Open HardwareAssembly Instructions
Guides for installation and assembly of the LulzBot line of products made by FAME 3D LLC.
Guides for installation and assembly of the LulzBot line of products made by FAME 3D LLC.
Gather the required materials:
1x- [AS-HE0022] Mini AeroStruder Hotend Assembly
1x- [AS-CB0003] Zero Sense 220mm Harness
1x- [AS-CB0050] Blower fan Harness, 250mm
1x- [AS-CB0051] Extruder Motor Harness, 180mm
1x- [AS-CB0052] Heatsink fan Harness, 220mm
1x- [AS-CB0053] Thermistor Harness, 120mm
2x- [AS-CB0054] Xmax switch Harness, 175mm
1x- [PP-IS0040] Mini Aero Blower Shroud w/ Inserts
1x- [PP-IS0041] Mini Aero Extruder Mount w/ Inserts
1x- [DC-LB0094] Serial number label sheets (blank) 100/pk
1x- [DC-LB0104] Tool Head Wiring Connector Alignment Label
1x- [EL-MT0040] NEMA 17 Half Height Stepper Motor, Moons
1x- [EL-SW0022] SWITCH BASIC SPDT 3A .110QC 125V
4x- [HD-BT0039] M3x12 SHCS
1x- [HD-BT0042] M3x30 SHCS
3x- [HD-BT0043] M3x35 SHCS
2x- [HD-BT0107] M2x10 SHCS
1x- [HD-BT0146] M3x12 BHCS
2x- [HD-BT0171] M3x20 BHCS
1x- [HD-BT0197] M4 Thumb Screw for Aero
1x- [HD-MS0430] Idler Spring for Aero
2x- [HD-MS0446] MR95-2RS Radial Ball Bearing Double Sealed Bore Dia. 5mm OD 9mm Width 3mm
1x- [HD-NT0011] M4 Nut
2x- [HD-WA0012] M2 Flat Washer
1x- [HD-WA0027] M3 SST Lock Washer
2x- [HD-WA0038] M3 Washer
1x- [PP-FP0135] E3D Aero Idler Lever
1x- [PP-FP0136] E3D Mirrored Aero 2.85mm Filament Guide
1x- [PP-FP0137] E3D Aero Acetal Gear w/ Filament Drive Shaft
1x- [PP-MP0204] Aero Mirrored Body w/ Threaded Insert
1x- [PP-MP0282] E3D Aero Steel Pinion Gear w/ set screw
Install the drive gear [PP-MP0282] onto the motor [EL-MT0040] using the printed drive gear spacer jig as shown. Apply Blue Loctite and torque the set screw to 3 in*lbs.
A set screw should come pre-installed in the gear, if not, ensure an M3x3 set screw is used. Set screws of any greater length will interfere with the larger gear during operation.
Install one sealed MR95ZZ bearing [HD-MS0446] into the extruder body [PP-MP0204] as shown.
Install the internal lock washer [HD-WA0027] as shown.
Using one M3 x 12 BHCS [HD-BT0146], fasten the exturder body [PP-MP0204] to the motor through the printed mount [PP-IS0041].
Install the bearing [HD-MS0446] into the heatsink [AS-HE0022] as shown.
Install the large drive gear [PP-FP0137] as shown. Make sure the faces of the two gears are flush with each other. Adjust the pinion gear as necessary. If adjustments are required, make sure to re-torque the pinon gear set screw.
Install the idler [PP-FP0135]] and the idler spring assembly [HD-NT0011], [HD-MS0430], and [HD-BT0197] as shown.
Install the filament guide path [PP-FP0136] as shown.
Install the heatsink assembly [AS-HE0022] onto the extruder body as shown.
Route the heater cartridge wires and the thermistor wires as shown.
Put the zero sense line [AS-CB0003] onto one of the M3 x 35 SHCS [HD-BT0043], then put it into the lower right mounting hole as shown.
Lift the zero sense line fastener out part way and slide the blower shroud [PP-IS0040] over the hotend.
Put in the other two M3x35 SHCS into the top two mounting holes, and put the M3x30 [HD-BT0042] and M3 washer [HD-WA0038] into the lower left mounting hole.
Make sure not to pinch the zero sense line.
Torque the fasteners to 3 in * lbs in the sequence shown in the photo.
Install the endstop switch [EL-SW0022] using 2x M2x10 [HD-BT0107] and 2x M2 washers [HD-WA0012] as shown. Make sure the switch is oriented as shown.
Using two M3 x 20 BHCS [HD-BT0171] with washers (HD-WA0038), install the blower fan [AS-CB0050] as shown. Route the wires through the gap near the blower fan mount and back to where the heater wires are.
Using four M3 x 12 SHCS [HD-BT0039]. install heatsink fan [AS-CB0052] as shown.
Be sure the fan is in the correct orientation. The label should not be visible and the screws should sit flush in the fan housing.
Install two endstop switch wires [AS-CB0054] and route them as shown. Connect the connectors and bend them in so that they clear the carriage when the toolhead is installed.
Connect motor harness [AS-CB0051] and thermistor extension harness [AS-CB0053] as shown.
Pin all the harnesses according to the diagram.
Wrap the zero sense line around the rest of the harnesses as shown and pin it into the connector.
Apply the direction arrow sticker [DC-LB0104] as shown on the pin 1 side of the connector (the side with the arrow).
Make sure your toolhead looks like the one in the pictures.
After assembly of the Mini AeroStruder is complete, it is necessary to verify the electrical properties of the toolhead, namely the heater cartridge and thermistor.
First we will test the resistance value of the heater cartridge;
To do so, first set your multimeter to Ohms which is signified by the capital Greek letter Omega.
Now touch the probes of your multimeter to pins 5 & 6 individually.
Note: Positive or negative probe positions are irrelevant to this test.
The display on the multimeter should now show a value around 19 Ohms.
Any value between 17.5 and 21.3 Ohms is acceptable, values outside of that range are cause for rejection of the heater cartridge and it should be replaced.
Next we will verify that the heater cartridge DOES NOT have continuity to the ground circuit.
To do so, the multimeter may remain in Ohms mode or be switched to an audible continuity test mode by moving the switch to the symbol representing sound waves.
Now touch one probe to the heater block, and the other to pins 5 & 6 individually.
Note: Positive or negative probe positions are irrelevant to this test.
Whether probing pin 5 or 6, the multimeter display should remain at 0 and no audible alarm should sound.
This indicates that there is no continuity between either lead of the heater cartridge and the toolheads ground circuit.
If the multimeter display reads anything but 0, or an audible alarm is heard during either half of this test, the heater cartridge must be rejected and replaced.
Next we will perform the same tests for the thermistor.
To do so, first set your multimeter to Ohms which is signified by the capital Greek letter Omega.
Now touch the probes of your multimeter to pins 17 & 18 individually.
Note: Positive or negative probe positions are irrelevant to this test.
The display on the multimeter should now show a value between 80 and 120 K Ohms.
Pay close attention to the units displayed on the multimeter's display; the letter 'K' should be displayed to the right of the value.
If a reading is given in Ohms or Mega Ohms (indicated by the letter 'M' to the right of the value displayed) or the kOhms reading is too low (values displayed as 1.xx or similar) or otherwise outside of the range stated above, the thermistor must be rejected and replaced.
Next we will verify that the thermistor DOES NOT have continuity to the ground circuit.
To do so, the multimeter may remain in Ohms mode or be switched to an audible continuity test mode by moving the switch to the symbol representing sound waves.
Now touch one probe to the heater block, and the other to pins 17 & 18 individually.
Note: Positive or negative probe positions are irrelevant to this test.
Whether probing pin 17 or 18, the multimeter display should remain at 0 and no audible alarm should sound.
This indicates that there is no continuity between either lead of the thermistor and the toolhead's ground circuit.
If the multimeter display reads anything but 0, or an audible alarm is heard during either half of this test, the thermistor must be rejected and replaced.
To finalize this test, verify that the zero sense line (ground circuit) has continuity to the nozzle.
This test is best performed in the audible continuity mode.
Touch one probe to the nozzle or heater block, and the other to pin 16 on the toolhead's connector.
Note: Positive or negative probe positions are irrelevant to this test.
An audible alarm should sound indicating that continuity is present.
If so, the toolhead has passed electrical testing and may proceed to final extrusion testing.
Congratulations!
Put the toolhead onto the test stand and run the test gcode. Make sure:
1) The heatsink fan is on anytime the tool's controller is powered on
2) That the blower fan runs without being too noisy or jittery
3) That the Hotend heats up in a controlled way
4) The stepper motor moves without skipping
Visually verify the extrusion and make sure there is no debris.
Remove the remaining filament from the tool head. Once the tool head is cool, insert a cold piece of filament into the tool head and trim it to approximately 30mm of filament.