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Folger Technologies 2020 Prusa i3 User Manual

Folger Technologies 2020 Prusa i3
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FOLGER TECHNOLOGIES, LLC
2020 i3 3D Printer Kit
BUILD GUIDE
Rev. A
Thank you for your purchase!
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Folger Technologies 2020 Prusa i3 Specifications

General IconGeneral
Filament Diameter1.75 mm
Nozzle Diameter0.4 mm
Heated BedYes
Nozzle TemperatureUp to 260°C
Power Supply12V, 20A
Build Volume200 x 200 x 180 mm
ConnectivityUSB, SD Card
Frame MaterialAcrylic
Print TechnologyFDM (Fused Deposition Modeling)
Supported MaterialsPLA, ABS, PETG
DisplayLCD

Summary

Step 3: Assemble Bottom Half Of Main Frame

1. Attach Corner Brackets to 375MM Beam

Attach corner brackets to the 375MM 2020 Beam using 4MM T-Nuts and Pan Head Bolts.

3. Attach SK8s to M5 T-Nuts

Attach SK8s to M5 T-Nuts using M5x8MM Bolts, ensuring tension screws face outwards.

5. Attach remaining SK8s and Motor Mount

Attach remaining SK8s to the top of the 2020 beam and the motor mount to the front face of the 375MM beam.

7. Secure Bottom Frame Together

Use remaining 2020 L Mounts to secure the bottom frame together by tightening the set screws.

Step 4: Attach Y Carriage Rails & Bearings

1. Place Bottom Frame and Slide Chrome Rod

Place bottom frame, slide 395MM chrome rod through front right SK8 about halfway.

2. Slide LM8UU Bearings onto Chrome Rod

Slide LM8UU bearings onto the chrome rod and push it through to the other SK8, avoiding rod corners.

4. Tighten SK8 Tension Screws

Tighten the tension screws on the SK8s to secure the chrome rods in place.

Step 5: Attach & Assemble The Upper Frame

1. Attach 295MM Beams Vertically

Attach 295MM 2020 Beams vertically to the bottom frame using L Mounts, ensuring 90MM spacing from the back.

3. Attach Top 375MM Beam

Attach the remaining 375MM 2020 Beam to the top of the vertical 295MM beams using L Mounts.

Step 6: Assemble The Aluminum Heat Bed Plate

2. Attach Bearing Mounts with Zip Ties

Attach printed bearing mounts using small zip ties through the guide holes.

3. Attach Bearing Holders and Belt Carriage

Use M3x20MM Bolts & Nylock Nuts to attach bearing holders; use M3x12MM Bolts for the belt carriage.

4. Attach Aluminum Bed Mount to Bearings

Attach the aluminum bed mount to the bearings on the bottom frame by pushing them into the LM8UU bearings.

5. Secure Bearings with Zip Ties

Tip the frame backward and close the small zip ties over the LM8UU bearings to secure them.

Step 7: Solder The MK2B Heated Bed & Attach Thermistor

1. Apply Solder to Contacts #1, #2, & #3

Apply solder to contacts #1, #2, and #3 on the MK2B Heated Bed.

3. Solder Black Wire to Contacts #2 & #3

Solder the black wire to contacts #2 and #3 for 12V/24V operation.

4. Solder Red Wire to Contact #1

Solder the red wire to contact #1 for power input.

5. Place Thermistor in Heated Bed

Place the glass of the thermistor into the small hole in the center of the heated bed.

Step 8: Attach the Heated Bed to the Aluminum Bed Plate.

1. Feed Bolts, Springs, and Thumb Screws

Feed M3X8MM bolts, springs, and aluminum bed plate, then secure with thumb screws.

Step 9: Attach Motors & Motor Mounts

2. Attach Rod Keepers to Motors

Attach metal motor mounts and acrylic rod keepers to the 2.6 motors using M3x12MM bolts and lock washers.

3. Mount 4.8 Motor to Motor Mount

Mount the 4.8 Motor to the metal motor mount using M3x8MM bolts and lock washers.

Step 10: Assemble Z Carriage

1. Insert LM8UU Bearings into Right Side Part

Insert 2 LM8UU bearings firmly into the 3D Printed: Right Side part.

3. Attach 2.6 Motor to Right Side Part

Attach the 2.6 Motor to the 3D Printed: Right Side using M3x20MM bolts, motor wires facing up.

4. Attach 20T Pulley to Motor Shaft

Attach the 20T Pulley onto the 2.6 Motor shaft and secure with set screws, tooth side down.

9. Press LM8UU Bearings into Extruder Carriage

Press 3 LM8UU Bearings into the 3D Printed: Extruder Carriage and secure with zip ties.

10. Slide 365MM Chromed Rod Through Bearings

Carefully slide the 2 365MM Chromed rods through the bearings in the 3D Printed: Extruder Carriage.

12. Push Chrome Rods into Right Side Part

Push the 2 ends of the chrome rods on the left into the 2 holes in the 3D Printed: Right Side part.

15. Attach GT2 Belt to Extruder Carriage

Attach 1M of GT2 belt to the back of the 3D Printed: Extruder Carriage by looping it around the upper belt block.

16. Feed and Attach Belt to Pulleys and Blocks

Feed belt over pulleys, back to the 20T pulley, and attach to the left side belt block, trimming extra belt.

Step 11: Attach the Extruder to the X Carriage

1. Remove Screws from Extruder Motor

Remove the 2 screws from the top of the motor, which is part of the Extruder Assembly.

2. Attach Motor to X Carriage

Attach the motor to the X Carriage by screwing it to the 3D Printed Part: Extruder Carriage using the removed screws.

Step 12: Attach Chrome & Threaded rod to the assembled X Carriage.

2. Thread Rods and Attach to Parts

Thread 235MM threaded rod through nuts and feed 320MM chrome rod through bearings on Left/Right 3D Printed Parts.

Step 13: Assemble The Front Pulley Assembly

1. Assemble Pulley Hardware

Assemble hardware in order: M3x30MM Bolt, washers, corner bracket, M3 washer, F623ZZ, 623ZZ, F623ZZ, M3 washer, washers, corner bracket, Nylock Nut.

Step 14: Attach the Pulley and Belt to the Y carriage.

1. Attach 20T Pulley to Large Motor

Attach the 20T Pulley to the Large Motor on the bottom frame using set screws, teeth on motor side.

2. Attach GT2 Belt to Y Carriage

Tip printer back and attach the GT2 Belt to the Y carriage using the same method as X Carriage installation.

3. Attach Belt to Belt Carriage and 20T Pulley

Attach belt to back of Belt Carriage, feed around 20T Pulley, then to front of Belt Carriage, leaving slack.

Step 15: Attach the Couplings and SHF8UU in preparation for the X Carriage to be attached in the next step.

1. Remove Set Screws from 2020 L Brackets

Remove 2 set screws from the 2020 L Brackets securing the top frame to the bottom frame.

2. Attach SHF8UU to Bottom Frame

Attach SHF8UU to the bottom frame using M4X14MM Bolt and M4 T-Nut, securing with removed set screw hole.

4. Attach 5x5 Couplings to 2.6 Motors

Attach 5x5 Couplings to each 2.6 Motor using set screws, leaving overhang for threaded rod.

Step 16: Attach X & Z Assembly to the Printer.

1. Loosen Z Axis Motor Mounts

Loosen Z Axis motor mounts on top of printer and pull them up as far as they will go to allow clearance.

2. Set Chrome Rods into SCH8UU's

Set X & Z Assembly chrome rods into the SCH8UU's on the bottom frame, ensuring they are pushed in fully.

3. Lower Motor Brackets for Rod Seating

Lower motor brackets to allow the top of the chrome rod to sit in the Acrylic Rod Keeper hole.

4. Screw 5MM Threaded Rod into Coupling

Screw the 5MM Threaded rod into the 5x5MM Coupling attached to the motor shaft until snug.

Step 17: Attach the Power Supply.

1. Attach 2020 Corner Brackets to Power Supply

Attach 2020 Corner Brackets to the left side of the power supply using M4X8MM Pan Head Bolts.

2. Attach Power Supply to Vertical Beam

Attach the power supply to the inner side of the right vertical 2020 Beam using M4X8MM Pan Head Bolts and M4 T-Nuts.

Step 18: Attach the Acrylic Electronics Mount

2. Attach Acrylic Mount to Frame

Attach the Acrylic Hardware Mount to the 2020 frame above the power supply using M4X8MM bolts and an M4 T-Nut.

Step 19: Assemble & Mount the Electronics

1. Attach Jumpers to Ramps Board

Attach jumpers to the Ramps Board, 3 per stepper driver, and optionally on the 5th slot for dual extruder.

2. Attach Ramps Board to Mega Board

Attach the Ramps Board to the Mega Board by lining up pins and pressing firmly.

3. Attach Heat Sinks to Stepper Drivers

Attach heat sinks to the A4988 Stepper Drivers by removing the sticky back protector and sticking to the chip.

4. Attach A4988 Stepper Drivers to Ramps Board

Attach the 4 A4988 Stepper Drivers to the Ramps Board, ensuring tuning screws face left.

5. Mount Electronics Assembly to Acrylic Mount

Mount the Electronics Assembly to the Acrylic Electronics Mount using M3x30MM bolts and Nylock Nuts.

Step 20: Attach the Motor Wires

1. Plug White End of Motor Cables into Motors

Plug the white end of each motor cable into each of the motors to attach a wire.

2. Plug Z Axis Motor Wires into Ramps Board

Plug the 2 Z axis motor wires into the left most top stepper driver on the Ramps Board.

3. Plug Y Carriage Motor Wire into Ramps Board

Plug the wire from the Y Carriage Motor into the 2nd (middle) stepper driver on the Ramps Board.

4. Plug Z Carriage Motor Wire into Ramps Board

Plug the wire from the Z Carriage Assembly motor into the 3rd (right most) stepper driver on the Ramps Board.

5. Plug Extruder Assembly Wire into Ramps Board

Plug the wire from the Extruder Assembly into the bottom right most stepper driver on the Ramps Board.

Step 21: Wire the Heated bed and the Extruder Heater to the Ramps Board

1. Strip Heated Bed Wires

Take black and red 16 gauge wires from the heated bed and strip the ends.

2. Connect Heated Bed Wires to D8 Ports

Connect the black wire to the (-) port and the red wire to the (+) port of D8 on the Ramps Board's power strip.

4. Connect Extruder Heater Wires to D10 Ports

Connect the 2 extruder heater wires to the +/- ports of D10 on the Ramps Board's power strip.

Step 22: Attach Heated Bed and Extruder Thermistors

1. Strip and Crimp Thermistor Wires

Strip thermistor wires and attach crimp ends, then plug into a 2 Pin Molex Connector.

2. Attach Extruder Thermistor to Ramps Board

Attach the Extruder Thermistor to the pins below the left most top Stepper Driver on the far right side of the Ramps Board.

3. Attach Heated Bed Thermistor to Ramps Board

Attach the Heated Bed Thermistor to the Ramps Board directly to the left and right of the Extruder Thermistor wire.

Step 23: Mount & Wire the End Stops

1. Plug White Wire into End Stops

Plug the white end of the wires into each of the End Stops.

2. Mount Z Axis End Stop

Mount the Z Axis End Stop to a 3D Printed End stop mount using an M3X8MM Bolt and M3 Nylock Nut.

3. Mount Assembled End Stop to Vertical Chrome Rod

Mount the assembled End Stop to the vertical chrome rod on the right side of the printer using an M3X18MM Bolt and M3 Nylock Nut.

8. Plug Z Axis End Stop Wire into Ramps Board

Plug the Z Axis End Stop wire into the 3rd row over on the lower left corner of the Ramps Board, red wire facing up.

9. Plug Y Carriage End Stop Wire into Ramps Board

Plug the Y Carriage End Stop wire into the 5th row on the Ramps Board, red wire facing up.

10. Plug X Carriage End Stop Wire into Ramps Board

Plug the X Carriage End Stop wire into the 7th row on the Ramps Board, red wire facing up.

Step 24: Wire Power Cable to the Power Supply

1. Cut and Strip Black Power Cable

Cut off the female end of the black power cable and strip the wires inside.

2. Determine Live and Ground Wires

Use a multimeter to determine which wires are live and which is ground for connecting to the power supply.

3. Connect Power Supply to Contacts #7, #8, #9

Connect the power supply wires to contacts #7 (blue/earth), #8 & #9 (black/line/neutral).

Step 25: Wire the Ramps to the Power Supply.

1. Strip Red and Black Gauge Wires

Take 240MM 16 Gauge Red and Black wires and strip the ends off both sides slightly.

2. Insert Wires into Green Ramps Connector

Insert wire ends into the Green Ramps Connector (Red, Black, Red, Black) and plug into the Ramps Board.

3. Wire Red Wires to Power Supply Positive

Wire the 2 16 Gauge Red wires to contacts #2 and #3 on the power supply (positive).

4. Wire Black Wires to Power Supply Negative

Wire the 2 16 Gauge Black wires to contacts #4 and #5 on the power supply (negative).

Step 26: Attach Wire Extension to Extruder Fan & Wire it to The Power Supply.

1. Cut and Strip Extruder Fan Wires

Cut off the end of the Extruder Fan and strip the ends of the wires slightly.

2. Solder Wire Extension to Fan Wires

Solder 1M of 22 Gauge Black & Red wire to the Extruder Fan wires.

4. Connect Extended Fan Wires to Power Supply

Plug the red wire to contact #1 and the black wire to contact #6 on the power supply for continuous fan operation.

Step 28: Mount Filament Feed Assist

1. Replace Z Axis Motor Bolt with Wire Keeper

Remove the bolt from the front left corner of the upper Z Axis Motor and replace it with a Wire Keeper, M3x30MM Bolt, and M4 Washer.

Step 29: Attach the Spool Holder

1. Attach 140MM Beam and Top L Bracket

Attach the 140MM 2020 Beam to the left vertical beam and place a top L Bracket to stop spool filament from sliding off.

Step 30: Wire Cleanup & Cosmetics

1. Organize Wiring with Wire Wrap and Keepers

Use wire wrap for extruder/X axis wires and Wire Keeper for extruder cables for a clean look.