Kossel Mini Building Guide

last update on 30th Jan, 2016

Building the Frame

Repeat this for the all 9pcs of corner partsTear off the 4 circular bases

Get 5pcs of M4X12 screws5pcs of square nut4pcs of M4 spring washer Assemble the screw as shown

Putting the motor onInstall the motor as shown

Do the same for the top side

Fasten these screws

Putting the 2020 beam on as shown (6pcs in total)

Putting the 2020 beam on as shown (6pcs in total)

Put 2 M4 square nut in one of the beam (we will use it later)

Motor Cable out on the side

Installing the 600mm beam

Install the 3pcs of 600mm beam as shown

Get the following:3pcs end stopper PCB,3pcs plastic stopper mount3pcs of M4x12 screw3pcs M4 Spring washer3pcs of M4 square nut6pcs of M2.5x12 screws

Install the 3pcs of plastic stopper mount on as shown

Install the 3pcs of end stopper PCB as shown.

Get2pcs flange bearing2pcs M3x25 screws2pcs M3 nuts1pcs M3 spring washer2pcs of flat washer

Step 1 Step 2 Assemble the 2 flange bearing as shown

Step 2Step 3

M3x25 screwM3 flat washer. M3 nut on the other side

Assembling the top frame

Assembling the top frame

Fasten the screw to lock the top frame in place.

Filament holder face up.

Insert the green circled part on to the top of the vertical beam (like the bottom frame)

Step 1 Step 2

Assembling the Roller (Rev.B)Get:3pcs M3x25 Screws4pcs M3 Spring Washers3pcs M3 Nuts

Step 1 Step 2

Step 3 Step 4

Fasten the M3 nut (3pcs) at the back of the roller

Assemble the roller (3pcs), nut & spring washer as shown.

Fasten the M3x40 screw to apply preload on the roller

Fasten the M3x25 (3pcs) with the M3 nut at the back

Step 1 Step 2

Step 3 Step 4

Get 3 sets of:3pcs M6x30 screws3pcs M6 Spring washer3pcs of Rollers6pcs of M6 Nuts

Assemble as shown

M6 Spring Washer here

Get 3 sets of:2pcs M3x40 screws2pcs M3 Spring washer4pcs M3 Flat washer

Assemble as shown

Assembling the Roller (Rev.A discontinued on 25th Jan,2016)

Assembling the Roller (Rev.A discontinued on 25th Jan,2016)

Get:3pcs M3x25 Screws3pcs M3 Spring Washers3pcs M3 Nuts

Assemble as shown

Step 1 Step 2

Assembling the JHeadStep 1 Step 2

Step 3 Step 4

Get:1pcs Fan1pcs End Stopper1pcs metal clip1pcs Jhead1pcs Allen key1pcs Spring1pcs Fastener2pcs M3x165pcs M3x201pcs M2.5x125pcs M3 Nuts7pcs M3 Spring Washer

Bend the flip as shown

Install the Allen key, spring and fasten as shown

Install the clip and M2.5x12 screw on the end effector as shown

Clip on the Jheadwith the Jheadholder as shown

Assembling the JHeadStep 5 Step 6

Step 7 Step 8

Put each of the roller guide into the vertical beam as shown

You may adjust the side screws to tighten or loosen the roller tension.

Letting in the hot end

Installing the timing belt

Put the timing belt around the carriage

Step 1 Step 2

Step 3

Use cable tie to fasten the belt as circled in green

Step 4

Assembling the Extruder

Wiring

Cut the power supply cable as shown

Black cable to the ve terminalWhite cable to the +ve terminal(It is suggested to double check the polarity using a multimeter)

Motor Cable Pin AssignmentBlue cable to 1B pinRed cable to 1A pinOrange cable to 2A pinGreen cable to 2B pin

These two are the fan cable

+ ve

- ve

Auto LevelEnd Stopper

XEnd Stopper

ZEnd Stopper

YEnd Stopper

MotorTemp sensor

Heater

- ve

+ ve

Kossel Wiring Diagram

12V Power Supply

Download the software required:

The Latest Arduino IDE (Please download the one that matches your OS):http://www.arduino.cc/en/Main/Software

The firmware on Google Drive (Unzip it to your desktop.):https://drive.google.com/folderview?id=0ByOzdApaqtWkfnNPcGlvM01pOGF

EQVl0Q3lPdGhJUDg1WW03TzNMcWF1NzlqQW0taFVqaXc&usp=sharing

Printrun - Pronterface (Please download the one that matches your OS):http://www.pronterface.com/

Slic3r: (Please download the one that matches your OS):http://slic3r.org/download

Install Arduino by executing the .exe file. Once completed, connect the Computer to Kossel USB port. Then verify the COM Port Number assigned, you should see a new Port appear in Device Manage as shown below (eg. COM3).

Download and unzip the Firmware from Google Drive (see P.12). Run file [Marlin_delta2/Marlin_delta2.ino] Go to ToolsPortselect the COM port appears as described on the left picture.

Installing the Arduino IDE

Go to Tools Board select Arduino Mega or Mega 2560

Setting the Arduino IDE

Click the Upload button to upload the Firmware Sketch to the Kossel Controller Board. Message Done Uploading will be displayed when the sketch has been uploaded successfully.

Uploading the Sketch

Run file [pronterface.exe] downloaded during in P.12. Set COM Port as per assigned in P.13, and Baud Rate to 250000, then click Connect. Once connection successful, messages will be shown as seen. Ignore message SD init fail as LCD Controller Board with SD Card not available.

Connecting Pronterface to Kossel

Location of the connect/disconnect button

Choose COM Port here

Choose Baud Rate here

Check Endstops & Auto Level Probe

X_maxEndstop

Z_maxEndstop

Y_maxEndstop

Z_minAuto Probe Trigger

Check z_min by hand:Auto Level Probe in contact with Switch (Deployed) => open Auto Level Probe NOT in contact with Switch (Retracted) =>TRIGGERED

Check X_max, Y_max ,Z_max by hand:Carriage in contact with Endstop Switch => TRIGGERED Carriage NOT in contact with Endstop Switch => open

Type in Code M119 in Pronterface and you should see the following code appears:

Check XYZ Carriages Homing

Press this button to for XYZ Homing

All XYZ Carriages will travel towards respective Endstops and slightly back off after in contact with respective Endstop switch. ***if any of the carriage travels downward, it means you have wired you motor inversely, please flip the wrongly wired motor pins

After pressed the Home button, all three axis will travel up until they hit the endstops.

Verify Current Position

Type in Code M114 in Pronterface and you should see the following code appears:

SENDING:M114X:0.00Y:0.00Z:210.00E:0.00

If output is X:0.00Y:0.00Z:0.00E:0.00 Controller Board have lost track of positions. Please home all Axis again.

Verify Hotend Heater

Before starting: Before switch on the Hotend,

make sure the Hotend fan is on. Do not leave the Hotend

unattended Click Off to cancel heating

of Hotend once Temperature verification completed.

Select 185(PLA) and click Set to switch on the Hotend.

Monitor the temperature until it goes up to 185C.

Verify Extruder

Enter M302 in Pronterface then click the Extrude button, verify extruder motor gear rotation:

Extrude Counter Clockwise RotationReverse Clockwise Rotation

Extrude Reverse

The firmware code #define EXTRUDE_MINTEMP 170 in Configuration.h will prevent Extruder Motor from any motions when Nozzle temperature is below 170C . To solve this, enter M302 in Pronterface can enable cold extrusion. Alternatively, you can rise the Hotendtemperature to above 170C (as in P.20) for this verification process.

All verification completed

X-

Things you need to know before Calibration

Z-Tower

Y-Tower

X-Tower

Print Space in Cartesian Coordinate

Y-Axis

X-Axis

Z-Axis

Nozzle

In order to start the calibration, it is essential to distinguish the XYZ axis and the Cartesian coordinate illustrated above.

Boundaries of the Cartesian space are specified by Min & Max parameters of XYZ Axis in [Configuration.h+ of Marlin_delta2 Firmware. Two key Coordinates needed during Calibrations are the HOME Coordinate [0,0,Zmax] and Center of Bed [0,0,0].

Y_min

X_max

HOME:[0,0,Z_max]

Nozzle

X_min

Y_max

Z_minBED CENTER:[0,0,0]

Nozzle movement can be controlled by the GUI above, minus(-) sign meaning to move towards the min direction and vice versa. The number 0.1,1,10,100 are the magnitude of movement in mm.

Pronterface GUI

Things you need to know before Calibration

Other than GUI, the nozzle movement can also be set by using command prompt. For example, entering g1 x0 y0 z10 will command the nozzle to move to *0,0,10+ Cartesian space. It will be usually when it comes to Auto Leveling Calibration.

HOME:[0,0,Z_max]

Nozzle

[0,0,10]

Things you need to know before Calibration

Entering G29 to the command prompt will initial the auto leveling calibration, it consist a set of continuous procedures which eventually align Nozzle to move at uniform Z Height above a flat Print Bed.

After sending G29, 3 procedures as below will be automatically executed: 1. Deploy Z Probe by hand2. Probe Print Bed (at 37 Locations) 3. Retract Z Probe by hand

Check out the Youtube video below for Auto Leveling Calibration process:https://www.youtube.com/watch?v=Ioh9LRERDy4

Auto Leveling Calibration

Please read through page 25-28 before sending the g29 command

The XYZ coordinates shown below is where the pushing of Z Probe (in X direction) against GT2 belt will begin from, you can try modify the coordinate and play around with it:

void deploy_z_probe() {feedrate = homing_feedrate[X_AXIS];destination[X_AXIS] = 25;destination[Y_AXIS] = 95;destination[Z_AXIS] = 100;prepare_move_raw();

feedrate = homing_feedrate[X_AXIS]/10;destination[X_AXIS] = 0;prepare_move_raw();st_synchronize();

}

Auto Leveling Calibration

Deploy Z ProbeThe default Z Probe deployment mechanism is by pushing the horizontal part of Z Probe against the GT2 belt on Z-Tower. Our Z Probe are not designed for auto deploy, it is recommended to manually deploy the Probe by hand, then sending G28 to home before sending G29 for auto leveling. In case the auto Z Probe deployment method is preferred, make sure the XYZ coordinates is suitable for your built and horizontal portion of Z Probe is extended.

Horizontal part of Z Probe

Auto Leveling CalibrationZ Probe OffsetIt is the most important parameter to be calibrated, the displacement of leveling probes tip relative to the nozzle tip. The offset parameter can be altered by modifying the following code in [Configuration.h+ of Marlin_delta2 Firmware. #define Z_PROBE_OFFSET {0, -14, -4, 0}The first slot is x-offset, y-offset, z-offset respectively. In the above case x-offset is 0, y-offset is -14 and z-offset is -4.

Nozzle

X-axis

Y-axis

Z-axis

Leveling Probe

Leveling ProbeNozzle

Auto Leveling Calibration Procedure1. Deploy Z Probe manually by hand. Send code M119 to verify Z_min: open 2. Send code G28 to home all axis.3. Send code G29 to start the Auto Bed Leveling procedures. 4. Once completed probing at the Last Probing Point, use your fingertip as a

support to lift the Z Probe to docking position. 5. Send GCODE G1 X0 Y0 Z40 to center the Nozzle. 6. Now place a piece of A4 paper on the print bed7. Use GUI to move Nozzle gradually in Z direction towards Print Bed until the

nozzle tip is in contact with the A4 paper.(The best case is when you can slide the paper without tearing it off by the nozzle tip)

8. Send code M114 to verify if Z value is zero (0). If yes, G29 Calibration completed. If the Z value is >0, take a note of the value, it will be used in next step.

9. If Z Value obtained in step 8 greater than 0, reduce the Z Value in *#define Z_PROBE_OFFSET {0, 14, -6.5, 0} [eg, if the Z value obtained in step 8 is 0.4, then add it to Z_PROBE_OFFSET and it will become Z_PROBE_OFFSET {0, 14, -6.1, 0}]

10. Re-upload the firmware as in P.15.

All Calibration Done!

Starting your first Print

Run slic3r.exe downloaded from P.12

Drag the file 10mm_cube.stl to the Drag your objects here

You can download the file 10mm_cube.stl inside the Google drive link below: https://drive.google.com/drive/folders/0ByOzdApaqtWkfnNPcGlvM01pOGFEQVl0Q3lPdGhJUDg1WW03TzNMcWF1NzlqQW0taFVqaXc

Starting your first Print

After loaded the 10mm_cube.stl file, drag the cube to the left bottom of the grid map [it is the Cartesian coordinate (X0,Y0) of the Print Bed]. This move ensure the print start at the center of the Print Bed.

Starting your first PrintUse the following settings on the Print Settings tab

Starting your first PrintUse the following settings on the Filament Settings tab

Starting your first PrintUse the following settings on the Printer Settings tab

Starting your first PrintClick the Export G-code button and save the G-code file on your desktop

Starting your first PrintLoad the G-code generated in P.34Deploy the Z ProbeClick the Print Button to start your first printPrinter will execute the probe leveling procedure.Retract the Z probe by hand after leveling.The print will automatically start when the Hotend temperature reaches 210C.

The END

HAPPY PRINTING!

http://reprap.org/wiki/Print_Troubleshooting_Pictorial_Guide

Trouble shooting Guide

APPENDIX

APPENDIX