4) Download Makerware and install here http://www.makerbot.com/makerware/
4.5) Download and install proftweak here https://github.com/nothinglabs/proftweak
You MUST use Sailfish version of Replicator-G to update and configure Sailfish firmware.
5) Download the LATEST version of RepG here http://www.thingiverse.com/thing:32084/#files
6) Unzip the Replicator-G file to a folder. Leave all the RepG files in their own folder, don’t move them around (don't move the EXE). Open RepG ( click on the ReplicatorG.exe)
7) Make sure your bot is NOT plugged into the computer via USB yet.
8) Open RepG Preferences> Advanced....point the python and pypy interpreters to the correct file location. (See attached PDF for details).
9) From the RepG menu, select "Preferences". Click the "Advanced" button. Change the "Firmware update URL" field from: http://firmware.makerbot.com/firmware.xml
To
http://jettyfirmware.yolasite.com/resources/release/firmware.xml
Then click "Close". Wait until the RepG is done doing its thing! You should see some stuff happening.
10) Connect your bot’s USB cable to both the bot and the computer you will be performing the upgrade from. Next, power your bot on. But DO NOT connect from RepG to the bot. Check the "Connection (Serial Port)" sub-menu of ReplicatorG’s "Machine" menu. Make sure that you see the USB port for your bot listed. If it does not appear, then select the "Rescan serial ports" item of that sub-menu. You cannot proceed until your bot’s serial port appears(ie. COM 1). Again, DO NOT actually connect from RepG to the bot: the firmware upload process itself will automatically perform that step.
11) From ReplicatorG select the "Upload New Firmware" sub-menu of the "Machine" menu. SELECT your correct machine type!!!! For example, loading Replicator 2 firmware on an original Replicator 1 bot results in nothing on the LCD!!!
12) Select the latest firmware to install (note that versions ending in "b" means for broken SD card hardware=AKA cannot detect card insertion), select the COM port, click Next, then Upload
15) Once you are done shut the printer down and shut down RepG. Do not connect the USB to the bot yet….
16) Open RepG make sure this is selected …..click Machine > Machine Type > The Replicator "whatever version you have" (Sailfish)" . Be sure to select the names ending in Sailfish to connect to Sailfish firmware.
17) Make sure the usb is plugged into the computer and the Printer and turn it back on, open up RepG. If it does not connect then click the connect button and get a connection
18) On RepG click Machine > Onboard Preferences. In the lower left hand corner of the window is a button to "reset motherboard to factory settings". Do that now!
19) Give the machine a little time to do the above step, then shut down the bot and repg and then load them both back up and connect them.
20) On RepG click Machine > Onboard Preferences. Click on the "Homing/VREFs". Ensure that the X and Y Home Offsets are somewhat near 151.998 and or 74.998. Also validate that the toolhead offsets (different than homing offsets) are either values less than 1.0mm (AKA 0.85 or something) or is a value less than 33.0mm (For Replicator Duals) and 35mm for Replicator 2X! In other words, if it's over 34mm( and we are taking an original wooden Replicator, or Greater than 35mm on a 2X) you are going to have a problem. Reset to 0 if the number is too large. Again, valid values are less than 1mm (0.88), less than 34mm (33.35) or (32.87). The real nozzle spacing is (33mm for Replicator Duals and 35mm for Replicator 2X) and the offset is the adjustment from that value. In the case of then entire measured number being given, it just uses that. Note that sometimes after an update, it is not uncommon to see the Tollhead offset be 10 times too large. In other words, over 300mm. Nothing on the bot is 300mm of travel so an offset of greater than 35mm on any bot is a sure sign you need to reset Toohead offsets to 0mm and commit.
21) On RepG click Machine > Onboard Preferences. Click Acceleration(Misc) and set right and left deprime values to 0.
You should be good now. You need to carefully level your build plate(a learned skill, may take you hours at first) and make sure you don’t slam your nozzles into the plate.
Now you should run the calibration script for the D4 in the file > scripts > Calibration -> Replicator 1 dual nozzle calibration. That will bring up gcode then you need to build that gcode for the sd card. Then put that x3g file on the sdcard and print it. Then put the correct lines into the bots consule as you see here: http://www.makerbot.com/support/replicator/troubleshooting/nozzle-align/
why pypy?
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