Technical Manual BigRep ONE-2015!05!23
Technical Manual BigRep ONE-2015!05!23
General Infos
Whenever an update in the technical manual appears you can download this
updated subchapter in the reseller portal. Recent changes will be listed in the
changelog.
Please replace updated subchapters in the printed manual.
0. General Infos / Updates BigRep
2016-05-23
New chapter structure all versions
VI-D New Subchapter ‘Starting Guide Simplify3D’ all versions
2016-04-20
II-B New jumper settings in config for ONE.3b only ONE.3b
VI-C Maintenance Config Overview: new config all versions
VI-C New stepper values in config for ONE.3b only ONE.3b
VI-C New jumper settings in config for ONE.3b only ONE.3b
I. Mechanics BigRep
I Mechanics
I-A Overview
* 2016-04-07
Portal
Frame Bed
Red marked screws must be provided with toothed washer to guarantee proper
grounding
I-A 1/3
I. Mechanics BigRep
D B
A
C
z
y
x G I E
I-A 2/3
I. Mechanics BigRep
I-A 3/3
I. Mechanics BigRep
I-B 1/1
I. Mechanics BigRep
I-C 1/2
I. Mechanics BigRep
1 2
2b
2a
I-C 2/2
I. Mechanics BigRep
I-D Portal
* 2016-04-07
Overview
BigRep has three moving Axis, X, Y and Z. If you are standing in front of the printer
the movement of the axis is as following:
›› X-Axis: moves the extruder in X direction from left to right.
›› Y-Axis: moves the X-Axis Y direction from front to back
›› Z-Axis: moves the X-Axis and Y-Axis (portal) up and down
Mechanical Description
X-Axis and Y-Axis are driven by one stepper motor (Nanotec) each + belt and pul-
ley.
Z-Axis is driven by one stepper motor (Nanotech) + belt and several pulleys
Maintenance
Please have a look at section V - Maintence of the technical manual for further in-
formations.
All motors and pulleys can be replaced if needed.
X- and Y-Axis are using self-lubricated carriages and have to be lubricated with
industrial grease about once a year. We recommend mineral oil-based lubricants.
All belts have to be lubricated with silicon spray about once a year.
It is important to check the tension of the belts, which should be around 20Hz.
Note
As Silicon and Grease react with each other, please make sure that you never put
silicon spray at the X- or Y-Axis.
I-D 1/
I. Mechanics BigRep
I-E Extruder
* 2016-04-07
Overview
g
l
a
c f
d e k
The extruders are the main unit for 3D printing with the BigRep ONE. The extruder
contains the hot end (n) where the filament is heated and then squeezed through
the nozzle (o).
The BigRep ONE is equipped with two extruders which can be changed individ-
ually. Given the two extruders, the two nozzles can be used simultaneously for
separate printing projects (with the same or differing diameters), e.g. to print ad-
ditional support material for supporting structures alongside the main object.
If you want to use other nozzle diameters than the ones installed, the extruders
need to be retrofitted. You can either replace the entire extruder or only the hot
end. In both cases the extruder must first be removed from the machine.
I-E 1/6
.
Extruder Features
Filament cleaning sponge (filament must be fed
through this when loading new filament)
Main cooling
2x Screws to Lever to release idler fan (always on)
remove wheel spring. Push to
Front Cover the right to load /
unload filament
BigRep Logo
(lights up when
extruder is
connected)
I-E 2/6
Hole + Slot
(aligns to printer when
Access hole for screw installing extruder)
to remove hot-end
Hot-end cooling
fan (always on)
Filament cooling fan
(turned on/off by
software during print) Nozzle heater
Left Front Right (HOT, do not touch!) Back
I. Mechanics BigRep
X-Stage
Mounting the extruder Step 1:
Extruder slides straight
back onto X-Stage mount
Step 2:
First engagement is with the attachment screw. User
begins screwing it in by hand to pull extruder back
I-E 3/6
Step 3:
Pins line up with extruder hole / slot
Step 4:
User hand tightens attachment screw to
secure extruder Step 5:
User makes 2x electrical
connections on back of extruder
I. Mechanics BigRep
X-Stage
Adjustment to set height of nozzle
I-E 4/6
I. Mechanics BigRep
User Accessible Components
Shown with front cover removed
Main filament
drive wheel
I-E 5/6
Idler wheel
Turn this direction to
increase idler wheel
spring pressure
I. Mechanics BigRep
I. Mechanics BigRep
Auto Leveling
BigRep ONE comes with an auto leveling X-Axis to Bed
The laser sensor is mounted to the X-Axis left from the extruder
The sensor measures the distance between X-Axis and Bed
Before you start a print, the sensor measures (with 3 points) the distance be-
tween Axis and Bed + automatically levels correct z-height during a print in case
the planarity is not 100% correct in total
The laser cannot balance minimums and maximums within the bed.
I-E 6/6
I. Mechanics BigRep
adjustable roller
adjustable sponge
I-F 1/1
I. Mechanics BigRep
I-G 1/1
II. Electric BigRep
II Electric
II-A Overview
* 2016-04-07
Printer configuration: 200-240V, needed: at least 200V & 16 Amp
Preassembled Schuko Plug can be replaced
II-A 1/1
II. Electric BigRep
II-B 1/7
II. Electric BigRep
Overview of components
* The uninterruptable power supply (UPS) fuse must be removed prior to any transport.
( )
II-B 2/7
II. Electric BigRep
Doors
1. fan
2. thermostat (35°)
3. case documents
4. grounding
6. fuse panel
7. air filter
8. grounding
Fuse panel
II-B 3/7
II. Electric BigRep
Boogieboard
Boogieboard is the electronic control center of the printer, which operates all of
the electronic elements of the printer. The boogieboard also contains a SD-card
with firmware and config. The LEDs at the boogieboard tell us if something is not
working proper.
II-B 4/7
II. Electric BigRep
LEDs
1. BED: Led´s on when heating
2. End stops: LED´s 1 on when end stops are not triggered
3. Filament out sensor T0 and T1: LED´s on when filament in
4. Emergency-Stop: LED´s on when not hit
5. Extruder heating T0: LED´s on when heating
6. Extruder heating T1: LED´s on when heating
7. Extruder T0/T1: green if extruder is not activated (upper position)
8. Extruder T0/T1: red if extruder is activated (lower position)
II-B 5/7
II. Electric BigRep
UPS onboard
UPS ensures that the PC will have power for a short time in case of a current pow-
er interruption.
Due to security reasons the fuse of the UPS is plugged out during transportation
and has to be plugged in before the setup.
There is one spare fuse delivered with every printer.
Important
After the machine is switched off, the operator has to wait 30s before it is al-
lowed to switch on the machine again. Otherwise the PC wont start.
II-B 6/7
II. Electric BigRep
Output of each motor has to have correct jumper settings (white switches on blue
panel)
Each output comes with green and red LED´s which display issues in case the
motors are not working proper:
›› All LED´s green: everything working proper
›› All LED´s red: bug --▷ needs replacement
›› Single LEDs red: fuse triggered, if not faulty wiring or replacement is needed
Note: Different jumper settings for Y Motor depending on printer version. Please
note also the information in VI-C Maintenance Config Overview from 2016-04-20.
endstufen_einstellung
X Motor (all printer versions) Z Motor (all printer versions) T0, T1 Motor (all printer versions)
Leadshine DM556 Leadshine DM556 Leadshine DM442
OFF ON Switch number Function OFF ON Switch number Function OFF ON Switch number Function
X 8 32 microsteps X 8 32 microsteps X 8 32 microsteps
X 7 32 microsteps X 7 32 microsteps X 7 32 microsteps
X 6 32 microsteps X 6 32 microsteps X 6 32 microsteps
X 5 32 microsteps X 5 32 microsteps X 5 32 microsteps
X 4 half standstill current X 4 half standstill current X 4 same standstill current
X 3 2,7 A rms X 3 3,1 A rms X 3 1,69 A rms
X 2 2,7 A rms X 2 3,1 A rms X 2 1,69 A rms
X 1 2,7 A rms X 1 3,1 A rms X 1 1,69 A rms
Y Motor (not for ONE.3b and higher) Y Motor (only for printers ONE.3b and higher)
Leadshine DM556 Leadshine DM556
OFF ON Switch number Function OFF ON Switch number Function
X 8 32 microsteps X 8 8 microsteps
X 7 32 microsteps X 7 8 microsteps
X 6 32 microsteps X 6 8 microsteps
X 5 32 microsteps X 5 8 microsteps
X 4 half standstill current X 4 half standstill current
X 3 2,7 A rms X 3 2,7 A rms
X 2 2,7 A rms X 2 2,7 A rms
X 1 2,7 A rms X 1 2,7 A rms
II-B 7/7
II. Electric BigRep
II-C 1/1
II. Electric BigRep
II-D 1/1
II. Electric BigRep
II-E PC
* 2016-04-07
Overview
›› Linux PC
›› Pronterface and BigRep GUI preinstalled
›› Operator can switch between Pronterface and GUI during the machine is
running.
›› Pronterface recommended for maintenance
›› Hard drive on-board – data/printing files can be saved at the machine.
›› Preinstalled G-Codes for setup and maintenance
›› Can be connected to the Internet via Ethernet cable (at the left side of the
control unit)
›› Open the back-cover of the PC with 4 hex screws
Open the back-cover of the PC with 4 hex screws
II-E 1/1
III. Software BigRep
III Software
III-A Overview
* 2016-04-07
›› Linux System incl. Pronterface preinstalled
›› Printer is based on smoothieware [http://smoothieware.org/]
›› Config File is part of the firmware and defines all settings of the BigRep ONE
›› Pronterface and BigRep GUI preinstalled
›› With Pronterface the user can operate the printer
›› Optional: BigRep GUI
›› Slicing software is not part of the printer. Recommended Slicing Software:
simplify3d. Presettings at BigRep Customer/Reseller Portal.
III-A 1/1
III. Software BigRep
III-B Firmware
* 2016-04-07
›› Smoothie is a free, open-source, high performance and modular G-code
interpreter and CNC control system for the Smoothieboard 32bits control-
ler. [http://smoothieware.org/]
›› Smoothie is a firmware. That is a program that executes on a micro-control-
ler, basically a very simple/small computer used for very specific tasks. The
micro-controller is located on a controller board, for example Smoothie-
board (BigRep: Boogieboard), where it executes the Smoothie firmware.
›› This program receives instructions from your computer ( typically G-code,
generated by CAM software), and executes them, for example by moving
stepper motors in a coordinated fashion, and operating tools.
›› Firmware is written by BigRep and based on the open source smoothie
project, like many other FDM 3D Printer and/or CNC milling machines.
›› Firmware updates will be pushed automatically to the printer by BigRep if
connected to the Internet.
III-B 1/1
III. Software BigRep
III-C Config
* 2016-04-07
›› Config file defines all operational settings of the printer
›› Example: Acceleration of axis, buffer smoothieboard, offset, stepper values
etc
›› Most of the values are not allowed to change
›› Small amount of values are allowed to change and have to be changed in
case hardware is replaced (for example new extruder):
›› Stepper Value Extruder (flowrate)
›› Stepper Value X-Axis, Y-Axis and Z-Axis
›› Offset nozzle T0-T1
›› Z-Probe Offset
Part of config file
You will find the full config in VI-C Maintenance Config Overview
III-C 1/1
III. Software BigRep
III-D GUI
* 2016-04-07
III-D 1/2
III. Software BigRep
Menu Structure
Start Screen
Main
Reset Printer
Connect / Disconnect
Turn Off
Prepare Print
Home & Level Temp. & Material Load / Change Object Move Print Head
Home All Axes Select Etruder or Bed Select Drive, File, X/Y-Movement, Z-Mo-
X-/Y- /Z-Homing Extruder on / off, Confirm vement, X/Y-Speed,
Auto Bed Leveling Set Temp, Extrude, Z-Speed, Home all,
Change Filament Home X/Y/Z
Change Filament
Select Filament, Edit
Filament Parameters
III-D 2/2
III. Software BigRep
III-E Pronterface
* 2016-04-07
Pronterface is a free, open source software
Access to Pronterface: hitting “exit UI”
In case the BigRep GUI is not working due to any software bugs the operator can
always switch to pronterface
III-E 1/1
III. Software BigRep
III-F 1/8
III. Software BigRep
III-F 2/8
III. Software BigRep
III-F 3/8
III. Software BigRep
III-F 4/8
III. Software BigRep
III-F 5/8
III. Software BigRep
III-F 6/8
III. Software BigRep
III-F 7/8
III. Software BigRep
M909 Set microsteps (1/n), ONLY for advanced M909 A16 B64
drivers handled by motordriver module,
M909.1 will also set the steps/mm accor-
dingly
M910.x setup advanced driver chips that support M910
SPI setup, parameters are specific to each
chip see chip docs
M1910.x Move a given number of steps, without M1910 X100 F100
acceleration ( for testing only ) M1910.1 will
stop the motor
M957 (with Spindle module enabled) Report the M957
current spindle speed and PWM value
M958 (with Spindle module enabled) Report M958 P0.1
the current spindle PID parameters. M958
Px.xx Ix.xx Dx.xx will set them (to save the
new values, you need to edit config file
manually).
M999 Reset from a halted state caused by limit
switch, M112 or kill switch
III-F 8/8
IV. Setup BigRep
IV Setup
IV-A Overview
* 2016-04-07
Setup has to be done by BigRep staff or certified
BigRep Reseller.
Printer comes preassembled (excl. spool cabinet)
in a wooden, IPPC certificated, box:
›› Weight ca. 750 kg / 1.650 lbs (500 kg / 1.100
lbs printer + box)
›› Dimensions: [Length x Width x Height]
225 x 200 x 200 cm
Printer runs through longterm QS testing before it leaves BigRep facility.
Power supply has to be changed if needed.
Printer comes with preassembled Schucko Plug, which can easily be changed.
Setup regularly takes two business days, incl. testprint and instruction .
Scope of Delivery (depending on model)
›› BigRep ONE (incl. 2 extruders)
›› 2 hot ends (preassembled, nozzle diameter 1mm)
›› 1 separate hot end with nozzle, diameter 1mm
›› Hex key for exchanging hot ends
›› Scraper to remove objects
›› 2 electrical fuses for the UPS (in the control cabinet)
›› 25mm spacer (for leveling)
Additionally in the Advanced Kit
›› PVA pack
›› Nozzle cleaning station
›› Extended run-time UPS
›› Web access + web-cam
IV-A 1/1
IV. Setup BigRep
Once printing has started, the device may not be made accessible to any unau-
thorized persons!
To allow for a satisfactory printing process, make sure to:
›› Avoid high humidity
›› Keep the temperature in the operating environment between +15 °C and
+40 °C
›› Avoid strong drafts during the printing process
›› Avoid direct exposure of the device to sunlight
›› Not operate the device on surfaces particularly sensitive to vibrations
›› Avoid serious indoor air pollution with dust (e.g. sanding dust)
IV-B 1/1
IV. Setup BigRep
IV-C Unpacking
* 2016-04-07
There are two possibilities to get the printer out of the box:
1. Use a forklift and belts and lift the printer out of the box
2. Use the front side of the box as a ramp and pull out the printer by hand. The
front side comes with preassembled angle brackets
Tools
Electric Screwdriver, Phillips Head, Knife [Optional: Forklift Truck & Belts]
Note
Please mention: This is a job for at least two people. It is ok if the second person
is one of the customer’s staff. As the box comes with a preassembled ramp and
the printer has wheels, it is possible to pull the printer out of the box [option no1]
without a forklift truck [option no2]
Procedure
1. Open the front side of the box (labeled as front) with an electric screwdriver.
The front side of the box will be used as a ramp in case you do not have a
forklift available.
a.
b.
2. Open the back side of the box with an electric screwdriver.
3. Loose all of the wooden fixing/transport security beams
IV-C 1/5
IV. Setup BigRep
6. Now the printer is ready to be pulled out of the box. We have two options
Option 1
Use a forklift and belts and lift the printer out of the box
a. Take off the lid and both sides of the box – use the electric screwdriver to
unscrew all screws
b. Put the belts under the frame at two sides of the printer.
IV-C 2/5
IV. Setup BigRep
c. Use a lift truck and lift the printer from the upper side:
d. Done
Option 2
Use the front side of the box as a ramp and pull out the printer by hand. The
front side comes with preassembled angle brackets.
If you choose Option 2, it is not necessary to take away the sides and the lid
of the box.
a. Make sure that all 4 brakes are loosen
b. Lay down the ramp at the front side of the box, with the flat (outside)
side up. Make sure that there is no space between box and ramp.
c. Now gently pull out the printer straight out of the box with at least two
persons.
IV-C 3/5
IV. Setup BigRep
7. After the printer is pulled out and at its final location, you can take away all
of the transit support
8. A
t the end loose the accessories box and spool holder from the printing
table. Please note: The printing table already comes with orange kapton
tape assembled. So please do not remove the orange kapton tape.
IV-C 4/5
IV. Setup BigRep
IV-C 5/5
IV. Setup BigRep
IV-D 1/1
IV. Setup BigRep
IV-E 1/1
IV. Setup BigRep
IV-F 1/1
IV. Setup BigRep
IV-G Assembling
* 2016-04-07
Spooler cabinet
Note:
If there is no standardized power network a local electrician should always do the
electric setup (see 4.5).
Steps:
1. Take the spool cabinet from the printing bed.
2. Use the eight screws you will find in the accessories box .
3. Assemble the spool cabinet at the back wall of the printer above the control
unit.
Table / Bed
The screws at the frame of the table have to be loosen after transportation in
order to ensure expansion while heated:
1. Unscrew all 8 Torx (T20) by 2-3 turns.
Note:
If possible a second person should hold the cabinet while the first person
screws in the 7 (2x M8x30. 5xM8x40) screws.
IMPORTANT: Use gloves while working with these screws as they are lubricated.
Fuse
Steps:
Plug in Fuse UPS
1. Open control unit.
2. Take Fuse next to USP and plug it in .
3. Close control unit.
Extruder
Important:
Machine has to be switched off during assembling the extruders!
Assemble both extruders at T0 and T1:
1. Take extruders out of accessories box.
2. Put Extruder T0 to the left bracket (with the pins).
3. Use the preassembled screw at the front to attach the extruder to the
bracket.
4. Connect both marked plugs to the back of the extruder.
IV-G 1/1
IV. Setup BigRep
IV-H 1/2
IV. Setup BigRep
IV-H 2/2
IV. Setup BigRep
IV-I 1/2
IV. Setup BigRep
IV-I 2/2
IV. Setup BigRep
IV-J 1/1
IV. Setup BigRep
IV-K Extruder
* 2016-04-07
Extruder extrusion test/calibration flow rate
1. Heat up both ext. sides to 220° and change the extrusion length to 300mm
and speed to100 mm/min.
2. Make sure you have filament inside extruder tubes and they both reach the
end of the nozzle
3. Measure 300mm and 400mm from the upper end of the teflon tube on top of
the extruder mark both with a pen
4. Press Extrude
5. After extrusion stops, measure the real length of extrusion. If the length of
extrusion differs from 300mm, you have to adapt the stepper value settings
in the config
Note
In case it is more or less than 300mm, for example 260mm:
300/260 = 1,15 --> multiply 1,15 with the present config value and and change the
value within the config + save config
Important
When you change any value in the config you have to save it!
Filament Out Sensor
1. Cut the filament above the extruder on T0 and T1
2. Print test-sample
3. Check if printer stops immediately when filament pass through feeding
wheels
4. Change filament and press resume
5. Note if extruder starts with last line printed
IV-K 1/1
IV. Setup BigRep
IV-L 1/1
V. Maintenance BigRep
V Maintenance
V-A Overview
* 2016-04-07
Regular maintenance which has to be done in a certain range of time is very little:
›› Lubricate Axis
›› Lubricate Belts
›› Check security stops
›› Check tension of belts
Expendable items/Replacements
›› Printbed tape
›› Nozzle
›› Extruder
All items + BigRep Filament can be ordered at www.bigrep.com/shop with a re-
seller discount
V-A 1/1
V. Maintenance BigRep
2. First layer
a. You need two persons
b. Take one tape and pull off the first part of the protection film (yellow)
V-B 1/5
V. Maintenance BigRep
c. One person is standing in the back, holding up the tape at both ends
(no pressure, just hold it up to avoid that it sticks on the bed to early)
d. The second person starts to push the tape onto the bed with using the
roller (high pressure)
e.
f. Go on in straight lines and try to avoid bubbles (You can get rid of them
afterwards with using a needle)
g.
V-B 2/5
V. Maintenance BigRep
3. Second Layer
a. Start with the second layer, overlapping the first layer for at least 1cm
and go on similar to the first layer
b.
c.
V-B 3/5
V. Maintenance BigRep
b.
c. Cut off one straight line of the second tape, choose a gap between both
tapes of 1-2mm (high pressure needed)
d. Pull off the overlapping line
e.
5. Last steps:
a. Use the roller for all edges and borders again
b. Cut off the overlapping parts at the borders
V-B 4/5
V. Maintenance BigRep
c.
d. Switch off bed heating
e.
V-B 5/5
V. Maintenance BigRep
3. Now loosen the screw which holds the hot end into the extruder
V-C 1/3
V. Maintenance BigRep
V-C 2/3
V. Maintenance BigRep
a. Take a new hot end (yellow tube 0.5mm, blue tape 1mm) and push it into
the extruder --▷ there is one adjust pin (marked red) which defines the
directions
V-C 3/3
V. Maintenance BigRep
2. Make sure that there is no Filament left in the extruder. If so please have a
look at manual.
3. Make sure that the hot ends cooled down.
4. Pull out both plugs at the extruders back
a. Turn the inner safety lock (red marked in right figure) anticlockwise and
then pull out the plug
V-D 1/2
V. Maintenance BigRep
5. Loose the clamping bold at the extruders front side (no tools needed), turn
anticlockwise and make sure that you hold the extruder with the other hand
6. Take the new extruder and attach it to the plate with using the dowel pins
(marked red)
7. Screw on the clamping bold at the extruders front side (no tools needed),
turn clockwise and make sure that you hold the extruder with the other
hand
8. Attach both plugs at the extruders back
a. Screw on the security lock clockwise
9. Restart the machine
V-D 2/2
V. Maintenance BigRep
V-E 1/1
V. Maintenance BigRep
V-F Lubricate
* 2016-04-07
Axis
Regularly clean and lubricate the X-guide rail (H), Y-guide rail (F), Z-lead spindles
(C), and Z-guide shafts (B).
Please only use approved industrial lubricants. We recommend mineral oil-based
lubricants for rolling or plain bearings.
Regularly check the lubrication of individual components. Ensure that they are
always covered by a thin lubricating film.
Belts
Lubricate X, Y and Z belt with silicon spray.
To lubricate the Z-Belt, you have to open the cover at the top of the machine in
each edge.
To lubricate X and Y belts you have to open the cover of the axis.
V-F 1/1
V. Maintenance BigRep
V-G Belts
* 2016-04-07
Maintenance
All belts have to have a certain tension, measured in Hz. In order to measure the
tension you have to open the covers of the axis, manually hit the belt like a guitar
and measure the tension with a trumeter. The tension of X and Y Axis should be
around 15-18 Hz.
You can lower or increase the tension of the belts by using the screws at the
brackets which holds the belts to the axis.
Replacement
Belts can easily be replaced.
You have to open the cover of the axis, loosen the screws at the brackets (4 in
total), take away the old belt and guide the new belt through the pulley.
V-G 1/1
V. Maintenance BigRep
V-H Leveling
* 2016-04-07
1. Check table mounting
a. Angled ==> Z-Min sensor bottom edge = 10m
b. Straight ==> Z-Min sensor bottom edge = 65mm
2. Home Z
3. Start PRO-Mode by pressing „Down“ for 3 Seconds
4. Look for option „SenS2 and confirm by pressing „Teach“
5. Change to the Komparativ-Mode (N2) with „up“ and „down“ and confirm by
pressing „Teach“
6. Drive the printer to the absolute position (6.5mm)
7. Screw the table up/down until the sensor shows „+4900“ on the posi-
tions x100y100 - x100y980 - x1000y100 - x1000y980
8. Lock nuts of the table and check again
9. Drive the printer to the absolute position (6.5mm)
10. Press „Teach“ at position x100y100
11. Drive printer to 9.9mm/9.8mm at the actual position
a. If error 41 go 0.1 down
12. Press „Teach“ ==> „GooD“ should be displayed
13. Request position with „M114“
14. Get the shown Z Value for the config (leveling-strategy.three-point-leveling.
probe_offsets -150,-70,Z-Value) (should be around 16.5)
15. Activate HOLD-Mode
16. Turn both Extruder Heads to the top position with help of the adjusting
screws (x100y100)
17. Calibrate Extruder
a. if feeler gauge 0.5mm drive to absolute Z-Position 0.5mm
18. Perform Firstlayer_adhession test (Starting high = 0.2mm), Use vernier
caliper!
a. If Extruder is to close the Z-probe Value needs to be decreased
b. If the Extruder is to far away the Z-probe Value needs to be increased
V-H 1/1
V. Maintenance BigRep
V-I Software
* 2016-04-14
How to Update new software
1. Stop a print, or wait for print to stop (naturally)
2. Select ‚Turn off Printer‘ and select ‚Exit UI‘ This will return you to Linux OS
screen
3. Click the bottom left corner (run) and select ‚accessories‘, then ‚LX Terminal‘.
This will give you ‚Terminal (text command line) control of the machine
4. To VIEW the current version, type sudo apt-get update (checks availabili-
ty, password required) and apt-cache policy bigrep-one
You should see info like:
Installed: 0.5.X
Candidate: 0.5.X
5. To update software type in update_one (password required)
6. Turn on and off machine twice!
Change config
1. Open X-Term in Linux
2. Go to sudo leafpad /mnt/boogie/config
3. Enter password
4. Change setting
5. Save config
6. Turn the machine off and on after saving new values
V-I 1/1
VI. Appendix BigRep
VI Appendix
VI-A General Info
* 2016-04-07
Where do I find technical information as a reseller?
›› Technical Manual – will be updated continuous
›› Setup List
›› Onepager freight/setup for clients
›› Reseller Portal at bigrep.com ▷ the reseller portal contains customer FAQs,
technical manuals for resellers, a online platform/forum and includes a
ticketing system
Which materials can I use for my clients?
›› Official User Manual
›› Posterguide
›› Simplify3d.com
›› Customer Portal at bigrep.com ▷ each customer will get a login to a perso-
nal customer portal, incl. guides, FAQ and a ticketing system
VI-A 1/1
VI. Appendix BigRep
VI-B Shipping/requirements/Unpacking
* 2016-04-07
1. Shipping
a. Shipping: Do you like to handle the shipping?
b. Unloading: Do you have a forklift/lifttruck? yes no
(loading-forks at least 71inch/180cm long)
yes no
If not: please let us know as soon as possible, we will provide you a quote
from our freight forwarder and handle the shipping - also door to door if
preferred.
PLEASE MAKE SURE THAT THERE ARE NO DOORS BETWEEN UNLOADING AREA
AND FINAL LOCATION OF THE PRINTER SMALLER THAN 200 CM IN WIDTH AND
210 CM IN HEIGHT!
3. Electricity
a. The printer comes with a 200V - 240V configuration and an european Schuko plug which
can be replaced by a local plug if necessary.
b. Maximum power consumption is 2700 watt, average 1500 watt.
c. You need at least 200 volt and 16 ampere.
4. Delivery Address
VI-B 1/4
Bigrep – Shipping/requirements/Unpacking page 2/2
VI. Appendix BigRep
5. Setup
Moving Box: The box can be moved with a standard hand pallet truck
Moving Printer: The printer comes on wheels and can easily be moved after unpacking
8. Additional Information
VI-B 2/4
VI. Appendix BigRep
Frame Cover
o Correct Colour?
o No: scratches, cracks etc?
o Detent Edge Disc: correct position?
o Washers at both sides?
Dragchain
o Proper wiring within dragchain?
o All strain-relief existing?
o All dragchains roper fixed ?
Bed
o No scratches?
o Polyimide film (orange tape) proper glued, no bubbles?
o Loosen screws at the side of the bed?
Control Unit
o Both identification plates existing?
Spool Holder
o No scratches?
o Correct ?
o Free movement of drivers roller?
Back Wall
o No scratches?
VI-B 3/4
VI. Appendix BigRep
Informationen Seriennummern
informations serial number
Kunde Drucker
customer printer
Adresse Schaltschrank
customer adress control cabinet
Postleitzahl Extruder 1
postal code extruder 1
Auftragsnummer Extruder 2
order number extruder 2
Software Version X-Y Rahmen
softwareversion x-y frame
Mechanik i.o. n.i.o.
mechanics
X
Achsen verfahren Y
moving axis
Z
links
Funktionstest Extruder left
functiontest extruder rechts
right
Elektrik i.o. n.i.o.
electrics
linker Extruder
left extruder
Funktionstest Heizungen rechter Extruder
functiontest heaters right extruder
Druckbett
printbed
Not-Aus
Sicherheitseinrichtung emergency button
safety system Sicherheitsschaltleiste
safety shutdown board
Warranty starts with the date of signature - or differently agreed, please document below
FAT 1 - Abnahme ohne Einschränkung
acceptance without restrictions
FAT 2 - Abnahme mit vereinbarten Nachbesserungen
acceptance agreed rework
BigRep Kunde
manufacturer customer
Date
Signature
VI-B 4/4
VI. Appendix BigRep
Old New
beta_steps_per_mm 53.33 44.44
This results in changed dipswitch positions at the stepper driver of the Y-axis. It is
found in the cabinet to the left. Check the labels.
VI-C 1/9
VI. Appendix BigRep
Old New
temperature_control.bed.hysteresis 1 0.1
VI-C 2/9
VI. Appendix BigRep
CX – Config file
Manuals Gen3
#Version: 1.32
# NOTE Lines must not exceed 132 characters
# Robot module configurations : general handling of movement
G-codes and slicing into moves
default_feed_rate 4000
# Default rate ( mm/minute ) for G1/G2/G3 moves
default_seek_rate 4000
# Default rate ( mm/minute ) for G0 moves
mm_per_arc_segment 0.5
# Arcs are cut into segments ( lines ), this is the length for
# coordinates robots ).
pause_z_move 5
# amount of z move in mm for pause and freeze routines
# see https://github.com/grbl/grbl/blob/master/planner.c#L409
# and https://github.com/grbl/grbl/wiki/Configuring-Grbl-v0.8
# Cartesian axis speed limits Max speed for each axis – NEVER change this value
x_axis_max_speed 100000 without instructions.
# mm/min
y_axis_max_speed 35000
# mm/min
VI-C 1/9
VI. Appendix BigRep
CX – Manuals Gen3
z_axis_max_speed 700
# mm/min
beta_step_pin 1.4
# Pin for beta stepper step signal
beta_dir_pin 1.8 #
Pin for beta stepper direction
beta_en_pin 0.16
# Pin for beta enable
beta_current 1.5
# Y stepper motor current
beta_max_rate 35000.0
# mm/min
gamma_step_pin 1.9
# Pin for gamma stepper step sign
gamma_dir_pin 1.10 #
Pin for gamma stepper direction
gamma_en_pin 0.17
# Pin for gamma enable
gamma_current 1.5
# Z stepper motor current
gamma_max_rate 300.0
# mm/min
extruder.T0.step_pin 1.14 #
Pin for extruder step signal
extruder.T0.dir_pin 1.15 #
Pin for extruder dir signal
extruder.T0.en_pin 0.18 #
Pin for extruder enable signal
VI-C 2/9
VI. Appendix BigRep
CX – Manuals Gen3
extruder.T0.mv_pin 0.4! #
Pin for extruder moving signal, for multi extruder usage
extruder.T0.fan_en_pin 0.0 #
Pin for associated fan to cool the filament
# extruder offset
extruder.T0.x_offset 86.75 Offset (distance) of both extruders/nozzles to each
# x offset from origin in ### mm 80.75 mm distance nozzle + other in X direction. Change if necessary after testing
6mm extruder.t1.offset ### dual extrusion.
extruder.T0.y_offset 6 # Offset (distance) of both extruders/nozzles to each
y offset from origin in mm other in Y direction. Change if necessary after testing
extruder.T0.z_offset 0 # dual extrusion.
z offset from origin in mm
delta_current 1.5 #
First extruder stepper motor current
extruder.T1.step_pin 1.16 #
Pin for extruder step signal
extruder.T1.dir_pin 1.17 #
Pin for extruder dir signal
extruder.T1.en_pin 0.19 #
Pin for extruder enable signal
extruder.T1.mv_pin 0.5! #
Pin for extruder moving signal, for multi extruder usage
extruder.T1.fan_en_pin 0.1 #
Pin for associated fan to cool the filament
extruder.T1.x_offset 6 # x
offset from origin in mm ## if T1 is activated and G1 XO was
run the result is 6mm distance to the endstop ##
extruder.T1.y_offset 6 # y
offset from origin in mm
extruder.T1.z_offset 0 #
z offset from origin in mm
epsilon_current 1.5 #
Second extruder stepper motor current
extruder_lift_enable true
# only active extruder is down, other inactive extruders are
lifted up
extruder_lift_wait 1400
# because off slow movement of the lift, we have to wait to be
sure the nozzle is down, in ms
VI-C 3/9
VI. Appendix BigRep
CX – Manuals Gen3
filament_detector_strategy.binary.enable true
# binary strategy module should be loaded
# the mapping of a filament detector to the appropriate
extruder is 1:1 according the order within this config file
filament_detector.T0.enable true
# set to trueif filament detection should be used
filament_detector.T0.pin
1.25! # pin on the boogieboard used for the
filament detector
filament_detector.T0.strategy
binary # binary enabling means on/off sensor like
endstops, i.e. only filament availability is supervised
# ignored if false.
#laser_module_pin 2.5
# this pin will be PWMed to control the laser. Only P2.0 -
P2.5
temperature_control.T0.sensor pt100 #
see http://smoothieware.org/temperaturecontrol#toc5
temperature_control.T0.pt100_pin 0.24 #
Pin for the thermistor to read
temperature_control.T0.heater_pin 2.0! #
Pin that controls the heater
*
VI-C 4/9
VI. Appendix BigRep
CX – Manuals Gen3
#temperature_control.T0.beta 4066 # or
set the beta value
#
All configuration is ignored if false.
#temperature_control.T0.bang_bang true
temperature_control.T0.p_factor 31.5 #
permanently set the PID values after an auto pid
temperature_control.T0.i_factor 3.978 #
temperature_control.T0.d_factor 62 #
temperature_control.T0.K1_factor 0.95 #
factor used for smoother PID temperature control mechanism
temperature_control.T0.heater_power 100 #
maximum used power from this heater
temperature_control.T0.max_pwm 255 #
max pwm, 64 is a good value if driving a 12v resistor with
24v.
temperature_control.T0.max_temperature 260 #
Max temperature in °C allowed for hotend heater.
temperature_control.T0.min_temperature 10 #
Min temperature in °C, which is recognized from the
temperature sensor.
#temperature_control.T0.readings_per_second 20
#temperature_control.T0.set_m_code 104 #
#temperature_control.T0.set_and_wait_m_code 109 #
#temperature_control.T0.designator T #
temperature_control.T1.sensor pt100 #
see http://smoothieware.org/temperaturecontrol#toc5
temperature_control.T1.pt100_pin 0.26 #
Pin for the thermistor to read
temperature_control.T1.heater_pin 2.1! #
Pin that controls the heater
#temperature_control.T1.beta 4066 # or
set the beta value
#
All configuration is ignored if false.
#temperature_control.T1.bang_bang true
temperature_control.T1.p_factor 31.0 #
permanently set the PID values after an auto pid
temperature_control.T1.i_factor 3.978 #
temperature_control.T1.d_factor 62 #
temperature_control.T1.K1_factor 0.95 #
factor used for smoother PID temperature control mechanism
temperature_control.T1.heater_power 100 #
maximum used power from this heater
temperature_control.T1.max_pwm 255 #
max pwm, 64 is a good value if driving a 12v resistor with
24v.
temperature_control.T1.max_temperature 260 #
Max temperature in °C allowed for hotend heater.
temperature_control.T1.min_temperature 10 #
Min temperature in °C, which is recognized from the
temperature sensor.
#temperature_control.T1.readings_per_second 20
#temperature_control.T1.set_m_code 104 #
#temperature_control.T1.set_and_wait_m_code 109 #
#temperature_control.T1.designator T #
temperature_control.bed.sensor pt100 #
see http://smoothieware.org/temperaturecontrol#toc5
temperature_control.bed.pt100_pin 0.25 #
Pin for the thermistor to read
VI-C 5/9
VI. Appendix BigRep
CX – Manuals Gen3
temperature_control.bed.heater_pin 2.4 #
Pin that controls the heater
#temperature_control.bed.beta 4066 #
or set the beta value
#
All configuration is ignored if false.
#temperature_control.bed.p_factor 13.7 #
permanently set the PID values after an auto pid
#temperature_control.bed.i_factor 0.097 #
#temperature_control.bed.d_factor 24 #
#temperature_control.T0.K1_factor 0.95 #
factor used for smoother PID temperature control mechanism
#temperature_control.bed.max_pwm 255 #
max pwm, 64 is a good value if driving a 12v resistor with
24v.
temperature_control.bed.max_temperature 120 #
Max temperature in °C allowed for heated bed.
temperature_control.bed.min_temperature 0 #
Min temperature in °C, which is recognized from the
temperature sensor.
temperature_control.bed.bang_bang true #
set to true to use bang bang control rather than PID
temperature_control.bed.hysteresis 0.1 #
set to the temperature in degrees C to use as hysteresis
#
when using bang bang
#temperature_control.bed.readings_per_second 20
#temperature_control.bed.set_m_code 140 #
#temperature_control.bed.set_and_wait_m_code 190 #
#temperature_control.bed.designator B #
#switch.misc.enable true
#
#switch.misc.input_on_command M42
#
#switch.misc.input_off_command M43
#
#switch.misc.output_pin 2.4
#
#switch.misc.output_type digital
# just an on or off pin
VI-C 6/9
VI. Appendix BigRep
CX – Manuals Gen3
#switch.spindle.enable false
#
# Endstops
endstops_enable true
# the endstop module is enabled by default and can be disabled
here
#corexy_homing false
# set to true if homing on a hbit or corexy
alpha_min_endstop 1.18v!
# add a ! to invert if endstop is NO connected to ground
alpha_max_endstop 1.19v!
# NOTE set to nc if this is not installed
alpha_homing_direction home_to_min
# or set to home_to_max and set alpha_max
alpha_min 0
# this gets loaded after homing when home_to_min is set
alpha_max 1065
# this gets loaded after homing when home_to_max is set
beta_min_endstop 1.20v!
#
beta_max_endstop 1.21v!
#
beta_homing_direction home_to_min
#
beta_min 0
#
beta_max 1070
#
gamma_min_endstop 1.22v!
#
gamma_max_endstop 1.23v!
#
gamma_homing_direction home_to_min
#
gamma_min 0
#
gamma_max 1000
#
alpha_fast_homing_rate_mm_s 50
# feedrates in mm/second
beta_fast_homing_rate_mm_s 50
# "
gamma_fast_homing_rate_mm_s 4
# "
alpha_slow_homing_rate_mm_s 25
# "
beta_slow_homing_rate_mm_s 25
# "
gamma_slow_homing_rate_mm_s 2
# "
alpha_homing_retract_mm 5
# distance in mm
beta_homing_retract_mm 5
# "
gamma_homing_retract_mm 5
# "
#endstop_debounce_count 100
# uncomment if you get noise on your endstops, default is 100
VI-C 7/9
VI. Appendix BigRep
CX – Manuals Gen3
# optional Z probe
zprobe.enable true #
set to true to enable a zprobe
zprobe.probe_pin 1.28v #
pin probe is attached to if NC remove the !
zprobe.slow_feedrate 2 #
mm/sec probe feed rate
zprobe.return_feedrate 4 #
mm/sec probe return feed rate
#zprobe.debounce_count 100 #
set if noisy
zprobe.fast_feedrate 500 #
move feedrate mm/sec
zprobe.probe_height 30 #
how much above bed to start probe, value must be higher than
the probe z trigger on position
zprobe.max_bed_tilt 3 #
offset of z-min, which will not trigger z min endstop, because
of tilted plane
# Pause button
pause_button_enable true
#
# Panel
panel.enable false
# set to true to enable the panel code
panel.lcd smoothiepanel
# set type of panel
panel.encoder_a_pin 3.25!^
# encoder pin
panel.encoder_b_pin 3.26!^
# encoder pin
VI-C 8/9
VI. Appendix BigRep
CX – Manuals Gen3
#panel.encoder_b_pin 3.26!^
# encoder pin ; GLCD EXP2 Pin 5
#panel.click_button_pin 1.30!^
# click button ; GLCD EXP1 Pin 2
#panel.buzz_pin 1.31
# pin for buzzer ; GLCD EXP1 Pin 1
#panel.button_pause_pin 2.11^
# kill/pause ; GLCD EXP2 Pin 8 either
#panel.back_button_pin 2.11!^
# back button ; GLCD EXP2 Pin 8 or
#panel.menu_offset 0
# some panels will need 1 here
#panel.alpha_jog_feedrate 6000
# x jogging feedrate in mm/min
#panel.beta_jog_feedrate 6000
# y jogging feedrate in mm/min
#panel.gamma_jog_feedrate 200
# z jogging feedrate in mm/min
#panel.hotend_temperature 185
# temp to set hotend when preheat is selected
#panel.bed_temperature 60
# temp to set bed when preheat is selected
custom_menu.power_off.enable true #
custom_menu.power_off.name Power_off #
custom_menu.power_off.command M81 #
return_error_on_unhandled_gcode false
#
# network settings
#network.enable false
# enable the ethernet network services
#network.webserver.enable false
# enable the webserver
#network.telnet.enable false
# enable the telnet server
#network.ip_address auto
# use dhcp to get ip address
# uncomment the 3 below to manually setup ip address
#network.ip_address 192.168.1.3 #
the IP address
#network.ip_mask 255.255.255.0
# the ip mask
#network.ip_gateway 192.168.1.1
# the gateway address
#network.mac_override
xx.xx.xx.xx.xx.xx # override the mac address, only do this if
you have a conflict
VI-C 9/9
VI. Appendix BigRep
Intro
NOTE: This is a quick start guide, especially made for using simplify3d with your BigRep. You will find the most
important settings and descriptions to get started. For in depth knowledge about the software and each single setting,
we recommend to visit www.simplify3d.com/support.
Overview
VI-E 1/7
VI. Appendix BigRep
Most important:
• Avoid support
• Use correct size/measurements
• Place the model directly to the bed
In detail:
• Import Model: click at File / Import Model and
load a new .stl file
• Rotate: click at the model (1.), rotate in X,Y or
Z direction (2.)
• Scale: choose percentage or millimeter, before
uniform scaling recommended (2.)
• Last step: click at Center and Arrange (3.)
after
VI-E 2/7
VI. Appendix BigRep
Most important:
• Choose the correct extruder (T0, T1)
• Choose the correct nozzle diameter you have
installed at the machine (.5 or 1mm)
In detail:
• Extrusion Multiplier = Flowrate, choose 1 as
standard
• Extrusion Width = Single Outline Width, 10-20%
more than nozzle diameter is recommended,
but not a must
• Ooze Control = avoid overflow during z-moves,
standard values are recommended
In detail:
• Top Solid Layers = number of solid layers at
the top of your sample. Choose at least 2.
Increase if you use little infill.
• Bottom Solid Layers = number of solid layers
at the bottom. 3 are recommended and
most often sufficient
• Outline/Perimeter Shells = number of loops
at the “walls”. Choose the correct amount to
avoid gaps or little infill structure.
• Start Points = the “seam” for z-moves.
Choose start point to for example “hide” the
seam in the back
VI-E 3/7
VI. Appendix BigRep
Most important:
• Always choose at least a skirt with one outline
to avoid imperfections within the first line of
your print
In detail:
• Skirt = One outline with offset
• Brim = Skirt with no offset and several lines.
Choose Brim to avoid warping and to ensure
that the print sticks to the bed more solid.
• Raft = Brim with layers also underneath the
print object.
Most important:
• Choose at least 10% infill, more than 30% are
most often not necessary
In detail:
• Internal Fill Pattern = determines the infill
geometries. Recommended geometries are
Grid (fast) and Honeycomb (solid)
• Interior Fill Percentage = determines the interior
solidity
solid (honeycomb)
fast (Grid)
VI-E 4/7
VI. Appendix BigRep
In detail:
• Support Infill Percentage = how solid your
support will be. 20% is most often a sufficient
value.
• Dense Support Layers = interface between
support and model. Should be at least 2.
• Support Pillar Resolution = determines the
resolution of each support pillar. 1.5mm is
recommended for small parts. Up to 5mm for
big prints.
In detail:
• Show in preview = determine the preview mode.
Recommended: Build table, Toolhead, Retractions
& Coloring Feature Type
• Preview By = use the slider next to End, to inspect
layer by layer
• Save Factory File = Click at File-Save Factory File
to save
VI-E 5/7
VI. Appendix BigRep
Advanced
Most important:
• Check automatic support
• Remove/add single structures
In detail:
• Activate = click at Tools/Custimze Support
Structure
• Support Pillar Resolution = determines the
resolution of each support pillar. 1.5mm is
recommended for small parts. Up to 5mm for
big prints.
• Generate Automatic Support = Generates before
supports structure similar to the regular slicing after
• Remove existing supports = remove single
support pillars
To use your customized support structures,
just click at Done and start slicing
Most important:
• You can create as many different processes
(settings) in z-direction or layers as you like to
• Use different extruders (materials or colours)
for different layers within one print
• Especially for different infill settings very useful
In detail:
• Add = create a new process. Settings will be
duplicated
• Layer Modification = click at Advanced within
your process settings. Determine the start- and
stop height of the selected process
• Prepare to Print = Make sure to Select All
processes after you clicked at prepare to print
Process 1 – 15% infill & 0.8mm layer Process 2 – 40% infill & 0.6mm layer
VI-E 6/7
VI. Appendix BigRep
In detail:
• Preparation: Create single processes for
each model
• Select Models = within your process settings
click at Select Models and choose one
model
• Prepare to Print: After you clicked at Prepare
to Print, select Sequential printing: object-by-
object
What to do:
• Option 1 - Add another loop:
Go to Layer settings and increase
Outline/Perimeter Shells
• Option 2 – Increase Extrusion Width:
Go to Extruder settings and increase Extrusion
Width
• Last step: Change settings, slice again, inspect
tool path
VI-E 7/7