German RepRap X400CE User manual

X400CE 3D Printer Manual
German RepRap GmbH
https://www.germanreprap.com
English versions are available at https://wiki.germanreprap.com/en/

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Inhaltsverzeichnis
X400CE 3D Printer Manual ............................................................................................................. 2
Technical data ................................................................................................................................. 3
System requirements ...................................................................................................................... 3
MAC OS X ................................................................................................................................... 4
Windows ..................................................................................................................................... 4
LINUX .......................................................................................................................................... 4
Important notes ............................................................................................................................... 4
Return / Original wrapping .............................................................................................................. 5
Operation ........................................................................................................................................ 5
Other matters ................................................................................................................................. 5
Toxic fumes ..................................................................................................................................... 5
Safety cut-off .................................................................................................................................. 5
Maintenance ................................................................................................................................... 5
Safety notes ..................................................................................................................................... 6
Power supply ................................................................................................................................... 7
Cleaning .......................................................................................................................................... 7
Playing children .............................................................................................................................. 7
Mains voltage .................................................................................................................................. 7
Humidity, solar radiation, heat, open fire ....................................................................................... 7
Ventilation ....................................................................................................................................... 8
Long absence, thunderstorms, accessibility of the power plug ....................................................... 8
Installation site ............................................................................................................................... 8
Disposal .......................................................................................................................................... 8
Assembly ........................................................................................................................................... 9
Tools ............................................................................................................................................. 10
Optional tools ........................................................................................................................... 10
Assembly overview ....................................................................................................................... 11
Basic information .......................................................................................................................... 25
The Frame version 2013 with Profile connectors, round, plug connection .................................... 26
Preparation of the rear frame rod ............................................................................................. 26
Preparation of the front frame rod ........................................................................................... 28
Assembly frame ........................................................................................................................ 29
Version 2014 of the frame with slide-in profile connectors ........................................................... 31
Preparation rear frame ............................................................................................................. 31
Preparation front frame ............................................................................................................ 33
Frame assembly ....................................................................................................................... 34
Assembly guiding rods ............................................................................................................. 36
Z-axis ............................................................................................................................................ 37
Bearing holders bottom ............................................................................................................ 37
Preparation Z-axis motor .......................................................................................................... 39
Assembly Z-axis motor ............................................................................................................. 42
Z-axis-trapezoidal threaded spindle ......................................................................................... 43
Z-axis timing belt ..................................................................................................................... 45
Assembly Acrylic glass distance plate ...................................................................................... 46
Energy chain guide ................................................................................................................... 47
Assembly of the guiding rods ................................................................................................... 48
Assembly Printing Bed holder ................................................................................................... 51
Alignment printing bed holder .................................................................................................. 53
The Y-axis ................................................................................................................................. 55
Y-axis opto end stop ............................................................................................................ 55
Stepper motor Y-axis ........................................................................................................... 56
Idler pulley ........................................................................................................................... 58
The X and Y axis, version with SLS parts ...................................................................................... 61

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The X-axis ................................................................................................................................. 61
Preparation X-glider ............................................................................................................. 62
Assembly cylinder fitting screw ........................................................................................... 63
Opto end stop X ................................................................................................................... 64
Opto flag Y ........................................................................................................................... 65
Assembly X-glider ................................................................................................................ 67
Guiding rods holder .............................................................................................................. 67
Y-axis carriage ..................................................................................................................... 68
X-axis carriage ..................................................................................................................... 69
Y-axis ........................................................................................................................................ 72
Y-axis end stop .................................................................................................................... 72
Stepper motors Y-axis .......................................................................................................... 73
Idler pulley ........................................................................................................................... 74
Installing the Y-axis carriage ................................................................................................ 76
Timing belt Y-axis ................................................................................................................ 78
Timing belt X-axis ................................................................................................................ 80
The X-und Y axis version with milled aluminium parts .................................................................. 82
The X-axis ................................................................................................................................. 82
Preparation Y-carriage ......................................................................................................... 82
Opto end stop X ................................................................................................................... 84
Opto-flag Y ........................................................................................................................... 86
X-axis carriage ..................................................................................................................... 88
Y-axis ........................................................................................................................................ 91
X- and Y-axis carriage .......................................................................................................... 91
Timing belt Y-axis ................................................................................................................ 93
Timing belt X-axis ................................................................................................................ 96
The extruder ................................................................................................................................. 98
Der DD1-Extruder ..................................................................................................................... 98
Assembly of the counter bearing ......................................................................................... 98
Mounting of the counter bearing .......................................................................................... 99
Filament screw ................................................................................................................... 100
Construction of the extruder base ..................................................................................... 101
Extruder fan ....................................................................................................................... 102
Assembly of the compression spring ................................................................................. 103
DD2-Extruder ......................................................................................................................... 106
Extruder hinge ................................................................................................................... 106
Mounting extruder hinge .................................................................................................... 107
Filament screw ................................................................................................................... 109
Extruder block .................................................................................................................... 110
Extruder-fan ....................................................................................................................... 111
Mounting spring ................................................................................................................. 113
Hot-End .................................................................................................................................. 114
Thermal barrier & Nozzles ................................................................................................. 114
Hot-End Assembly .............................................................................................................. 116
Assembly Extruder with SLS-Parts .......................................................................................... 121
Installation extruder with milled aluminium parts .................................................................. 123
Electronics .................................................................................................................................. 126
Z-axis end stop ....................................................................................................................... 126
Z-axis end stop assembly ....................................................................................................... 127
Energy chain Y-axis ................................................................................................................ 129
Electronics fan grill ................................................................................................................. 130
Electronics fan ........................................................................................................................ 131
Preparing of the case connection (heated bed) ...................................................................... 133
Case connection (heated bed) ................................................................................................ 134
Base plate .............................................................................................................................. 135
ATX socket .............................................................................................................................. 136
Arduino board ......................................................................................................................... 138
Preparation of the Pololus ...................................................................................................... 139
Assembly of the cooling fins ................................................................................................... 140
Fastening of the Pololus ......................................................................................................... 141
Fastening of the RAMPS .......................................................................................................... 142
Printing bed ................................................................................................................................ 143
The heated printing bed .............................................................................................................. 145
Isolation connection cable (Heated bed) ................................................................................ 145

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Sticking on the heating pad (Heated bed) .............................................................................. 145
Heated bed thermistor (Heated bed) ..................................................................................... 146
Insulation (Heated bed) .......................................................................................................... 148
Assembly of the heated bed (heated bed) ............................................................................. 149
Printing bed energy chain (Heated bed) ................................................................................. 151
Printing bed cable (Heated bed) ............................................................................................. 154
Wiring ......................................................................................................................................... 155
Connection of the RAMPS ....................................................................................................... 155
Power connection control electronics (heated bed) ................................................................ 157
Connection control electronics (heated bed) .......................................................................... 158
Connection heated bed (heated bed) ..................................................................................... 159
Heated bed control electronics (Heated bed) ......................................................................... 161
LCD/MSD PCB panel (LCD/MSD) .............................................................................................. 162
Extruder energy chain and cable loom ................................................................................... 164
Attachment fabric tubing ........................................................................................................ 168
Frame Cablemount ................................................................................................................. 168
Installation spacer profiles ..................................................................................................... 169
Cable loom extruder ............................................................................................................... 170
Cable loom X-/Y-axis ............................................................................................................... 176
Cable loom Y-/Z-axis ............................................................................................................... 178
Review wiring (firmware 2.x) .................................................................................................. 180
Review wiring (firmware 1.x) .................................................................................................. 181
Assembly machine foot .......................................................................................................... 182
Grounding of the housing ....................................................................................................... 183
ATX-power supply unit ............................................................................................................ 184
Preparation acrylic glass frontside ......................................................................................... 187
LCD-Controller (LCD-Controller) .............................................................................................. 188
Preparation X400 Mobile-Storage-Device (X400 Mobile-Storage-Device) ............................... 188
Assembly X400 Mobile-Storage-Device (X400 Mobile-Storage-Device) .................................. 189
Assembly acrylic glass front part ............................................................................................ 190
Wiring LCD-Controller/X400 Mobile-Storage-Device (LCD-Controller / X400 ........................... 191
Mobile-Storage-Device)
Case ............................................................................................................................................ 193
Lid of the electronics box ....................................................................................................... 193
Cable cover ............................................................................................................................ 194
Side parts ............................................................................................................................... 194
Distance plate ........................................................................................................................ 195
Finish of the Frame ................................................................................................................. 196
Acrylic Case ................................................................................................................................ 196
Base cabinet ............................................................................................................................... 199
Commissioning ............................................................................................................................. 201
Firmware ..................................................................................................................................... 202
Repetier-Host .............................................................................................................................. 205
Slic3r ........................................................................................................................................... 208
Mobile-Storage-Device ................................................................................................................ 209
Windows ..................................................................................................................................... 209
Mac OS X ..................................................................................................................................... 210
Calibration .................................................................................................................................... 212
Printer control ............................................................................................................................. 218
GCode generation ....................................................................................................................... 219
Slic3r ...................................................................................................................................... 220
Repetier-Host ......................................................................................................................... 222
Troubleshooting .......................................................................................................................... 223
The motors cannot be controlled .............................................................................................. 224
The motors rotate in one direction only .................................................................................. 225
The printer breaks off printing and stops responding .......................................................... 226
Contrast wrong on the LCD-Controller .................................................................................... 227

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The printer cannot be connected to the host PC ................................................................... 228
No commands are transmitted to the printer ........................................................................ 229
Too little material is printed ..................................................................................................... 230
Glue on of the PET-foil bubble-free .......................................................................................... 231
The Y-axis cannot be moved and only produces loud noises ............................................... 232
Extruder can not reach the set temperatur ............................................................................ 233
Printing interruption with Windows ............................................................................................. 234
Support ......................................................................................................................................... 236
Documentation ........................................................................................................................... 237
Telephone ................................................................................................................................... 237
Support tickets / E-mail ............................................................................................................... 237
Forum (Community) .................................................................................................................... 237
Legal disclaimer ........................................................................................................................... 238
Software-Changes / Use of applications ...................................................................................... 239
Contact ....................................................................................................................................... 239

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X400CE 3D Printer Manual
X400 3D-Drucker
The X400 3D printer is a large-capacity rapid prototyper. Its main advantage is the
considerably larger printing space of about 47,5 liter. On top of that, it is possible to
extend and modify it.
This manual is divided into several sections. Starting with the assembly, then the installation of the
software and firmware and on to commissioning and troubleshooting.
Technical data
Floor space (L/W/H) about 650 x 650 x 700 mm, without base cabinet
●
Weight about 35kg, without base cabinet
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Print area (X/Y/Z) up to 390mm x 400mm x 330mm, about 56 liter
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Layer thickness min. 0.1mm, <0.1mm experimental
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Reproduction accuracy +/- 0.01mm
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Tolerance +/- 0.01mm, Shrinkage factor depending on the material
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Speed max. 15mm3 / second, depending on the printing and the material
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Extruder DD-Extruder 1.75mm / 3mm Material, Nozzle: optionally 0.3 0.4 0.5 0.75 1.0
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Max. operating temperature 280°C
●
Operating voltage 110/240V AC, ~ 600 Watt (incl. heated bed)
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Material ABS,PLA,PS,PP,PE,HDPE,LDPE,Wood, inter alia 1.75mm/3mm
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System requirements
MAC OS X
OS X 10.5 or higher
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Windows
Windows XP or higher
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.NET framework 4.0 or higher
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OpenGL 1.5 or higher
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LINUX
OpenGL 1.5 or higher
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ideally Ubuntu/Debian
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Important notes
Return / Original wrapping
Please retain this documentation and the original package of this printer in case you need to ship it
for repairs or to a new address. 3D printers are inherently sensitive to bumping or knocking and are
best protected in their original box. Returns that are not properly packaged cannot be repaired under
warranty.
Operation
Do not cut the power while the printer is active. This can lead to the loss of data as well as damage
some electronic components.
Other matters
All information in this guide is current at the time of printing. We reserve the right to amend the
hardware, software or the documentation without prior notice. The latest information will always be
available at http://www.germanreprap.com.
Toxic fumes
Depending on the plastic being used there is a danger of toxic fumes developing if the printer is
running too hot for that filament. Always make sure to set the correct temperature for the plastic used.
The maximum temperature is generally printed on the filament spool and can also be looked up on
our website. (http://www.germanreprap.com).
Safety cut-off
The device has a thermal protection mechanism built-in. If the temperature exceeds the safe working
limit the printer turn itself off after issuing a warning message.

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Maintenance
Every 12 months the printer has to be serviced by trained personnel. This includes checking the
safety devices as well as all mechanical components. German RepRap offers this as a service. Please
contact us via [email protected] for more details.
Work on a mains power supply should only be carried out by trained specialists. It is essential to note
the safety regulations. Property or personal damage may be caused by improper installation, which
the installer bears liability for.
Proper handling of the chemicals necessary for maintenance and care is obligatory, as well as
complying with the regulations and operation notes regarding the chemicals. Directions of the
manufacturer must be followed at all times and appropriate protective clothing has to be worn.
Property or personal damage may be caused by improper use of the chemicals, which the operator
alone bears liability for.
The 400x400mm corrugated card board, wich is part of the X400
heated bed, is not part of the wrapping, but rather it is a
important part for the build-up of the heated bed.

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Safety notes
Power supply
Always ensure that the power lead has not been damaged. Disconnect the device immediately if the
power lead shows any sign of damage. Have the power supply inspected by an authorised electrician.
Only use the power supply that came with the printer. An electric shock from a faulty power lead can
be fatal!
Only use the power supply if your mains voltage is 100-110V or 220-240V AC. Only use the correct
power lead for your mains socket.
Cleaning
Pull the power plug before cleaning the device. Use a dry cloth and only clean the surface.
Handling the chemicals necessary for maintenance and servicing has to take place properly and
under adherence to of for this valid regulations and application notes to the chemicals. To the
specifications of the manufacturers absolutely for this is to be responded, it is appropriate protective
clothing to be carried, and the dosage regulations are to be kept exactly.Special and personal injury
can be caused by inappropriate handling chemicals, for which alone the operator is responsible.
Playing children
Touching the internal parts of the power supply can cause an
electric shock!
Mains voltage
Only operate the device with the indicated supply voltage (visible on the backside of the device or on
the external power supply) The device must not be connected to the mains until all connections were
double checked.
There is a fire hazard if the mains voltage is too high!

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Humidity, solar radiation, heat, open fire
Protect the device from extreme humidity, dripping and splash water (do not place any liquid-filled
containers such as beverages on it). Do not place the device near a heater, do not expose it to
extended direct sunlight and do not operate it in damp rooms. Only use the device in a moderate, not
a tropical climate. Do not put any open flames such as candles on the device!
Ventilation
The heat arising in the device is sufficiently discharged. Nevertheless do not install the device in a
closet or in a shelf with insufficient ventilation. Never cover the ventilation slots of the device, if there
are any.
Do not place any object on the device. To allow heat to dissipate, please allow at least 30cm above,
20cm to each side and 30cm behind the device unobstructed.
The device only complies the declaration of conformity if the transparent case is assembled and the
door closed while operating.
Long absence, thunderstorms, accessibility of the power
plug
To completely disconnect the device from mains power just pull the power plug out of the mains
socket. Make sure this socket is accessible. In case of longer absence and possible thunderstorms,
switch off the device with the power switch and then disconnect it from the mains. This also applies
for USB appliances connected to the device.
Installation site
Every electronic device develops heat. The heating of the device is within the permitted range though.
Sensitive surfaces may discolor over time due to heat exposure. Moreover, the rubber feet of the
device may cause color changes on furniture surfaces. If applicable, please place the device on a solid,
appropriate and plane base!
Please mind the practicability when choosing the installation site (sufficient working height).

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Disposal
Electronic equipment may not be disposed in the domestic waste - in accordance with Directive
2002/96/EG of the European Parliament and the Council of 27th of January 2003 about electric and
electronic equipment it has to be professionally disposed. At the end of its use please dispose this
device at one of the public collection point intended for this.

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Assembly
The manual refers to the X400 3D printer by German RepRap GmbH. The necessary components are
included in the complete kit.
Tools
A decent tool kit as well as a few consumables are necessary for the assembly of the X400 3D printer.
Allen key
Allen key set (preferably with ball ends)
●
Spanners
5.5 mm
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7 mm
●
10 mm
●
13 mm (for the spools stand)
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19 mm (for Hot End union nut)
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Measurement devices
Folder rule or tape measure
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Vernier caliper
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Water level
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Other tools
Circlip pliers
●
long nosed pliers
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Soldering iron
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Screwdriver (different sizes)
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Side cutter
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Drill bits
3 mm
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4 mm
●
6 mm
●
12 mm
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Optional tools

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These tools can be used to simplify some steps. The assembly, however, is possible without
them.
Cable stripper (for the wiring)
●
Cordless hand drill with hex bit set
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Sharp knife
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Thread locker (for example Loctite?, medium tight)
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Set of “Helping Hands” if need be with magnifier (for soldering)
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Bench vise with at least 65mm range
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Consumables
Tin-solder
●
Assembly overview
This overview depicts the parts used in the different steps of the assembly.
For all aluminum profiles, a through hole is marked with a red arrow.
Aluminum profile type “horizontal A”

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Aluminum profile type “horizontal B”
Aluminum profile type “horizontal C”
Aluminum profile type “horizontal Y/A”

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Aluminum profile type “horizontal Y/B”
Aluminum profile type “vertical”
The vertical aluminum profiles are longer (70 cm) than the horizontal aluminium profiles (~59cm).
Aluminum tape

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The aluminium tape is used to hide the cables inside the aluminum profiles.
©Arduino MEGA 2560
Base plate
Carriage Cablemount

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Carriage Clamp Belt
Carriage Clamp LM12UU
Carriage Fanmount