The 3D Printer: First Durbie Prusa Mendel

If you can afford to pay, buy from reputable brand to have a better quality of the parts or product. New buyer without electronic background knowledge should get their RepRap printer from local store to have better support.

Romscraj is new and the staff are helpful. They are willing to share some tips and precaution base on their own experience in RepRap. They are keep improve the quality of the parts and product.

Durbie Prusa Mendel

Print Material: PLA and ABS same with other printers?
Only support PLA. Durbie using Replacement AC Adapter (Output: 12V ~ 10A).
For ABS to print, you may need a small fan at the extruder and to increase the heated bed temperature so that the material will stick well on the heated bed, you also need to source or buy a new Replacement AC Adapter (Output: 12V ~ 15A) as recommended by one of their staff.
(They don't support ABS print and they don't sell Replacement AC Adapter (Output: 12V ~ 15A).

Built size: 200 x 200 x 140mm?
(Actual built size: 190 x 190 x 90mm)

The maximum width for the X-axis is 190mm to prevent the hot-end hit or run over the heated bed 4 screws at the side.

X-Axis - (left side)

X-Axis - (right side)

The maximum length for Y-axis is 190mm after the end stop (20x40mm) installed:

End-Stop -Y Position

The maximum height for Z-axis is 90mm.
Can squeeze to 10mm height by lowering the heated bed. Not tested yet..

Built size z-axis (1)

Built size z-axis (2)

Getting Durbie to work

Hardware:
Motherboard: Custom Gen6 to Gen6.d
Firmware: Marlin

Software:
Host Software: kliment/PrintRun (Pronterface)
GCode Conversion: Skeinforge

Documentation:
Built: Durbie Prusa Mendel Reprap 3D Printer
Electronic: Gen6.d
Source files: GitHub

Computer: Windows 7 Pro 64-bit

Solving software issues

Firmware:
Change Baud at 540000 to Baud 115200 seems reduce the

missing character or garbage on Pronterface console
printer keep resets shown on Pronterface console

Host Software:
Upgraded Kliment/PrintRun windows dependencies to support Windows 7 64-bit:
(Solved serial connection error)

Solving built issues

I have went to romscraj.com at Mid View City for support few times =(

02March2012
Problem: Noticed that at the motherboard, the L-connectors for the power cable and the hot-end cable burned or melted. Do not know the stability of Gen6.d board.
Resolution: Waiting an email reply from Romscraj..

Romscraj HotEnd Cable L-connector (right side)

Romscraj HotEnd Cable L-connector (left side)

Romscraj Power Cable L-connector (Top view)

Romscraj Power Cable L-connector(Side view)

Update on 09March2012: A friend bought it for me at Sim Lim Tower, Singapore. (60 cents per pair) as no email respond from Romscraj after a week:

L-connector (Hamilton Sim Lim Tower)

15February2012
Problem: Extruder 4-wire cable to PCB faulty. One of the pin-1(black wire) not crimp properly and cause thermistor report no value at Pronterface software. Tested with multimeter.
Resolution: Exchange new cable.

Romscraj HotEnd 4-wire cable

Problem: Romscraj have not release the Skeinforge profile sample.
Resolution: We have to Do-It-Yourself (DIY) to get the Skeinforge settings works or wait for their release.
Update on 25Febraury2012: Romscraj contacted me that they have released the skeinforge41 profiles for Durbie

14February2012
Problem: X and Y Stepper motor generate high pitch noise when move it a step with Pronterface software. (Stepper motor by Minebea Motor Manufacturing Corp):

X - Y Stepper using 17PM-K140-04V Minebea Motor is a two-phase hybrid stepper motor (Low Noise, Low Vibration), the parameters are: the step-angle is 1.8°, Length 42, 0.38nm, 1.0-1.4A
Z - E Stepper using 42BYG250-33 is a two-phase hybrid stepper motor, the parameters are: the step-angle is 1.8°, 0.21nm，0.4A

Resolution: romscraj confirmed that it is normal. It is also happen on their printers. X-Y using same stepper and Z-E using different stepper

Problem: romscraj provide different Z and E stepper motor and it have not files at the motor shaft
Resolution: I leave it as is for the time being and will monitor for the skip steps.

Romscraj X-Y stepper(left) and Z-E stepper(right)

Filing motor sharf

Problem: X,Y and Z axis moveable from Pronterface but the hot end thermistor showed no value at Pronterface. Error message 'Extruder switched off. MINTEMP triggered'. It seems like MINTEMP for thermistor short/failure protection not working or thermistor failed.
Resolution: romscraj have reload the marlin firmware and tested that Pronterface heater temperature. (by tapped it directly from the PCB heater connector pin). They have also gave me a new thermistor, 100mm heat shrink, 100mm hot temperature cable x 2 to patch the extruder up.

Error Message: Extruder switched off. MINTEMP triggered

Romscraj tiny 100K thermistor

12February2012
Problem: Stepper motor pulley defect. Noticed that the hole on the motor pulley for tighten the stepper motor shaft together not drilled
Resolution: Exchange new motor pulley

Romscraj motor pulley hole for tighten not drilled

Problem: Different sizes M4 wing nut cause 53-tooth-drivegear cannot fit properly with extruder's stepper motor 1x 9-toothdrive gear
Resolution: Exchange correct size of M4 wing nut (Image right side)

Romscraj M4 Wing Nut with different Shape (Side view)

Romscraj M4 Wing Nut with different Shape (Top view)

07February2012
Problem: RP Parts to tight to assemble with non-printed parts like threaded rods. It is not smooth.
Resolution: Use needle files on RP Parts
Note: May need to print 0.1-0.2mm bigger hole diameter to prevent files the RP Parts.

Problem: Motherboard pins for Hot Bed and Fan bend 90degree cause by improper packing. Motherboard does not come with a box
Resolution: Bend the pin back to normal direction. PCB should keep in proper box before shipped out.

Problem:Power cable(35cm) and the power source cable(90cm) is too short to properly put the printer on the table. Either one should have at least 150cm length for better movement on the standard table.
Resolution: Get my own computer power cable(150cm).

Romscraj Power Source

Problem: Documentation. No electronic wiring diagram for end-stop and heated bed.
Resolution: Went to romscraj office to have better look at the printer wiring and electronic mount position.
Updated on 07February2012: romscraj uploaded latest documents to Github.com/romscraj for gen6.d and Assembly Instructions

Endstops for X, Y, Z: