E-Series Filament Runout Sensor Installation Guide
The required tools and materials for this procedure are as follows:
- Filament Runout Sensor kit (includes Filament Runout sensor assembly, wiring leads, small adapter, and x2 zip ties)
- Firmware for your Pulse model (please contact our Support team with your Pulse model number)
- 2.5mm hex driver or Allen key
- 3.0mm hex driver or Allen key
- Flush-cut pliers
Before attempting any of the following, please be sure that the Pulse printer is unplugged from the wall outlet to avoid serious injury from electrical shock.
STEP 1: Remove Tubing
Begin by removing the bowden tubes from the top and bottom of the BondTech BMG extruder. See this guide.
STEP 2: Remove Extruder
Using the 2.5mm hex driver, remove the (x3) M3 screws as shown in the photo below, then carefully remove the BMG extruder assembly from the E-stepper mount.
STEP 3: Disassemble Extruder
Separate the two halves of the BMG, then remove the aluminum groove-mount adapter.
STEP 1: Insert FRS Assembly
Insert the Filament Runout Sensor assembly. Note that the new assembly will need to be tilted to insert the PTFE tubing, before seating the grove mount into place.
STEP 2: Reinstall Extruder
Rejoin the two halves of the BMG extruder, and attach the assembly back onto the E-stepper mount. Be sure to route the wires as shown in the photo below. Reinstall the (x3) M3 screws and tighten. Reinstall the long bowden tube.
TETHERED OR UNTETHERED?:
The wiring configuration on the Filament Runout Sensor will depend on how you plan to print with your Pulse:
- If printing Tethered (connected to MatterControl via USB cable) then the Green wire will need to be connected to the lower pin.
- If printing Untethered (printing via SD card) then the Green wire will need to be connected to the center pin.
STEP 1: Remove Power Supply Access Panel
Flip the Pulse on its side. Using the 2.5mm hex driver, remove the (x4) M3 screws that are retaining the power supply access panel. Then remove the access panel.
STEP 2: Loosen Power Supply Mount
Locate the (x2) M3 screws inside of the lower power supply shroud, then insert the 2.5mm hex driver through the holes on the shroud as shown in the photo below. Remove these screws.
STEP 3: Loosen Power Supply Mount (continued)
Using the 3.0mm hex driver, loosen the (x2) M4 screws located on the right side of the Pulse frame and pull the power supply assembly away from the frame a few millimeters.
STEP 4: Route FRS Wiring Along Power Supply
Carefully route the Filament Runout Sensor wires along the existing extruder stepper wires, and position them in the provided channels.
STEP 5: Retighten Power Supply Mounting
Using the 3.0mm hex driver, tighten the (x2) M4 screws to secure the power supply assembly against the frame; keeping the wires in place.
STEP 6: Reinstall Power Supply Access Panel
Reinsert the (x2) M3 screws securing the lower power supply shroud to the frame extrusion, and reinstall the access panel and corresponding (x4) M3 screws.
STEP 7: Route FRS Wiring Along Frame
Route the Filament Runout Sensor wires along the bottom of the frame and through the lower wire channel.
STEP 8: Secure FRS Wiring
Using the 2.5mm hex driver, loosen the wire clamp and slide it back a few millimeters. Insert the Filament Runout Sensor wires, then reposition and tighten the wire clamp back in place.
STEP 9: Prep Braided Sleeve
Remove the mainboard box cover and locate the large braided wire bundle. Using a pair of flush-cut pliers, snip and remove the zip ties from both ends of the wire bundle.
STEP 10: Route FRS Wires Through Braided Sleeve
Work the Filament Runout Sensor wires into the braided sleeve on the wire bundle, and through the grommet. Attach the new zip ties and trim them flush. Reattach the mainboard box cover.
STEP 11: Mainboard Connections
Plug the Filament Runout Sensor connector into the corresponding mainboard connection; see diagrams below for your mainboard type.
Note: the 32-bit mainboard will require the provided small adapter.
STEP 1: Settings Adjustment
Navigate to Printer > Hardware, and enable the "Has Filament Runout Sensor" option. If the Printer tab is not visible, please see this article.
STEP 2: Firmware Reflash
Connect to MatterControl and reflash the provided firmware for your Pulse model -- please contact our Support team with your Pulse model number.
The firmware reflash process will differ depending on the mainboard type: see this article for the 8-bit board type; or this article for the 32-bit board type.
STEP 3: Hardware Test
Navigate to the Terminal tab and type M119 to report the endstop statuses; the Filament Runout Sensor (ros_) should be reporting as "Open".
Load filament into the extruder and type M119 again; the Filament Runout Sensor should now report as "Triggered".
Congratulations! Your new Filament Runout Sensor has been successfully installed!