for the fan, and an internal rim to secure the hot end assembly. Due to the plastic used, heating the hot end to above 220 Celsius without the fan running can cause damage and deformation. Hot end temperatures above 230 Celsius, will cause damage even with a fan, and require switching to a dual-fan end effector. 2.2.2 Hot end assembly 2.2.2.1 Aluminum heat sink The aluminum heat sink is a long hexagonal part located above the hot end, designed to absorb heat before contact with the plastic mount. The brass tip of the Teflon tube providing filament is screwed into the top. 2.2.2.2

Thermistor

The thermistor detects the temperature of the hot end by reading voltage and sends this data back to the control box. The tip of the thermistor is embedded in the hot end with muffler cement. Two wires lead out from the hot end. These wires are delicate and damaging them will result in a non-functional hot end.









7

2.3 Extruder assembly The extruder assembly is located on top of the printer frame and consists of the filament spool and holder and the extruder mechanism. The mechanism delivers a precise amount of filament to the hot end by using a biphasic stepper motor, toothed wheel, and a tensioning spring. As the stepper motor turns, the teeth catch the filament and force it through Teflon tubing leading to the th e end effector, providing the required length of filament to the hot end exactly when needed. If the toothed wheel is failing to grip the th e filament, a 3.5mm Alan wrench can be used to tighten the two screws corresponding with the tensioning spring.

2.4 Control box The control box serves as an intermediary between a computer and the printer, transferring commands relating to the file to be printed. It consists of two main parts: the power supply and the control board. The power supply provides the 24 volts needed to run all aspects of the printer, including the control board. The control board accepts commands from the operator and converts them into signals which run all fans, motors, and the hot end. 2.4.1 Power supply









8 2.4.2 Control board The control board is a Smoothie Board 4XC. It is powered by the power supply, and has a 5-volt regulator to provide power to its own processor. The control board receives inputs for the end-stops and thermistor, and relays them to the computer. It also outputs DC current to the biphasal stepper motors, fan, and current-carrying element. element. The fan is powered by a small MOS FET, and the current-carrying current -carrying element element is powered by a large MOS FET.

2.5 Supporting features Supporting features of the printer include: Arm rods Six aluminum bars with steel ball bearings affixed with steel epoxy, which connect the end effector and carriages, allowing for multiaxial motion. Filament holder Printed rack made of two base pieces (which rest on the aluminum frame bars not occupied by the extruder mechanism), two vertical printed supports, and a plastic tube with end caps to hold the filament spool. Print bed A 250mm diameter composite polymer plate, allowing for PLA printing without the need for an adhesive.









9

3. Electronics 3.1 CAT 6B Connection Point Maps

Figure 3.1. Smoothieboard connection points E









10

Figure 3.2. Smoothieboard connection points X – M1 A B C D E F G

2.0 .5 .4 M1 x 2 — — 1.25s

Y – M2 2.1 .11 .10 M2 x 2 — — 1.27s

Y – M3 2.2 .20 .14 M3 – 3 — — 1.29s











11

4. Computer programs 4.1 CAD software Models can be made or modified with any CAD software that can output an STL file type (.stl). The printability of a file should shou ld be considered when choosing or creating models.

4.2 Slicing programs For the printer to interpret a 3D model, the file must be converted, or “sliced,” to provide a three-dimensional three-dimensional path for the end effector to deposit filament. Once an STL file is selected, it can be opened in a slicing program. There are many parameters for any given slicing program which reflect the properties of the printer being used. Many of these variables can be manipulated to provide the desired print quality and speed. Some important variables to consider when slicing an STL file: Nozzle diameter This setting must match with the nozzle size you are using. If they do not match, the









12 This is the density percentage of the bulk of the print. Higher infill (50%-80%) will use more plastic, take longer, and result in heavier, sturdier prints. Lower infill (5%-20%) will be quicker, and result in lighter, more fragile prints. Layer height This setting adjusts the thickness of each layer of the print. Higher layer thicknesses will result in faster prints, but decrease print quality, while thinner layer heights take longer, but produce a cleaner result. The Kijenzi prints well between 0.15 and 0.35mm. Speed Speed settings are usually broken up into several independent independent sub-settings: infill, perimeter, and bottom layer speeds. The trade-off for speed is quality, but Kijenzi printers can print at about abo ut 150mm/s (infill) and 80-100mm/s (perimeter) (perimeter) without much loss in quality. Speeds lower than 60mm/s (infill) and 40mm/s (perimeter) (perimeter) are usually unnecessary. After being sliced, the file needs to be exported in a G -code format (.gcode), the type of file that can be read by the printer. Free, open-source slicing programs; Cura and Slic3r.

4.3 Pronterface









13

5. Calibration Due to construction and other variables, the height of the print bed is often not completely even across the board. To account for this variability, a full calibration will determine what to consider as zero for key points p oints on the print bed, allowing for good print adhesion everywhere, even on large prints. For smaller prints, minor adjustments to the central zero point (G0Z0) will often suffice. These tweaks can be made by homing the end effector (G28), going to G0Z10, manually lowering the head to a proper tension (measured with paper), inputting this new zero (M306Z0), and then homing (G28).

5.1 Full calibration instructions 1. Home end effector (G28 command) Set zero coordinate 2. Bring end effector down to zero (centered on print bed)









14 c. Incrementally lower to print bed (G0A# command) d. Lower end effector until paper can be moved, but has friction when pulled. e. Use M114 command to find Z height value f. Use M666 command to output information about Z value coordinates i. Find the M666X# value for the Z coordinate ii. Add this Z value to the Z value found with the M114 command iii. Input this new value into a new M666X# command. g. Use M666X# command to set after-homing start location for tower X. i. (For towers Y and Z, the M666A# command will use Y and Z as variables, accordingly.) h. Use G28 command to home i.

Use G0A# command to return to 10mm above the location found with M114 command

j.

Lower end effector 10mm to confirm paper friction at zero coordinate









15

6. Frequently Encountered Issues & Fixes 6.1 ABG Towers Error 6.1.1 During homing, one tower’s carriage does not return to its to its home position. When the two remaining towers reach their end stops, the malfunctioning tower’s carriage lowers at the same rate as the last two, performing the ‘double bounce’ seen during a G28 or Home Command. Cause The end-stop of the malfunctioning tower is either not plugged in or not being read by the Smoothieboard. Solution First, ensure the ethernet cord is plugged in. Next, unplug the Smoothieboard from all power and remove the Smoothieboard box cover and ensure the end-stop is plugged correctly into the board. Next, ensure the end-stop wires are inserted correctly into the CAT6 adapter. Close the box, then th en return power to the Smoothieboard and try another G28. If still not functioning correctly, use a new end-stop wired directly to the board. If the end-stop is read during an M119, replace the end-stop in the tower with











16 and surrender to madness, the best of us already have. If wiring directly to the board does not fix the problem, it may be necessary to replace the Smoothieboard. Error 6.1.3 When homing/after entering G28, one or more carriages move down instead of up. Cause The effected motor(s) have been installed backwards. Solution SHUT OFF THE POWER. Next, open op en the config file. For the Alpha A lpha tower, find line ‘alpha_dir_pin’ and add an ! after the value. For the Beta tower, find line ‘beta_dir_pin’ and add an ! after the value. For the Gamma tower, find line ‘gamma_dir_pin’ and add an ! after the value. Save the config file. Disconnect the Smoothieboard from power









17 Error 6.2.2 Filament is not being extruded through the tip, and the motor does not spin. Cause The extruder motor is not connected. Solution First, ensure the extruder ethernet is plugged correctly into its port. If the printer is connected to power and your computer, open Pronterface and connect to the printer. On the temperature graph, if a temperature is read that is not 0 Celcius, the ethernet is plugged correctly into the port. If not, attempt to unplug and replug the ethernet cable into the port. Once establishing the cable and an d port are working correctly, disconnect the printer from power and the computer. Remove the lid from th e control box. Trace the 4 lines from the th e ethernet port that lead to the extruder motor controls









18

6.3 Temperature errors Error 6.3.1 Temperature slowly increases, raises and drops, and falls out completely Cause Hot end barrel connector failure Solution TURN OFF POWER. Disconnect the printer from your computer and disconnect the power cable from power source completely. Remove the male barrel connector from the control board. Inspect for damage. If there is a sign of a short, replace the male barrel connector and ensure good insulation between the two ends. If no short is present, check the female barrel adapter for visible short. If there is sign of a short,

kijenzi printer user manual revised

Recommend Documents