Upcoming Jetty Firmware V33 Release

The firmware referenced in this manual can be found on Thingiverse: Thing 15380
and Thing 17855

Note: This is not an official Makerbot firmware release

Introduction

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This manual details the functionality of V3.3 of a replacement motherboard firmware designed to provide much needed features for the Gen 4 LCD Interface. This firmware allows complete standalone operation for the ThingOMatic, Cupcake, Reprap and other 3D printers. Additionally it can be used to provide acceleration on Gen 4 and Gen 3 electronics.

These videos were created with an earlier version of Jetty Firmware…

A video highlighting some of the new features: [http://www.youtube.com/watch?v=ONPvZaEAoBQ]

An older video demonstrating acceleration can be found here:
[http://www.youtube.com/watch?v=AY6_h80hKOI]

Documentation for Jetty firmware can be found here:

Requirements

Installation & Setup

For detailed directions on installing and setting up the Jetty Firmware, please refer to the Jetty Firmware Setup Guide.

Features

  • Acceleration — print faster!
  • Extruder (change filament)
  • Preheat
  • Continuous jog on hold button
  • Lifetime filament counter
  • Jog "User View" (X,Y directions orientated to user)
  • Build: "Time Left", "Elapsed", "Z Position", "Percent Complete", "Filament Usage"
  • Pause during build
  • Auto Pause @ Z Position
  • Multi colored printing with single extruder
  • Page Up / Down in menus / file lists
  • Print Another
  • Override GCode temperature
  • Supports 16x4, 20x4 and 24x4 LCD displays
  • Automated Build Platform (ABP)
    • Multiple copies
    • Copy n of N indicator during Build
    • Advance belt button
    • Profiles (saves recalibrating when swapping platforms)
  • Profiles (swapping plastics)
  • Calibration
  • Home Offsets
  • Mood Light Support: [http://www.thingiverse.com/thing:15347]
  • Buzzer Support: [http://www.thingiverse.com/thing:16170]
  • Homing
  • Steppers Enable/Disable
  • Safety Cutout support (prints stop when triggered)
  • End Stop Testing
  • Long filenames in Build menu. (up to 31 chars)
  • Extruder fan control
  • Fix for corrupted LCD when USB connected: [http://www.thingiverse.com/thing:16181]
  • Motherboard / Extruder firmware versions
  • Many other improvements not listed here

Related Things

These are mods you can build for your bot that are supported by the new firmware:

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Buzzer

Your bot can now buzz to signal: Print finished, Print Paused and Safety Cutout Triggered: [http://www.thingiverse.com/thing:16170]

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Mood Light

Pimp your bot! Controllable RGB Mood Lighting for your ToM: [http://www.thingiverse.com/thing:15347]

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LCD Fix

Fix for corrupted LCD when powered up whilst USB connected: [http://www.thingiverse.com/thing:16181]

Multi colored printing (Single Extruder)

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This firmware easily allows you to do multiple colored prints with a single extruder (without having to split your models into parts) using the new "Pause @ ZPos" feature.

The buttons shown here are designed to replace the buttons on your Gen 4 Interface and they can be found here: [http://www.thingiverse.com/thing:15941]

Here is a step by step guide showing you how to print in multiple colors.

To print in 2 colors, you need to know 3 things:

  • The Z Position of your first layer
  • The layer height
  • The Z position within the model you need to change color
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Step 1: First we need to determine the Z Position of the first layer in mm's. To do this, you start printing and wait for the first layer to start printing. Take a note of "ZPos" on the display. In this example it's 0.45mm.

If your model is building fast, then you can use the "OK" screen to hold on the ZPos screen, and the "Z+" key to advance through the various build screens.

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Step 2: We enter the Pause@ZPos value, i.e. the Z Axis Position where the print will automatically stop.

In this particular example, we need to stop at a Z position of 0.9mm within the model (this is at the start of layer 4, based on a 0.3mm layer height).

So we add 0.9 to the first layer height (0.45mm) = 1.35mm, and this is the value we enter into Pause@ZPos.

Hit "Cancel" to pull up the build menu, and choose "Pause at ZPos", using the Y+ / Y- keys and hitting "OK" to select.

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Step 3: We enter the Z Position determined above (1.35mm). Use the Y+ / Y- keys to change the number by a small amount. Use the Z+ / Z- keys to change the number by a large amount. When completed, select "OK" to save your entry.

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A waiting "Pause @ ZPos" is indicated by an asterisk to the lower righthand side of the display, as can be seen here.

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Step 4 When your print reaches the pause Z Position, your build will pause and the print head moves away from the build surface.

Use the X+ / X- / Y+ / Y- / Z+ / Z- keys to move the nozzle further away from the build so that you have some room to extrude some filament.

Note: Be careful not to hit an end stop or hit a physical stop, otherwise when you resume, the firmware will not know where the toolhead is in 3D space, and you will end up destroying your print.

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Step 5 Use the Fwd (OK key) and Rev (Zero Key) to change your filament to a different color. Hold the key down to continue extruding.

Extrude enough filament to completely change the color.

Pull the filament bundle when complete.

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Stage 6 Use the "Cancel" key to exit the pause menu. This will resume printing.

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You can see in this image that the second color is beginning to print on top of the first.

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The final product.

Menus

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When buttons are referred to in this document, please refer to this map of button locations.

The list of menu items can be navigated by using the X+ / X- keys to move up/down one item at a time, and Z+ / Z- to move up/down four items at a time.

This list wraps around to the beginning or end, so the fastest way to get to the menu you want, may be in the opposite direction.

The "Cancel" button is used to exit menus.

Monitor

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The monitor menu displays the machine name (top left), and the temperatures for the tool and platform. The number on the left displays the current temperature, and the number on the right displays the "Set Point", i.e. the temperature target.

A "Set Point" of zero means that a heater is off.

The monitor menu is typically used when printing from Computer, and / or you wish to see the current temperatures of your hot surfaces.

If you see "XXX" in any of these fields, then the temperature couldn't be obtained from the extruder controller. This likely means that your motherboard and extruder are not communicating.

If you see an incorrect value (i.e. 1024, 255 or 0), this indicates you have bad connection somewhere or a faulty component.

A temperature on the extruder that reads intermittently and lower than it should be, indicates a short between the thermocouple and heater block (often caused by the Kapton tape being pierced by the thermocouple).

Build from SD

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The "Build from SD" menu enables the user to build a .s3g (a compiled GCode file) from an SD Memory Card.

The first thing the user sees when entering this menu is a list of files. You can navigate this list by using the Y+ / Y- keys to move 1 file at a time, and the Z+ / Z- keys to move 4 file (or a screen) at a time.

Filenames that are longer than the screen size will scroll when that file is selected.

To select a file for printing, use the "OK" key.

Note that filenames are limited to a maximum of 31 characters in the firmware. Files that are longer than 31 characters may list partially, but will not be printable.

NOTE: When building, the build screen rotates through various information, Time Left, Completed %, Elapsed Time etc. To pause this rotation, hold down the "OK" key. To advance this rotation, use the "Z+" key.

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After selecting a file to print, the user is presented with an "Estimating" screen.

The estimating process calculates how long it will take to print your file by analyzing the file, and provides two additional screens "Duration" and "Time Left", which indicate the length of the print and the time left till your print is finished. The estimate phase works equally well with rafts and without rafts.

The time taken to estimate is dependent on the size of the file, so if you don't see this screen, it means your file was small and it has estimated the print time already.

During the estimation phase, you will see a percentage counter which indicates how much of the estimate phase has been completed, and "Duration" which indicates how many minutes the estimate phase has calculated the build will take so far.

The CPU on your Motherboard is an 8 bit, 16MHz processor and is very slow by today's modern standards, therefore it can take some time to run the estimation phase for larger files. Typically this is about 1-3% of the total time of the print, for larger prints.

Most of the time, the user will find this additional calculation is worth it to get an accurate build time. However, if you hit the "OK" key during the estimation, you can skip it, in which case "Percent Complete" will be less accurate, and the Duration / Time Left screen will not be shown during the build.

Another thing you can do is put the estimation time to good use, by setting "Preheat During Estimate Phase" to enabled. When you do this, your build platform and extruder will be heated to the settings entered in Preheat when estimation starts. You can do this in the Build Settings.

When this is enabled, for most medium sized to large prints, the time taken to preheat is longer than the time taken to estimate, so the estimation has a zero time cost.

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The "Duration" menu is displayed when the estimation has completed, but the build platform and extruder are still waiting to reach temperature. The screen indicates the duration of the build once the target temperatures have been reached.

The current temperatures are displayed on the left, and the target temperatures on the right.

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"Completed" indicates how much has completed of the build. If you have skipped estimation, the value will be a little less accurate than if you've allowed the estimate phase to complete.

The current temperatures are displayed on the left, and the target temperatures on the right.

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"Elapsed" indicates how much time has elapsed since you started printing. This counter stops when your print is complete. If you are printing multiple copies with an ABP, or you choose "Print Another", then Elapsed will include the time between the prints too.

The current temperatures are displayed on the left, and the target temperatures on the right.

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"Time Left" indicates the remaining print time. This screen is only displayed if you haven't "skipped" the estimation phase.

The current temperatures are displayed on the left, and the target temperatures on the right.

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"ZPos" indicates the Z Position. This is the position of the Z Axis. Once a build starts, Z = 0 represents the location at the build surface.

Due to your gcode and raft settings, the height of the first real layer of your build will rarely correspond to 0.

The current temperatures are displayed on the left, and the target temperatures on the right.

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"Filament" indicates the amount of filament used in the build so far. This is the amount of filament fed into the extruder, not the amount of noodle extruded.

When the build has finished or is cancelled, this filament amount is added to the total in the filament counter.

The current temperatures are displayed on the left, and the target temperatures on the right.

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"Acc" indicates acceleration statistic and consists of 3 numbers in mm/sec.

The first number is the minimum speed, the second number is the average speed, and the last is the maximumSpeed.

These values are calculated with the contents in the command pipeline buffer, which contains the next 16 line segments in the print.

The current temperatures are displayed on the left, and the target temperatures on the right.

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At any point during the build process, the "Cancel" button can be pressed to access the build menu. The options presented in the menu depend on which phase the build process is in. Use the Y+ / Y- to navigate the menu and the "OK" button to select a menu item. The "Cancel" key can be used to return to the build.

Possible menu items:

  • Abort Print - Stops printing and resets the motherboard
  • Pause - Pauses the print and moves the head away from the build
  • Pause at ZPos - Schedules a pause for when a Z Axis Position is reached
  • Print Another - Prints another copy (see below)
  • Continue Build - Returns to the build screen, same as using the "Cancel" key

Choosing the build menu during the build doesn't interrupt the build progress, but selecting an item within this menu may interrupt the build progress.

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When a pause is entered, either by selecting "Pause" or when the Pause at ZPos has been reached, the Pause screen is presented.

The number shown in brackets after "Paused" indicates the Z Position at which the print was paused.

When a pause is entered, the following things occur to prevent a blob of
filament occurring on the build and to prevent the nozzle melting part of the build:

  • Filament retracted by 1mm
  • The Y Axis is moved by 4mm
  • The Z Axis is moved up by 2mm

It's important that you have enough room for these movements to happen without hitting a stop, if you don't, you shouldn't use Pause.

It is possible that you will still get a fine "hair" of filament on your build, this is easily removed by pulling when your build is complete.

You can use the Y+ / Y- / X- / X+ / Z+ / Z- keys to jog the X/Y/Z axis by holding down the keys.

Because your firmware needs to keep track of the X/Y/Z positions for continuing the build, do not allow an axis to hit an end stop or reach a physical end whilst jogging, otherwise the tracking will be lost and so will your print.

The "OK" key is used to eject filament, and the "Zero" key is used to retract filament. These can be used to change filament colors mid print. The speed at which the extruder is run, is controlled by the Extruder mm/s in the Extruder menu. Typically you would use the jog keys to move the build well away from the nozzle before changing your filament.

If you are pausing, and change your mind, you will need to eject >1mm of filament before resuming to fill the nozzle.

To resume a print after pausing, use the "Cancel" key.

WARNING: When paused, your extruder and build platform will remain at temperature, so you do not want to leave your printer unattended when pausing.

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The "Print Another" menu item is available when a build has completely finished (this includes any homing commands). It will print another copy of your item.

This menu item is also available after printing a number of copies on your Automated Build Platform.

Jog

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Jog allows you to move the X, Y and Z axis around, using the X-, X+, Y-, Y+, Z- and Z+ keys.

There are 3 jog modes ~.1mm, ~1mm and Cont.., which can be selected by the "OK" key (or mode). This "mode" is remembered for the next time you visit the Jog menu.

  • ~.1mm moves in increments of approximately .1mm for each button press
  • ~1mm moves in increments of approximately 1mm for each button press
  • Cont.. moves continuously whilst the button is being held down

The limits of a jog are determined by the end stops, so if you have no end stop in a particular direction, be careful.

If your jog is not moving by the correct amount, please checkout the section on "Axis Steps:mm"

.1mm and 1mm moves are approximate because the "Axis Steps:mm" is often not a whole number. So for example, on a ToM, the X/Y moves are approximate and the Z move is accurate (because the Z Axis is 200 steps per mm)

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The X-, X+, Y-, Y+, Z-, Z+ buttons can be arranged in two different orientations by pressing the "Zero" button (or V):

  • Model View - Orientation of the model (same as the Control Panel in ReplicationG and reversed with respect to the user)
  • User View - The buttons match the direction of the button pressed.

This setting is remembered.

Preheat

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The Preheat menu is used to preheat the extruder and platform. Target temperatures for these can also be set here. To heat the extruder for example, select "Heat Tool0" using the X+ / X- keys and select the "OK"
key, the menu item will then change from "Heat Tool0" to "Cool Tool0". To stop the heating, you can then select the "OK" key on "Cool Tool0".

After selecting heating, you can leave the menu and do other things, the heating will remain on until you either start building something, switch it off from ReplicatorG or reset your motherboard.

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To set the target temperature for preheating, choose the "Set ? Temp" menu item and use the Y+ / Y- to change in 1 degree increments or Z+ / Z- to change in 5 degree increments. Use "OK" to set the temperature.

Note: The temperature specified in the gcode file will always override the preheat temperature at build time, unless "Override Gcode Temperature" is enabled in Build Settings

Extrude

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Use the Extrude menu to change or extrude filament. Normally you will want to preheat the toolhead using the Preheat Menu before attempting to extrude.

The "OK" key selects the duration of the extrude. Z+ extrudes filament, Z- reverses the filament. Press the "Zero" key to stop a previously requested forward or reverse.

The extruder temperature and set point is displayed on the left hand side of the screen.

Use the Y+ key (set mm/s) to change the speed at which the filament extrudes (see below).

Note: There's an under temperature check, to prevent extruder damage which can be overridden if you have no filament in the extruder.

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The extruder speed (for the Extruder and Pause menus) can be changed by changing the Extruder mm/s. Speeds between 1 and 254 mm/s can be set. Press "OK" to set the speed after changing.

Version 3.2 and higher of the firmware, changed Extruder RPM to Extruder mm/s. Please ensure after installation, that Build Settings / Acceleration Extdr. Step/mm is setup correctly (value for ToM MK7 = 4.4, calibrate if you're unsure).

A good starting point for the mm/s setting in the Extrude Menu would be 30 mm/s.

It refers to the amount of noodle being extruded.

Home Axis

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Home Axis homes the respective axis to its end stop. Press X+ or X- to home the X Axis, Y+ or Y- to home the Y Axis and Z+ or Z- to home the Z Axis.

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Choosing "endstops" by hitting the "OK" key enters a menu where you can configure which end stops you have present. This enables the firmware to calibrate and home in the correct directions (i.e. towards an endstop).

Add the numbers below for each end stop you have, and enter the total value:

X Min = 1
X Max = 2
Y Min = 4
Y Max = 8
Z Min = 16
Z Max = 32

For example on a ToM, you have X Min, Y Min and Z Max, 1 + 4 + 32 = 37.

Advance ABP

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Hold down the "OK" button to advance the Automated Build Platform belt manually.

Steppers

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The Steppers menu can be used to activate (power) the steppers or deactivate them. When activated, you will be unable to move the stepper motors.

This is commonly used to unlock the axis if you need to override ReplicatorG.

Note1: This doesn't effect the Hold Z setting in ReplicatorG. Hold Z only applies when a build is in progress, so if you Disable Steppers, you'll be able to manually move your Z axis.

Note2: Steppers can get warm when powered, possibly leading to damage if you have an incorrect "Ref" setting on your stepper driver.

Mood Light

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The Mood Light menu also requires an RGB mood light to be installed: [http://www.thingiverse.com/thing:15347]

Use the "OK" key to cycle through the available "Moods", and the "Cancel" key once the mood has been selected.

For further information about the moods, see the pdf manual in the above thing.

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When the Mood "Custom" is selected, the Zero key can be used to set the Red, Green and Blue Values for a custom color.

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Use the Y+ / Y- key to change the value by 1 and the Z+ / Z- key to change the value by 10. "OK" sets the value and moves to the next color.

Buzzer

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The V2.4 Gen 4 Motherboard comes with a space for a buzzer. Information on the type of buzzer to purchase, and how to attach it can be found here: [http://www.thingiverse.com/thing:16170]

The buzzer menu enables you to control the buzzer. The buzzer by default issues the following patterns on various events:

  • Safety cutout triggered: 7 long buzzes
  • Build completed: 2 short buzzes
  • Pause@ZPos: 4 short buzzes

The buzzer menu controls how many times these patterns are repeated. The value can range from 0 - 254 times. When set to 0, the buzzer is off, Use the Y+ / Y- keys to change the value by 1. Use the Z+ / Z- keys to change the value by 5. The "OK" key sets and stores the value.

Build Settings

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The Build Settings menu provides a sub menu of items that can be used to change the function of the build process.

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Estimate Preheat when enabled, preheats the build platform and the extruder to the set points defined in Preheat whilst the build is being estimated when building from SD card.

If disabled, the heating occurs when the relevant command is encountered in the gcode file.

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Override GCode Temperature, when enabled, overrides the first non zero temperature specified in the gcode file. This feature can be used to change plastics or temperatures without having to regenerate the gcode.

It can be used in conjunction with Profiles to set different temperatures for different plastics or conditions.

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ABP (Automated Build Platform) copies can be used to specify the automatic building of a number of copies of an object without having to cut and paste gcode. The number of copies can be changed between 1 and 254.

If you are not using the ABP platform, this should be set to 1.

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When an ABP Copies >= 2 is specified, an additional screen is added when building from SD card which displays the copy number currently being printed.

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Further information about the "Acceleration" menu can be found in:Acceleration Settings

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5D Extruder: Enable ONLY if you are using the 5D driver, this reverses the extruder to get around a bug in the 5D Driver Code in RepG.

Note: It's recommended not to use 5D, see Troubleshooting section for more information.

Profiles

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The Profile menu provides storage for 4 different configurations, allowing the user to quickly store and recall the following information:

  • Profile name
  • X Home Offset
  • Y Home Offset
  • Z Home Offset
  • HBP Temperature
  • Extruder Temperature
  • Extruder MM/s

Profiles can be used to store temperatures for different plastic types, temperatures for different seasonal conditions or to maintain calibration when switching between the Automated Build Platform and Heated Build Platform.

Use the Y+ / Y- to navigate up and down the list of profiles, then use the "OK" key to select a profile.

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The Profile Sub Menu displays a list of operations for a profile. Use the Y+ / Y- keys to navigate, and the "OK" key to select a profile.

Restore: Restores the information contained in the profile to the firmware. This will change your X/Y/Z Home Offsets, Bed/Tool0 Temperature settings in Preheat and Extruder mm/s in the Extruder menu.

Display Config: Displays information about the settings stored in the profile (see below):

Change Name: Allows editing of the profile name: (see below)

Save To Profile: Takes the current X/Y/Z Home Offset, Bed/Tool0 Temperature settings in Preheat and Extruder mm/s and saves them in the profile.

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"Display Config" displays the list of settings stored in the currently selected profile. Use the Y+ / Y- keys to scroll down the list of settings.

Note: These settings cannot by changed from within this menu, to do this you need to restore the profile, change the settings in the relative locations within the firmware (Home Offsets, Preheat, Extruder), and then choose "Save To Profile".

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Profile Names up to 8 characters long can be set in this menu. If your profile is less than 8 characters, then substitute spaces (located at the bottom end of the range) for the missing characters.

To move the cursor, use the X+ / X- keys. To change the character to the next higher / lower character, use the Y+ / Y- keys. To move faster through the character list, use the Z+ / Z- keys.

When you have finished editing, use the "OK" key to store your changes.

Extruder Fan

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The Extruder Fan menu enables you to switch the fan on the Extruder, either On or Off. This remains in effect until you restart or begin a build.

Calibrate

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The Calibrate menu calibrates the X/Y/Z Axis, and is similar to the Calibrate script in ReplicatorG.

Enter the menu and use the Z- key to advance through, following the instructions presented. The calibration menu can be cancelled at any point up until the last instruction, by using the "Cancel" key, and the previous settings will remain in effect.

If you have already calibrated and wish to make minor adjustments to a particular axis, use Home Offsets instead.

If you are swapping between the Heated Build Platform and Automated Build Platform, use Profiles.

Home Offsets

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Home Offsets are the distances from the end stop to the calibration points (i.e. Zero). They are the same as the X/Y/Z home offsets's in the "Motherboard Onboard Preferences" in ReplicatorG, and are set when Calibration is done.

To change the values, use the Y+ / Y- keys to change by a small amount, and the Z+ / Z- keys to change by a larger amount.

Note that smallest amount you can change by is 1 step of the stepper motor, and this will equate to a proportional amount of mm's, so you can not change the mm's by an exact amount of your choosing, only in steps.

To change a value (for example the X Offset), you must hit OK on each of X Offset, Y Offset and Z Offset. Only on the OK being hit on the Z Offset will all 3 values be written.

Filament Used

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Filament Used shows the lifetime amount of filament used in Meters and Feet. This counter is updated at the end of every print or when a print is cancelled. It is updated regardless of if you build from SD Card or build from computer.

The counter can be permanently reset to zero with the "OK" button. The "Zero" cycles between this Lifetime Odometer and the Trip Odometer:

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The Trip Odometer acts similar to a trip odometer on a vehicle. It measures the amount of filament used (independently from the lifetime odometer) since its last reset. You can use this to retain your lifetime odometer usage, whilst counting the amount of filament used on a particular project or print.

Position

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Shows the current position of the X, Y, Z and A axis in millimeters.

Test End Stops

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A common problem with maintaining your bots electronics is that you can forget to reconnect the end stops, which can damage your bot during operation.

The "Test End Stops" menu, provides the ability to test these are working. Enter the menu, and then depress the end stop manually. The display signals "N" when the end stop is not triggered, and "Y" when it is.

Axis Steps:mm

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Axis Steps:mm is used to configure various machine types and the mapping of their stepper motor movements to the amount of distance moved.

This settings governs the operation of a many functions within this firmware, e.g. distance jogged, amount extruded, pause@zpos, home offset settings.

By default this should have been automatically configured when you installed the firmware for a standard Thing-O-Matic with a StepStruder (Mk7, Mk6, or upgraded Mk5) or for a Cupcake with MBI stepper drivers and a StepStruder,

Axis Thing-o-Matic (Gen 4) Cupcake (Gen 3)
X Axis 00047.0698520000 00011.7674630000
Y Axis 00047.0698520000 00011.7674630000
Z Axis 00200.0000000000 00320.0000000000
A Axis 00050.2354788069

If you have another type of machine, then these settings are likely incorrect. To find the correct settings, load ReplicatorG and set your machine type to the correct one for your machine, then choose the "Machine" menu and "Machine Information".

You'll find the information you need in the "geometry" section for each axis. The "stepspermm" value is what you enter into Axis Steps:mm

Use the X- / X+ keys to move the cursor. Use the Z- / Z+ to change the number. Use the "OK" button to save the current value and progress to the next.

Homing Rates

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This menu sets the homing feed rates. This effects the speed at which homing, calibration, Continuous Jog (in the Jog menu) and jogging during a Pause occurs.

These values are in mm/min and should be set to the same values that RepG has.

Version

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The Version menu reports the motherboard and extruder firmware versions.

Also, the Jetty firmware revision is displayed. If contacting the authors, this revision number is very helpful in diagnosing any issues you may have.

FreeSram denotes that amount of memory left that hasn't been touch during the operation of the firmware in bytes. In normal operation, you should expect this to be low, as Arduino's and Sanguino's have a very small amount or RAM.

You will also see this number become lower as you use the firmware. However it should never reach 0. A value of 0, means that all the RAM has been used and the firmware operation is possibly corrupted. Pressing the "Reset" button will clear the RAM if the unlikely event this ever happens.

Because version numbers need to match each other and ReplicatorG, the Jetty firmware reports its main version number on the startup screen.

Acceleration

The acceleration driver in the Jetty Firmware allows you to print on a standard ToM up to 100mm/s and beyond.

Please note that this version (3.0b) should be considered Beta for the acceleration component. You can easily switch to the regular MBI non-accelerated driver if desired.

Technology

This is based on what is generally considered the current state of the art acceleration in the reprap community, Marlin [http://reprap.org/wiki/List_of_Firmware]

However a number of improvements have been added, which produce a print quality superior to Marlin. It can be considered Marlin Plus.

Enabling Acceleration

To enable acceleration, visit “Build Settings”, “Acceleration”, “Stepper Driver” and select “On - Planner” and hit OK.

Defaults

These are the defaults recommended for the ToM MK7, and serve as a starting point for further experimentation:

  • Stepper Driver: On-Planner
  • Extrdr Steps/mm: 4.4
  • X Max Feed Rate: 100
  • Y Max Feed Rate: 100
  • Z Max Feed Rate: 16 (8 for Cupcake)
  • A Max Feed Rate: 100
  • X Max Accel: 500
  • Y Max Accel: 500
  • Z Max Accel: 150 (100 for Cupcake)
  • A Max Accel: 60000
  • Acc Norm Move: 2000
  • Acc Extr Move: 4000
  • Min Feed Rate: 0.0
  • MinTrvlFeedRate: 100.0
  • MinPlannerSpeed: 2
  • JKN Advance K: 0.00850
  • JKN Advance K2: 0.00900
  • Noodle Diameter: 0.58
  • Minimum Segment Time: 0.0200
  • RevMaxFeedRate: 800.0
  • ExtruderDeprime: 4.0
  • Slowdown Limit: 4
  • Clockwise Extdr: 1
  • MaxSpeedChangeX: 30.0
  • MaxSpeedChangeY: 30.0
  • MaxSpeedChangeZ: 10.0 (2.5 for Cupcake)
  • MaxSpeedChangeA: 30.0

Note: If you jog from the Control Panel in RepG instead of the LCD Interface,
MinTrvlFeedRate should be set to 0.

Settings

Stepper Driver

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The driver to use for printing:

  • Off (non accelerated, original MBI driver)
  • Off - Strangled (non accelerated, uses the accelerated driver, but with feed rates constrained to MaxSpeedChangeX/Y/Z/A. Useful when printing accelerated speed .s3g's at non-accelerated speeds without having to regenerate the .s3g file)
  • On-No Planner (acceleration, but no planning between moves)
  • On-Planner (acceleration, with planning between moves (recommended))

Extrdr Steps/mm

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This is a critical setting for the LCD Interface, acceleration and the Extruder Advance Feature. It is the number of steps of the stepper motor that it takes to extrude 1mm of noodle.

If you are unsure of your value, the best way to determine it via the LCD interface is to select (calib) and calibrate it. Before calibrating, move some noodle through your nozzle so you get a clean start. 
 Then choose "(calib)" by hitting the X- key.

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Sselect a number of steps to eject by using the Y-/Y+/Z-/Z+ keys. You want to set the number of steps to produce a fairly long piece of noodle, e.g. 10cm's. Then press the "(extrude)" button - X-. Measure the length of noodle and press the "OK" key to move to the next screen.

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Finally enter that length in mm’s using the Y-/Y-/Z-/Z+ keys, and press "OK" when finished. Your Extrdr Steps/mm will then be automatically calculated for you based on the information you provide.

X/Y/Z/A Max Feed Rate

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The maximum feed rate your machine can sustain. This value is in mm/sec (note ReplicatorG commonly uses mm/min). This value bears no relation to the ReplicatorG value, as you’ll be able to run an axis much faster with acceleration than with out.

For extruder only moves (no X/Y/Z movement), see also: RevMaxFeedRate.

Note that when printing unaccelerated line segments — G1 gcodes preceded by a M127 mcode — the maximum speed change values are instead used as the maximum feed rates for the unaccelerated line segments.

X/Y/Z Max Accel

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This is the maximum acceleration in mm/s^2 for the axis.

A Max Accel

This is the maximum acceleration in mm/s^2 for the extruder, this is typically set to a very high value as acceleration is also controlled with Acc Norm Move / Acc Extr Move

Acc Norm Move

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X/Y/Z and Extruder max acceleration in mm/s^2 for moves that extrude filament (printing moves)

Acc Extr Move

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Maximum acceleration in mm/s^2 for moves that ONLY extrude filament and do not move in X/Y/Z.

Min Feed Rate

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Minimum feed rate whilst printing in mm/sec.

Any feed rates that are sent from RepG with a move that moves in X, Y or Z and extrudes will be increased to the minimum feed rate set here.

Ordinarily this value should be 0, if you want the firmware to follow the slower speeds set by RepG when putting down first layers, rafts etc.

MinTrvlFeedRate

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Minimum feed rate whilst traveling in X, Y or Z (not extruding) in mm/sec.

Normally you set this to the same value as the Extruder Maximum Feedrate.

However if you jog from the Control Panel in ReplicatorG, this will interfere with the ability to Jog because it will upgrade the Jog speed to the value set here, set this setting to 0.

MinPlannerSpeed

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Minimum planner junction speed (mm/sec). Sets the default minimum speed the planner plans for at the end of the buffer and all stops. This should not be much greater than zero and should only be changed if unwanted behavior is observed on a user's machine when running at very slow speeds. 2mm/sec is the recommended value.

JKN Advance K

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JKN (Jetty-Kubicek-Newman) Advance is an improved replacement for the Marlin Advance (Matt Roberts) algorithm and is derived from work by Bernhard Kubicek.

It controls the amount of additional plastic that is pushed out during the acceleration phase, and pulled in during the deceleration phase, this can be used to remove blobbing, or splaying on the corners of cubes, or at the junctions between line segments.

Valid values typically range from 0.000100 to 0.01000.

When JKN Advance K = 0, noodle segments typically show up a wedge shapes, when JKN Advance K is set to the correct value, the noodle segment will have uniform width.

JKN Advance K = 0.00000 switches off advance. Extruder Steps Per MM also needs to be set correctly for this setting to work.

To tune this value, it's recommended to start with JKN Advance K = 0.00000 and set JKN Advance K2 = 0.00000 and print a calibration cube. Turn upside down and look at the filament length along each side, you'll see it's wedge shaped. Change JKN Advance K to 0.001 and check again, keep increasing JKN Advance K in units of 0.001 until the noodle becomes uniform.

If JKN Advance K is set too high, you'll begin to see breakup in the top surface of the cube.

Note: Make sure that Clockwise Extdr is also set correctly, otherwise your Extruder Advance will be reversed, this typically leads to a spider appearance in prints.

JKN Advance K2

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JKN Advance K2 relaxes the pressure in the extruder melt chamber during the deceleration phase on each line segment. This can be used to reduce blobbing and splaying on the corners of cubes, or at the junctions between line segments.

Valid values typically range from 0.001000 to 0.02000.

JKN Advance K2 = 0.00000 switches off pressure relaxation. Extruder Steps Per MM also needs to be set correctly for this setting to work.

To tune this value, it's recommended to start tune JKN Advance K first and set JKN Advance K2 = 0.00000 and print a calibration cube. Look at the corners, you'll see they protrude in the direction of the filament travel. Change JKN Advance K2 to 0.004 and check again, keep increasing JKN Advance K2 in units of 0.001 until the corners are pulled in as much as possible.

If JKN Advance K2 is set too high, you'll begin to see breakup in the top surface of the cube.

Note: Make sure that Clockwise Extdr is also set correctly, otherwise your Extruder Advance will be reversed, this typically leads to a spider appearance in prints.

Noodle Diameter

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The diameter of the extruded filament in mm. This will always be larger than your nozzle diameter and also nozzle diameters vary, so it's recommended to measure a sample with calipers.

Note: Noodle Diameter was used in previous versions of the firmware, but it not used in this version, It is retained in case it's needed at a later date.

Min Seg Time

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Minimum time in seconds that a movement needs to take if the planning pipeline command buffer is emptied. Increase this number if you see blobs while printing high speed & high detail. It will slowdown on the detailed stuff.

RevMaxFeedRate

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This is the maximum feed rate permitted during extruder only moves (i.e. when x/y/z don't move) (mm/sec) This setting is used when priming or depriming the extruder and with JKN Advance. It's also used if the Reversal Plugin in Skeinforge is enabled.

This allows for a greater speed for extruder moves than for regular moves.

This should be set to at least the same as A Max Feed Rate. Eight times the value of a Max Feed Rate is a good value, provided your extruder can keep up. (When priming / depriming, the pressures are lower, so generally this value can be higher than when extruding filament).

ExtruderDeprime

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Extruder Deprime / Prime amount (mm's). When the pipeline command buffer completely empties, printing comes to a stop which can cause a blob or ooze (if traveling across a gap).

Setting this value causes the number of mm's specified to be retracted by the extruder when the buffer empties (deprime), and the same amount to be pushed into the extruder when the buffer fills again (prime).

A value of 0 switches Extruder Deprime off.

Note: Make sure that Clockwise Extdr is also set correctly, otherwise your deprime/prime will be reversed.

Slowdown Limit

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Slowdown limit specifies what to do when the pipeline command buffer starts to empty.

The pipeline command buffer is 16 commands in length, and Slowdown Limit can be set between 0 - 8 (half the buffer size).

When Commands Left <= Slowdown Limit, the feed rate is progressively slowed down as the buffer becomes more empty.

By slowing down the feed rate, you reduce the possibility of running out of commands, and creating a blob due to the stopped movement.

Possible values are:

  • 0 - Disabled - Never Slowdown
  • 1 - DON'T USE
  • 2 - DON'T USE
  • 3,4,5,6,7,8 - The higher the number, the earlier the start of the slowdown

Clockwise Extdr

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Clockwise Extruder (0 or 1) specifies the type of extruder you have. When viewed from the front of the stepper motor (the spindle), if the stepper moves clockwise to extrude material, this should be set to 1. If the stepper moves anti-clockwise to extrude material, this should be set to 0.

A ToM MK7 would be set to 1 (clockwise), if constructed as per Makerbot Industries build instructions.

This setting effects "Advance" and "Extruder Deprime".

MaxSpeedChangeX / Y / Z / A

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The maximum instantaneous change in speed in mm/sec along the X, Y, Z, or E axis between line segments. When transition between adjacent movements (line segments), there can be changes in the speed along each axis. These settings place an upper bound on these speed changes. This allows both control over the degree of "jerking" as well as prevents too quick of speed changes which might lead to missed steps — Z axis in particular — or stripped filament (E axis).

This helps to controls blobbing: the lower the value, the more blobbing is likely to occur at junctions. However, the higher the value, the more violent your bot movements may be, particularly on infill, where sharp angles between line segments occur.

Values that are too high can lead to slippage.

When printing unaccelerated line segments — G1 gcodes preceded by a M127 mcode — the maximum speed change values are additionally used as the maximum feed rates for the line segments.

Known Issues

  • Estimation during the build phase is “over estimated” when acceleration is enabled.

MCode Support

Acceleration Commands

All the M codes here, apart from the reset, cause the values to be stored in Eeprom.

Note a hardware reset is required afterwards to reread Axis Steps Per MM.

These defaults are a suggested starting point for a regular machine, if you've modified your bot, then the values maybe different.

Thing-O-Matic

M201 X500 Y500 Z150 A60000 (Sets the maximum acceleration in mm/s^2 for travel or print moves for X/Y/Z and Extruder)
M203 X100 Y100 Z16 A100 (Sets the maximum feedrate your machine can sustain in mm/sec)
M204 S2000 K4000 (Sets the default acceleration in mm/sec^2. S=normal moves K= filament only moves)
M205 S0 K0 Z2 (Sets "S" Minimum Printing Feed Rate, "K" Minimum Travel Feed Rate, "Z" Minimum Planner Speed - all multiplied by 10, except Minimum Planner Speed)
M206 S58 A800 K40 X4 Y1 (Sets "S" noodle diameter multiplied by 100, "A" RevMaxFeedRate, "K" Extruder Deprime multiplied by 10, "X" SlowdownLimit, "Y" ClockwiseExtr)
M207 S850 A900 K200 (Set "S" JKN Advance K - multiplied by 100000, "A" JKN Advance K2 - multiplied by 100000, "K" Minimum Segment Time multiplied by 10000 in seconds)
M208 A44 (Set Extruder Steps:mm, the number of steps to extruder 1 mm of noodle - multiplied by 10)
M209 S3 (acceleration on - planner, also disables override gcode temp)
M215 X4706985 Y4706985 Z20000000 A5023548 (Sets the number of steps to move 1 mm for each axis. The extruder is the for filament going in - all multiplied by 100000)
M216 X300 Y300 Z100 A300 (Sets Maximum Speed Change for X/Y/Z/Extruder - all multiplied by 10)
M200 (reset to pick up settings)

Cupcake

M201 X500 Y500 Z100 A60000 (Sets the maximum acceleration in mm/s^2 for travel or print moves for X/Y/Z and Extruder)
M203 X100 Y100 Z8 A100 (Sets the maximum feedrate your machine can sustain in mm/sec)
M204 S2000 K4000 (Sets the default acceleration in mm/sec^2. S=normal moves K= filament only moves)
M205 S0 K0 Z2 (Sets "S" Minimum Printing Feed Rate, "K" Minimum Travel Feed Rate, "Z" Minimum Planner Speed - all multiplied by 10, except Minimum Planner Speed)
M206 S58 A800 K40 X4 Y1 (Sets "S" noodle diameter multiplied by 100, "A" RevMaxFeedRate, "K" Extruder Deprime multiplied by 10, "X" SlowdownLimit, "Y" ClockwiseExtr)
M207 S850 A900 K200 (Set "S" JKN Advance K - multiplied by 100000, "A" JKN Advance K2 - multiplied by 100000, "K" Minimum Segment Time multiplied by 10000 in seconds)
M208 A44 (Set Extruder Steps:mm, the number of steps to extruder 1 mm of noodle - multiplied by 10)
M209 S3 (acceleration on - planner, also disables override gcode temp)
M215 X1176746 Y1176746 Z32000000 A5023548 (Sets the number of steps to move 1 mm for each axis. The extruder is the for filament going in - all multiplied by 100000)
M216 X300 Y300 Z25 A300 (Sets Maximum Speed Change for X/Y/Z/Extruder - all multiplied by 10)
M200 (reset to pick up settings)

Switching Acceleration On

M209 S3 (acceleration on - planner, also disables override gcode temp)
M200 (reset to pick up settings)

Switching Acceleration Off

M209 S0 (acceleration off, also disables override gcode temp)
M200 (reset to pick up settings)

LCD Support

This firmware supports 4x16 (standard) and 4x20 / 4x24. By default it's set to 4x16.

If you have a larger display, then increased display size is only used in the SD File listing. To change your display:

1. Disconnect the USB cable from the bot
2. Power bot.
3. Press reset button
4. Wait 5 seconds
5. Hold X- Button down until you will see the screen flicker as the bot does a reset (about 10 seconds)
6. Release button
7. Display is now in 20x4 mode

Repeat steps 4,5,6,7 to get to 24x4, and repeat again to get to 16x4.
(It's a loop 16x4 -> 20x4 -> 24x4 -> 16x4 etc.)

When finished, press the motherboard reset button to make sure the change has been picked up.

If you have a buzzer attached, you will also hear a beep at the end of step 5 to confirm the mode change.

Troubleshooting

  • Build from SD: Unable to print file. File can be seen, but won't print
    • Filenames must be <31 chars due to a limitation in the SD Card library. If a file is > 31chars, it won't print.
  • Display corrupted / misaligned
  • Build Platform / Tool Head switch off at the start of a print
    • Update to firmware 3.2 or higher, Then if you have an LCD interface, visit Build Settings / Override Temp and disable, or under the Preheat menu, change your temperature to something meaningful. If you don't have an LCD interface, issue the following gcode from RepG just once (i.e. do not enter into your start.gcode):

M209 S3 (acceleration on - planner, also disables override gcode temp)
M200 (reset to pick up settings)
Now, do a hard reset by hitting the reset button on your motherboard.

  • Read timed out / Packet timed out whilst issues acceleration GCode from RepG
    • This is due to the time eeprom writes take. You can ignore the messages from RepG, it will have saved the settings successfully.
  • Printing doesn't start, or stops soon after starting.
    • Unlike other firmware, Jetty firmware takes notice of the safety cutoff and will shutdown printing. If your safety cutoff hasn't tripped, check that your EStop cable is connected correctly at both ends and that Motherboard Onboard Preferences in RepG has "Emergency Stop" set to "Active high emergency stop (safety cutoff kit)"
  • Filament strips when using acceleration.
    • This can happen due to a variety of reasons. First check there's no dust around your filament pinch wheel (it reduces grip with the filament). Check the device pushing your filament against the pinch wheel is not gripping the filament too hard or too little. Check the REF voltage on your extruder stepper driver is set to the correct voltage. Finally, if you just have bad mechanics and you can't do anything about it, try reducing Acc Norm Move and Acc Extr Move to reduce the starting acceleration for the move, and if that doesn't solve the issue. If none of the above helps, then drop your A Max Feed Rate and print at a slower federate.
  • Pauses, slow movement during printing.
    • Please visit your skeinforge "Speed" settings and make sure that Travel Feed Rate is set to the same as your feed rate or higher. By default this is 50mm/s, and if you're running at 100mm/s feed rate, it should be at least 100mm/s or higher. Otherwise as infill happens it will stop extruding and move to a new location for another piece of infill at a slower speed.
  • Timeouts when printing from ReplicatorG.
    • Accelerated firmware has a many calculations to do, and the number of calculations executed per second is dependent on your acceleration settings. For that reason, ReplicatorG may time out occasionally. Generally it recovers, but it can cause a blob on your print. The best solution is to always print from SD Card, if you do that, your firmware has less to do and can print faster. If you have to print from ReplicatorG, then if it becomes an issue for you, reduce the acceleration and A Max FeedRate to slow down the rate of calculations.
  • Using 5D
    • We don't ! There are a number of reasons why 5D is not the best choice for Makerbot's.
    • There are bugs in ReplicatorG 0034 when using 5D: http://replicat.org/
    • There is a bug in RepG and makerbot4g driver which causes feed rates to be calculated incorrectly
    • 5D doesn't provide an advantage when using firmware that doesn't understand gcode natively (like Makerbots).
    • To switch to non 5D printing, switch off the Dimension plugin in skein forge. Also you probably inverted your E axis to get 5D working, make sure to put it back to normal in Motherboard Onboard Preferences.
  • Extruder reversed when using 5D Driver.
    • There's a bug in the 5D Driver in ReplicatorG that causes the extruder operation to be reversed when extruding in firmware, enable the 5D Extruder setting in Build Settings. Note it's recommended not to use 5D.
  • Problems Jogging in ReplicatorG Control Panel
    • MinTrvlFeedRate upgrades the jogging speed to the speed specified in this setting. Make this setting 0 if you use Control Panel to Jog, otherwise use the LCD Interface to jog. See MinTrvlFeedRate Setting
  • Print quality when printing from USB is not as good when printing from SD Card.
    • Your bot uses a very limited 8 bit slow processor with limited RAM. Communicating via USB takes up more a large amount of these resources, which results in the acceleration buffer being less full when printing from USB versus printing from SD Card. You can print from either, but you will get better results and faster prints when you print from SD Card.
  • Print defects, slipping axis, blobbing.
    • Use the defaults recommended here as a starting point. After you have working good prints, then you can change values gradually to speed up printing. The most frequent cause of issues is due to values being used which exceed the mechanical capability of the machine.
  • Slow printing from RepG or blobbing when printing from RepG.
    • Print from SD Card instead. Printing from RepG directly is slower than printing from SD Card because the firmware prints faster than the ReplicatorG can send print commands over USB.
  • Missing noodle on the ends of sides, Z moves or whenever filament is stopped.
    • Please use either Reversal in Skeinforge, or Deprime in the firmware, but don't use both. If you're already using one of these, you may need to tune it for your bot.

Source Code

More detailed information about the changes (and some additional changes / bug fixes not listed) can be found here:

[http://www.github.com/makerbot/G3Firmware/pull/88]

Source code for the changes can be found here: [http://www.github.com/jetty840]

Source code for changes to ReplicatorG can be found here:
[http://www.github.com/jetty840/ReplicatorG]

Credits

Credit goes to the following people:

  • The developers of the original firmware this was based on
  • Dan (Coding, Design and Testing)
  • Bernhard Kubicek (basis for JKN Advance)
  • Revarbat (basis of Build Time / Preheat)
  • RonGarrison (Extruder / EStop)
  • Eried (Page Up / Page Down, Testing)
  • Bob (Testing)
  • Others who have contributed with suggestions
  • Jetty (myself)

Release History

  • Version 3.3 (TBD):
    • Faster / Smoother printing
    • Considerably better print quality
    • Ringing fixed (you may need to fine tune with Advance K)
    • XYZ Jerk removed and replaced with DNewman's "Yet Another Jerk" (MaxSpeedChangeX/Y/Z/A)
    • Added JKN (Jetty-Kubicek-Newman) Advance
    • Support for new AltShell Skeinforge plugin
    • Bug where acceleration is sometimes not enabled, fixed
    • Temperature symbols indicate when HBP/Extruder are ready
    • Bar LED lit when Acceleration is enabled
    • Foo LED lit when command pipeline is filled, not lit when nearly empty (indicates acceleration load)
    • Added RevMaxFeedRate, ExtruderDeprime, SlowdownLimit and Clockwise Extdr acceleration settings
    • Added 5D Extruder reversal setting for users running the 5D driver
    • Added Stepper driver "Off - Strangled" mode to make switching an accelerated print to non-accelerated easier.
    • Removed snake easter egg menu item, sorry, had to go, needed the space.
  • Version 3.2 (28th Feb 2012):
    • Z Hold is now respected when acceleration is enabled
    • End stops respected when hit during an accelerated print
    • Fixed Marlin bug that caused positioning for the Extruder to be incorrect (effected Extrude and Pause Menus)
    • Fixed bug where cancel button in Extruder Too Cold Override, caused extrude anyway
    • Changed Extruder RPM to Extruder mm/s: see: Extrude for more information.
    • Fixed Pause positioning bug
    • Test End Stops now displays xmax, ymax and zmin too
    • Added support for larger LCD's: 4x20 and 4x24 LCD Support
    • End stops are now configurable, visit "Home Axis", effects Homing / Calibration: Home Axis
    • New Homing Rate menu to set homing feed rates. Values in mm/s, effects Jog, Homing, Calibration and Pause: Homing Rates
    • MCode "M209" now also sets Override GCode Temp to "Disabled" in the firmware to avoid an issue with corrupt eeprom causing users without an LCD to be unable to set build temps.
  • Version 3.1 (26th Feb 2012):
    • Acceleration print quality improvements (ringing fixed)
    • Feed rates in RepG etc. are now respected
    • Now supports cupcakes with stepper extruders
    • Fixed RepG Control Panel jogging issues
    • Added new Minimum Segment Time acceleration setting
  • Version 3.0b (17th Feb 2012):
    • Added acceleration (100mm/s now possible)
    • Added FreeSram to Version menu
  • Version 2.5 (25th Jan 2012):
    • Added ABP Multiple Copy support
    • Added "Print Another"
    • Added ability to override gcode temperature settings
    • Added "Preheat During Estimate"
    • Z+ button now advances through scroller
    • Added "Trip Odometer" to Filament Used
    • Added Profile for saving X/Y/Z Home Offset, Platform/Extruder Temps and Extruder Rpm, enabling HBP/ABP switching and different plastic types
  • Version 2.4 (21st Jan 2012):
    • New lifetime "Filament Counter"
    • Axis Steps:mm menu item to support other bots, different stepper / belts / gearing / extruders
    • New Build Estimator with near perfect accuracy (handles rafts too)
    • Jog Menu / Home Offsets report in millimeters
    • Jog faster now in pause
    • New filament usage display during build
  • Version 2.3 (18th Jan 2012):
  • Version 2.2 (13th Jan 2012):
    • Improved layout of "Cancel Menu" when building from SD
    • Added "ABP Advance"
    • Added Calibration Menu and Home Offsets Menu.
  • Version 2.1 (11th Jan 2012):
    • Fixed issue with build starting before HBP reached temp
    • Added "Pause at ZPos" to the cancel menu when building from SD Card (move down pass the Cancel entry). Enables the user to preprogram a set Z Position (in mm), where the build will pause. Multiple pauses can be set. Zero cancels the current pause. A preprogrammed pause is indicated by a "*" in the monitor. Your bot should not be left unattended when this feature is used, because the Extruder and HBP will remain at temperature during the pause.
  • Version 2.0 (9th Jan 2012):
    • Added "View Mode" button to Jog Menu, to display buttons from the user's point of view or from the model
    • Short, Long, Cont are now remembered.
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