13. prusa i3 mk2.5s / mk3s upgrade kit - installation...13. prusa i3 mk2.5s / mk3s upgrade kit -...

13. Prusa i3 MK2.5S / MK3S Upgrade Kit -Installation

How to install Bondtech extruder upgrade for the Prusa i3 MK2.5S / MK3S

Written By: Nuno Santiago

13. Prusa i3 MK2.5S / MK3S Upgrade Ki… 2019-11-01[minor]v1.17Approved Release:Guide ID: 43 -

This document was generated on 2020-12-14 09:20:04 PM (MST).

© 2020 support.bondtech.se/ of 47

INTRODUCTION

Product Page

This Guide relates to this Prusa i3 MK2.5S / MK3S Upgrade Kit:

https://www.bondtech.se/en/product/prusa...

Acknowledgements

This is a co-development work with some awesome guys in the Prusa Community like ChrisWarkocki, Grégorie Saunier (Bear Upgrades), Olof Ogland, Erik Bjorgan, Josh Jones, Kyle Wiehe,Marc Evertz, Matt Harrison, Ocie Ward, Sando Bendig, Vecko Kojchevski (Vecko Extruder), and lastbut not least Steven Mölby that have provided excellent feedback and suggestions of how todevelop the "perfect" extruder setup for the Prusa series printer. A lot of work has been spent in thisproject and we have tried to listen to all the inputs in order to find a solution that can be fitted to aPrusa i3 MK2, MK2S, MK2.5, MK2.5S. MK3, and MK3S.

Introduction

This kit contains the necessary parts to convert to our freshly designed extruder that uses 3:1gearing ratio for improved precision and resolution, optimized geometry for the heat-sink cooling andmany other improved features. It also reduces the moving weight to reduce vibrations and ghosting.

Compatibility

The upgrade is compatible with the following machines:

Prusa i3 MK2.5S

Prusa i3 MK3S

Additional Information




https://www.bondtech.se/en/product/prusa-i3-mk3s-extruder-upgrade/

The pictures in this guide is captured using a MK3s printer but can be applied to MK2.5S, with theexception of connecting the cables to your board. Please check Prusa's electronics guide on how toconnect the cables on your specific board.

Before Performing The Installation

Before installing your MK2.5S/MK3S Upgrade Kit, make sure you first performed the Strip ReusableParts procedure which Guide you can find here:

02. Prusa i3 MK2.5S / MK3S Upgrade Kit - Strip Reusable Parts

Recommendation

Download and print out Bondtech’s PTFE cutting fixture for precise measurement of the tube length.STL file can be downloaded using the link in the Parts section below.

You will need :

TOOLS:2.5mm Hex Key (1)Hobby Knife (1)

PARTS:PTFE cutting fixture STL (1)




https://support.bondtech.se/Guide/02.+Prusa+i3+MK2.5S+-+MK3S+Upgrade+Kit+-+Strip+Reusable+Parts/40

Step 1 — Disconnect Heater and Thermistor Cables

This step is optional but we recommend to do it as it makes it easier to assemble the hotend onthe new housing. Unplug the following cables:

Heater Block Cable

Thermistor Cable




Step 2 — Split Main Assembly

Take the main assembly from the upgrade kit box and split it in half.

Check if the Shaft Assembly is attached to the Housing that bears the Stepper Motor.

Check if the Hinge Shaft is attached to the Housing that holds the Hinge.




Step 3 — Assemble The Magnet Lever

Part supplied in the Bondtech upgrade kit: Lever.

Parts stripped from the MK2.5S / MK3S: Short Magnet; Long Magnet; Secondary Drive Gear;M3x18 Screw.

Insert and press fit the Short Magnet in the Lever;

The magnet must be fully pressed down and secured in the lever.

Insert the M3x18 screw in the screw hole of the Lever.

Mind the orientation of the parts.




Step 4 — Place The Magnet Lever

The Magnet Lever will be placed here with its screw aligned with the hole.

Perform this step minding the lever orientation:

Tip of the screw to the bottom; screw to the left; magnet to the right.

Screw the Magnet Lever all the way in and then loosen it a bit (half of a turn) so it can rotate freely.

Check if the lever can move back and forward without resistance.

Perform this check properly. Failing to do so will make you come back to this point from furtherway in this installation process.




Step 5 — Place The Long Magnet

Part stripped from the MK2.5S / MK3S: Long Magnet.

Perform this step minding the magnet orientation.

Insert the Long Magnet in this slot, all the way in.

Use an orientation that repels the Magnet Lever.

If the Magnet Lever is attracted by the Long Magnet, you must invert the Long Magnet's position.


If the Magnet Lever is repelled, the Long Magnet was inserted with the correct orientation.




Step 6 — Place The Secondary Drive Gear

Part stripped from the MK2.5S / MK3S. Secondary Drive Gear.

Perform this step minding the drive gear orientation.

The Secondary Drive Gear will be placed in the Hinge with its axis aligned between the slot andthe hole.

Lay down the Gear's shaft in the slot with the gear large teeth on the side of the slot.

First press the shaft into the slot, then push the shaft into the back hole until it's flush to both outerfaces of the Hinge.




Step 7 — Place The Primary Drive Gear

Parts stripped from the MK2.5S / MK3S: Primary Drive Gear; Square Nut.

Perform this step minding the orientation of the Set Screw with the Main Shaft's flat face.

The Primary Drive Gear will be placed on the Main Shaft with the Set Screw aligned with the flatface of the Shaft.

The Square Nut will be placed in the marked slot.

Press fit the Square Nut until it flushes to the Housing face.

Slightly fasten the Primary Drive Gear Set Screw.




Step 8 — OPTION A : Prepare The Hotend Using The Cutting Fixture

Part supplied in the Bondtech upgrade kit: PTFE Tube.

Part stripped from the MK2.5S / MK3S: Hotend Assembly.

Part we recommend you to 3D print: Cutting Fixture.

Proceed carefully while handling the Cutting Tool.

Insert the PTFE Tube in the Hotend all the way in and fit the assembly in the Cutting Fixture.

Use the Fixture's groove to guide the Cutting Tool.

Use a press down movement along the groove to cut the PTFE Tube.

Using back and forward movements to cut the PTFE Tube is not recommended.




Step 9 — OPTION B : Prepare The Hotend With No Fixture

Parts supplied in the Bondtech upgrade kit: PTFE Tube; Collet Clip.


If the PTFE Tube you took from your MK2.5S / MK3S is still good, you can use it and keep this oneas spare.

Insert the PTFE Tube in the Hotend all the way in.

While inserted, cut the PTFE Tube at 6,30mm from the Hotend's metal face.

Insert the Collet Clip between the Hotend's metal face and the Push-Fit to hold the PTFE Tube inplace.




Step 10 — Placing The Hotend In The Housing

Part supplied in the Bondtech upgrade kit: Posterior Housing Half.

Part stripped from the MK2.5S / MK3S: Hotend Assembly

If you are using a Bear X-Carriage remove the hex plug and install a M3 Nut before installing theHotend.

Proceed minding the orientation of the Heat Block and Nozzle.

Insert the Hotend in the Housing at an angle, PTFE Tube first.

After fitting the top of the Hotend, drop the Heat Block down into place.




Step 11 — Clamping The Extruder

Check all parts are in place before performing this step.

Perform the clamping minding these alignments:

The Main Shaft's tip must align with the bearing hole inside that rounded hole.

The head of this screw goes into that rounded groove.

The Hinge shaft must align with the matching hole.




Step 12 — Check The Extruder Clamping

Hold the Extruder with the Hinge facing you.

Use an Hex-key to check the alignment.

The filament hole on top should align with the filament grooves on the Primary Drive Gear.


Tighten the screw. Ensure the screw is fully set in the drive gear and towards the flat surface of theshaft.

No part of the set screw should stick out of the drive gear if installed correctly.




Step 13 — Prepare X-Carriage R2 Front

Part supplied in the Bondtech upgrade kit: 1x Square Nut.

Parts stripped from the MK2.5S / MK3S: 4x Square Nut.

Part we asked you to 3D print: X-Carriage R2 Front.

Perform the following steps:

Identify the 5 Nut Slots.

Insert each Square Nut into a Slot.

Press them in until they flush to the X-Carriage body.




Step 14 — Prepare Extruder Housing

Parts supplied in the Bondtech upgrade kit: Extruder Housing; 1x Square Nut.


Perform this simple step:

Find the Nut Slot near the Hotend.

Insert the Square Nut inside.

Press it all the way inside.




Step 15 — Attach X-Carriage Front To Extruder Housing

Parts supplied in the Bondtech upgrade kit: Extruder Housing; 3x M3x40 Screw.

Part we asked you to 3D print: X-Carriage R2 Front.

Perform this step minding the parts and connection holes alignment.

Use a M3x40 Screw to attach here.



Screw in and tighten to get it well attached.




Step 16 — Attach Stepper Motor Cable

Parts supplied in the Bondtech upgrade kit: Stepper Motor; Stepper Motor Cable.

Perform this simple step:

Plug the Stepper Motor Cable in the Stepper Motor white socket using the white plug.




Step 17 — Attach The Axial Fan

Parts supplied in the Bondtech upgrade kit: 4x M3x12 Screw;

Part stripped from the MK2.5S / MK3S: Axial Fan With Cable.

Perform the following steps minding the Axial Fan orientation shown in the pictures:

Guide the Stepper Motor Cable through the groove of the Extruder Housing.

Locate and find the 4 Housing holes to attach the Axial Fan.

Attach the Fan to the Housing using the 4 M3x12 screws.

There are no threads in the holes. The screws must open their own thread. Twist the screwsslowly and firmly but don't over tighten.

Place the fan so the Axial Fan Cable follows this path.




Step 18 — Prepare The Radial Fan Holder

Parts supplied in the Bondtech upgrade kit: Radial Fan Holder; 2x M3 nuts.

Perform the following easy step:

Press fit the Nuts into the Radial Fan Holder.




Step 19 — Attach The Radial Fan Holder

Parts supplied in the Bondtech upgrade kit: Radial Fan Holder; M3x10 Screw.

Perform the following step minding the orientation of the Holder against the Housing:

If it helps, pose the Extruder as shown in the picture.

Find the Housing's embedded nut.

Screw the Fan Holder into place.




Step 20 — Attach The Fan Shroud

Parts supplied in the Bondtech upgrade kit: Radial Fan Holder; M3x10 Screw.

Perform the following step mining the orientation of the Fan Shroud against the Housing:

If it helps, pose the Extruder as shown in the picture.

Find the Housing's embedded nut.

Screw the Fan Shroud into place.




Step 21 — Attach The Radial Fan

Parts supplied in the Bondtech upgrade kit: 2x M3x20 Screw;

Part stripped from the MK2.5S / MK3S: Radial Fan With Cable.

Perform the following steps minding the orientation of the Radial Fan in relation with the Housing:

Find the Radial Fan Holder embedded nuts and align them with the Fan fixation holes.

Orient the Fan's outtake into the Fan Shroud intake.

Screw the Radial Fan into place.

Route the Fan Cables using the grooves on the side of the Housing.




Step 22 — Attach The PINDA Probe

Parts supplied in the Bondtech upgrade kit: M3x16 Screw;

Part stripped from the MK2.5S / MK3S: PINDA Probe with cable


Locate the Probe holder in the Housing.

Slide the Probe through the Probe Holder and over about 5mm.

Use the M3x16 Screw to tighten the Probe in the Holder.

Tighten the Probe softly as further on we will have to set its Z-offset.

Route the Probe's cable as show in the picture.




Step 23 — Place The Filament Sensor Steel Ball

Part supplied in the Bondtech upgrade kit: Steel Ball Holder

Part stripped from the MK2.5S / MK3S: Steel Ball.

Perform the following steps minding the orientation of the triangular appendix in the Holder with thetriangular groove in the Housing' slot:

Place the Stell Ball in the Stell Ball Holder.

Locate the Holder's slot in the Housing.

Press fit the Holder and Steel Ball into place.




Step 24 — Extruder's Quality Check 1/3

Use 10 to 15 cm of 1,75mm filamentto perform this Quality check.

In the next 2 steps we will show youhow to do the following QualityChecks:

The Magnet Lever test lookingthrough this top window.

The Stell Ball test looking throughthe Hinge window.





With this test we check if the MagnetLever is functioning properly.

While inserting the filament throughthe filament intake of the extruder,the Magnet Lever should:

Move away when the filamententers.

If the Magnet Lever does not moveaway, main reason is the Leverscrew is to tight. Go back to Step04.

Move back when the filament exits.

If the Magnet Lever doesn't moveback, main reason is the LongMagnet is attracting the ShortMagnet of the Lever. Go back toStep 05.





With this test we check if the DriveGears are aligned with the FilamentPath.

While inserting the Filament throughthe intake of the Extruder, theFilament should:

Pass through the Filament SensorSteel Ball

If the Filament cannot pass the SteelBall, main reason is the MagnetLever is blocking the Steel Ballbecause it is in the wrong positionand too tight. Go back to Step 04 .

Reach the Primary Drive Gear, whileyou watch through the HingeWindow, and align with its teeth asshow in the video.

The filament is not supposed topush further through.

If the filament is not aligned with thePrimary Drive gear teeth, mainreason is the clamping of theExtruder was not done properly. Goback to Step 12.




Step 27 — Place Filament Sensor PCB And Cable

Part stripped from the MK2.5S / MK3S: Filament Sensor PCB; Filament Sensor Screw; FIlamentSensor Cable.


Put the PCB in place and tighten it with the Screw.

Plug the cable in, using the connection plug to grab the metal terminals of the PCB.




Step 28 — Place the Terminal Sensor Cover

Parts supplied in the Bondtech upgrade kit: Filament Sensor Cover; M3x10 Screw;


Put the Cover in place.

Screw it in using the M3x10.

Thanks to Vecko Kojchevski for his idea of securing the sensor cable with the cover. Check out hiswork here:




https://www.thingiverse.com/vekoj/designs

Step 29 — Place The Thumb Screw

Part supplied in the Bondtech upgrade kit: Thumb Screw;

Perform the following simple steps:

Insert the Thumb Screw into the Hinge hole.

Tighten it all the way in and then release it 2 to 4 full turns.

Depending on the material you are using, the Thumb Screw should be more or less tighten:

2 full turns release for Rigid materials.

4 full turn release for flexible materials.




Step 30 — Attach Extruder To Linear Guides

Part supplied in the Bondtech upgrade kit: 2x Black Zip Tie


Locate in the X-Carriage the holes to guide the Zip Ties.

Inserting and push them through minding the orientation of the lock.

Position the extruder on the Print Bed and align both Zip Ties with the sliding block's grooves.

Step 31 — Attach Extruder To Linear Guides

Attach the Extruder to the Linear Guide's Sliding Block.

Place the Drive Belt in the bottom horizontal groove of the X-Carriage R2.

Tighten the Zip Ties.

Clip both ends of the Zip Ties




Step 32 — Easing and Tensioning The Drive Belt

These Screws fix or release the X-axis Stepper Motor.

This screw changes the distance to center of the Stepper Motor.

Proceed like this:

Release the Stepper Motor.

Move the stepper Motor closer to the Extruder to loosen the Drive Belt, before placing both ends ofthe Drive belt in the X-Carriage

Move the stepper Motor away from the Extruder to thighten the Drive Belt, after placing both endsof the Drive belt in the X-Carriage

Check the Drive Belt's tension before fixing it in position.

Tighten the Stepper Motor after finished positioning it.




Step 33 — Attach The Drive Belt To The Extruder

These grooves in the X-Carriage R2 will hold the Drive Belt in place.

Place one end of the Drive Belt in one X-Carriage's drive belt grooves.

Loosen the X-Axis Stepper motor to give you more room to place the second end of the Drive Belt,as instructed in the Step before.

Place the other end of the Drive Belt in the other X-Carriage's drive belt groove.

Increase tension in the Drive Belt and fix the X-Axis Stepper Motor at that position to finish thisstep.




Step 34 — Preparing the X-Carriage Rear

Part stripped from the MK2.5S / MK3S: M3 Nut.

Part we asked you to 3D print: X-Carriage R2 Rear.


This is where the M3 nut will be placed.

Press fit the M3 nut in position.

These cables will cross the X-Carriage Rear in the next step.




Step 35 — Cross Cables Through X-Carriage Rear

Cross the following cables through the X-Carriage in this order:

Stepper Motor Cable

PINDA Probe Cable

Radial Fan Cable

Axial Fan Cable




Step 36 — Place Main Cable Guide Through X-Carriage

Pass the Main Cable Guide through the X-Carriage Rear.

Insert the tip of the Main Carriage Guide

In the bottom center hole of the X-Carriage Front




Step 37 — Attach X-Carriage Rear

Check if all cables plus the Main Cable Guide are crossing through the X-Carriage Rear beforeattaching it.

Check if the Main Cable Guide is properly inserted in its place. Press it forward just to be sure.

Use these 5 M3x10 Screws...

And these 5 holes of the X-Carriage...

To attach it in place.




Step 38 — Attaching The Heater And Thermistor Cables

Grab the Heater and Thermistor Cable Holder

And orient its screw to this hole in the X-Carriage Rear.

Then Screw the holder in with this screw.




Step 39 — Attach The Main Cable Sleeve 1/3

Parts supplied in the Bondtech upgrade kit: 3x Zip Tie

Part stripped from the MK2.5S / MK3S: Main Cable Sleeve


Roll the Sleeve around the cables

And pass the Zip Ties through the Heater and Thermistor Cable Holder using these 3 holes.

Tighten the Zip Ties.


Cut the Zip Ties tips

As short as possible





Wrap the Main Cable Sleeve around the cables starting from the fixed tip...

up until there is no more Sleeve to wrap.

Step 42 — Plug Cables To Control Box 1/3

Plug for Heater Cable

Plug for Axial Fan Cable

Plug the Heater Cable in.

Plug the Axial Fan Cable




Step 43 — Plug Cables To Control Box 2/3

Plug the Radial Fan Cable in.

The Filament Sensor Cable has 3 wires: a Pair (usually Red and Black); and a Single (usuallyWhite).

Plug the Filament Sensor Cable into the bottom Row!

Mind the orientation of the Sensor cable.

Placing the Single wire to the left.

Plug the thermistor Cable in.




Step 44 — Plug Cables Into Control Box 3/3

Plug PINDA Probe Cable in.

Plug Stepper Motor Cable in with the black wire on top.

Ensure the orientation of the motor cable is correct otherwise the extruder will turn the wrongdirection!

If the motor is turning in the opposite direction, reverse the connector.

New Stepper Motor Cables have a dupont connector with lock and can only be inserted oneway, (with the blue wire on top).

Place the Sleeve tip slightly crossing the Main Cable Port.

and route the cable to allow the Control Box to close.




Step 45 — Attach Main Cable And Close Control Box

Use the Main Cable Half Ring...

to secure the Main Cable in Place by screwing it to the other Half Ring in the Control Box.

Before closing the Control Box, mind the positioning and rouring of the cables.

Close the Control Box Door

Step 46 — Close Control Box

Fasten the Control Box Door withthis screw on the opposite side ofthe Control Box.




Step 47 — Level PINDA Probe 1/2

Lower the Print Head by rotating the lead screws of the Z-axis...

... until the nozzle touches the Build Plate

Step 48 — Level PINDA Probe 2/2

Loosen the PRINDA Probe by releasing pressure on the Holder.

The PINDA PRobe should hoover about 1mm above the Build Plate. To set this distance use oneZip Tie laying down in the Build Plate.

Let the PINDA Probe slide down until it reaches the Zip Tie.

After the Probe is in position, tighten the Holder back on by fastening the screw.




Step 49 — Attach "Powered By Bondtech" Sticker

Part supplied in the Bondtech upgrade kit: Powered By Bondtech Sticker

If you like, place the sticker on your MK2.5S / MK3S at a place of your choosing.

To complete the installation you need to flash our new firmware. Follow this link Bondtech Prusa i3- Firmware Update




https://support.bondtech.se/Guide/00.+Bondtech+Prusa+i3+-+Firmware+Update/44

13. prusa i3 mk2.5s / mk3s upgrade kit - installation...13. prusa i3 mk2.5s / mk3s upgrade kit -...

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