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A guide to upgrading your Ultimaker 2 3D printer to use the E3D-Extruder and range of hot ends.
+
[[File:Ultimaker Upgraded.jpeg|right|thumb|Ultimaker 2 with E3D Upgrade Kit.]]
 +
This page provides a full guide to installing the [http://e3d-online.com/ E3D Ultimaker 2 Upgrade Kit], including the [http://e3d-online.com/ E3D] [http://e3d-online.com/Titan-Extruder Titan Extruder] and [http://e3d-online.com/E3D-v6 V6 HotEnd] into your [https://ultimaker.com/en/products/ultimaker-2-plus Ultimaker 2 Series] 3D printer.
  
This guide was originally written by Steve Wood of Gyrobot, many thanks for his contribution.
+
This upgrade kit is compatible with:
 +
*Ultimaker 2/ Ultimaker 2 Extended
 +
*Ulimaker 2+/ Ultimaker 2 Extended+
  
'''Please note that this guide is a work in progress and will be updated periodically'''
+
This article is a companion to the [https://www.youtube.com/user/ThomasSanladerer '''Video Guide''' by Thomas Sanladerer] showing the upgrade process. It is recommended to follow this page and his guide in tandem. Read the [[#Preparation|Preparation]] section before beginning the installation process.
  
=Introduction=
+
'''Ensure your printer is switched off, disconnected from the power supply and cooled down before handling'''.
Please familiarise yourself with this guide and your printer before choosing to continue.
 
  
[[File:Example.jpg]]
+
This guide is based on work originally written by Steve Wood of Gyrobot, many thanks for his contribution.
<br style="clear:both;">
 
  
=You Will Need=
+
=Requirements=
 +
===Upgrade Kit Contents===
 +
[[File:Kit Contents.jpeg|right|500px|Kit Contents]]
 +
*[http://e3d-online.com/Titan-Extruder E3D Titan Extruder] Kit
 +
**3mm Groove Mount Bowden Adaptor
 +
**PTFE Bowden Tubing
 +
**NEMA 17 Stepper Motor with Cable
 +
*[http://e3d-online.com/E3D-v6 E3D V6 HotEnd] 3mm Bowden - 24V, 30W, PT100
 +
**Wiring Loom and Braided Sleeve
 +
**V6 Nozzle Fun Pack
 +
**V6 Silicone Sock
 +
*[http://www.thingiverse.com Printed Parts]
 +
**Four Layer Adaptor Body
 +
**2x Fan Duct
 +
**Bowden Depressor Tool
 +
*Fixings
 +
**12 x M3 Nut
 +
**16 x M3 Washer
 +
*[http://e3d-online.com/Edge E3D Edge] Sample Filament
 +
*Allen Keys
  
* 1 x Ultimaker 2
+
===Tools Required===
* 1 x [https://e3d-online.com/E3D-on-Ultimaker E3D for Ultimaker Upgrade Kit]
+
*Pliers or 7mm Hex Wrench
** 1 x NEMA17 Motor (Only required if you can't remove the one from your extruder)
+
*Small Phillips-Head Screwdriver
** 1 x [http://e3d-online.com/Titan-Extruder E3D Titan Extruder]
+
*Allen Keys (Included)
** 1 x E3D-v6 (1.75mm or 3mm Bowden 24V 40W PT100 1700mm wiring)
 
** 1 x Set of [http://www.thingiverse.com/thing:1627634 Printed 'XY' Carriage]
 
** 1 x Bowden Adaptor for [https://e3d-online.com/Bowden-Adaptor-1.75mm-Filament 1.75mm] or [https://e3d-online.com/Bowden-Adaptor-3mm-Filament 3mm] filament
 
** 1 x Ultimaker Fixings Kit
 
*** 12 x M3 Hex Nuts
 
*** 16 x M3 Washers
 
*** 10 x Cable Ties
 
  
=What Tools Are Required=
+
=Preparation=
 +
#Begin by removing the filament from the printer in the normal manner used for [https://ultimaker.com/en/resources/16955-changing-filament Changing Filament] but do not insert a new spool, simply continue through the process pressing OK at each stage.
 +
#Wait for the HotEnd to cool back down, you can check this by going to '''MAINTENANCE > ADVANCED > Heatup nozzle'''. If the second temperature (eg. 27C/'''0C''') is not already at 0C, rotate the dial to set this, wait for the first temperature to reach room temperature (eg. '''27C/'''0C).
 +
#Factory reset your printer by scrolling to '''MAINTENANCE > ADVANCED > Factory Reset''' and press '''YES'''. When the setup wizard loads, do not run through it, instead switch the printer off. [[File:UT_Reset.jpeg|centre|800px]]
 +
#Disconnect the power supply.
  
<gallery>
+
=Installation=
File:Wire Cutters.jpeg|Wire cutters for trimming or stripping wires. Could use scissors or craft knife etc.
+
==Printhead==
File:Phillips-Screwdriver.jpeg|Phillips screwdriver for unscrewing UM2 hot end heater retaining screw.
+
===Ultimaker Printhead Dissassembly===
</gallery>
+
#Lower the bed by pressing down on it gently until it reaches the bottom.
 +
#Unscrew both of the part cooling fans from the Ultimaker head, save the screws as we will use them later. [[File:Fan_Unscrew.jpeg|centre|500px]]
 +
#Remove the bowden clip from the bowden collet. [[File:Bowden_Clip_Removal.jpeg|centre|500px]]
 +
#Press down on the bowden collet with your fingernails or the bowden removal tool, then pull upwards on the tube, it should slide out. [[File:Bowden_Removal.jpeg|centre|500px]]
 +
#Unscrew the four long thumbscrews holding the Ultimaker printhead together, keep these as we will use them later. [[File:Screw_Removal.jpeg|centre|500px]]
 +
#Carefully remove the rail from it's bracket on the left side by pulling up on it using the bracket for leverage. [[File:Rail_Removal_Dual.jpeg|centre|800px]]
 +
#The lower and upper sections of the Ultimaker printhead should now be free from the assembly. [[File:Upper-Lower_Section_Free.jpeg|centre|800px]]
 +
#Gently lift the rail and slide out the middle section from its bearings. The head assembly should now be free from the rails. If wires remain tangled, one side of the other rail may need to be unclipped from its bracket in a similar manner to free them. [[File:Middle_Section_Free.jpeg|centre|500px]]
 +
<!--#Clip any rails you removed back into their brackets. (Tom does this later)-->
 +
#Detach all of the connectors from the Ultimaker head, keep the two 30x30mm part cooling fans as we will use them in the next section. [[File:Cable_Disconnection.jpeg|centre|500px]]
  
=Disassembly=
+
===E3D Printhead Assembly===
 +
#Take the two 30x30mm part cooling fans we saved from the Original Ultimaker Printhead. Screw these into the two printed fan ducts with the label on the inside and the wiring exiting from the tallest side of the duct as shown. [[File:Fan_Screw.jpeg|centre|500px]]
 +
#Carefully turn the printer onto its right side.
 +
#Slot the first section of the new printhead into the lower bearing as shown. [[File:Layer_1.jpeg|centre|500px]]
 +
#Pass the cables for the two part cooling fans and the heatsink fan though the wiring hole in the first section of the printhead, hold these in place for the next few steps. [[File:Fan_Cables.jpeg|centre|500px]]
 +
#Pass the wires though the second section (light grey) of the printhead as show then slot it over the bearing. Pass the wires thought the third (dark grey) section as shown. [[File:Layer_2-3.jpeg|centre|800px]]
 +
#Gently lift the upper rail and slot the third section into the upper bearing as shown. Slot the rail back into its bracket when complete. [[File:Layer_3.jpeg|centre|500px]]
 +
#Pass the wires though the top (black) section and slot it over the upper bearing. [[File:Layer_4.jpeg|centre|500px]]
 +
#Slot the four long thumb screws from the original Ultimaker printhead through the four holes in the new printhead with washers between the screws and printed parts as shown. [[File:UT_Screw_Dual.jpeg|centre|800px]]
 +
#Connect the wiring loom to the cables from the printhead, each connector should only go in one way. [[File:UT_Connectors.jpeg|centre|500px]]
 +
#Add a washer then nut to the other side of the bolts and tighten with pliers or a hex wrench. [[File:UT_Nuts_1.jpeg|centre|500px]]
 +
#Add another nut to each bolt then slot the heatsink fan onto the back of the heatsink with the cutout side of the fan bracket facing towards the top. The bottom flat surface of the fan bracket should align with the bottom of the heatsink. The wires should be routed around the sides of the bracket as shown below (viewed from the top right), running through the fan bracket cutout channel when installed. [[File:UT_heatsink_fan_detailed.jpeg|centre|800px]]
 +
#Add a washer to each bolt then slot the part cooling fan assemblies onto the bolts as shown, onto the left and right sides. [[File:UT_Nuts_2_Part_Fan.jpeg|centre|500px]]
 +
#Add a final washer and nut to secure the part cooling fan assemblies and tighten. Ensure they do not go below the level of the nozzle to avoid fouling during printing. [[File:UT_Nuts_3.jpeg|centre|500px]]
 +
#Insert the new bowden tube into it's collet as shown. When properly seated it should not be able to be pulled out. [[File:UT_Bowden_Dual.jpeg|centre|800px]]
 +
#Slide the braided sleeve down over the connectors and into the top of the printhead. [[File:UT_Braided_Sleeve.jpeg|centre|350px]]
 +
#Remove the bowden clips from the original Ultimaker wiring loom and attach them to the braided sleeve and bowden tube of the new loom as shown. [[File:UT_Bowden_Clips_Dual.jpeg|centre|800px]]
  
* Heat your hot end up and retract your filament as if you were going to change filament.
+
==Extruder==
* Turn the heat down and wait for the HotEnd to cool.
+
===Ultimaker Extruder Dissembly===
* Unplug your Ultimaker 2 from the power supply.
+
#Remove the two screws shown below from the back of the Ultimaker. [[File:Motor_Cover_Screws.jpeg|centre|500px]]
* Remove all of the black cable clips between the Bowden feed tube and the hot end wiring loom.
+
#It should now be possible to remove the motor cover. [[File:Motor_Cover_Removal.jpeg|centre|800px]]
<div><ul>
+
#Remove the bowden clip form the original Ultimaker extruder using your fingernail or a screwdriver. [[File:UT_Extruder_Bowden_Clip.jpeg|centre|500px]]
<li style="display: inline-block; vertical-align: top"> [[File:Cable-clips.jpg|left|thumb|UM2 Black cable clips.]]
+
#Hold the motor in place from the front and remove the four screws in the extruder shown below. The motor and extuder should now become free. Rest the motor at the bottom of the Ultimaker for now.[[File:UT_Extruder_Removal.jpeg|centre|800px]]
</ul></div>
 
 
 
==Removing the XY Carriage==
 
 
 
* Fully unscrew all four long vertical thumbscrews at the top of the carriage.
 
<div><ul>
 
<li style="display: inline-block; vertical-align: top"> [[File:UM2-XY-Carriage.jpg|left|thumb|Existing UM2 XY Carriage.]]
 
</ul></div>
 
* The upper and lower black layers in the plastic carriage should loosen easily so the bearings can be popped out sideways.
 
* Once the bearings are removed the carriage can be removed, piece by piece from the printer to work separately.
 
* The linear bearings will be left on the rails, we re-use them with the new XY Carriage.
 
 
 
==Removing Part Fans==
 
 
 
*Trace the wires from the two part fans back through the wiring loom about 150mm and disconnect at their plugs. The black net sleeving can be easily be peeled back.
 
*Unscrew both fans from the metal fan ducts and put the fans and screws by for later.
 
*Remove the 4 screws (or in my case only two) that hold the metal twin fan duct to the hot end heatsink block. The fan duct can now be removed.
 
<div><ul>
 
<li style="display: inline-block; vertical-align: top"> [[File:UM2-Fans.jpg|left|thumb|UM2 part cooling fans.]]
 
<li style="display: inline-block; vertical-align: top"> [[File:Fan-ducts.jpg|left|thumb|UM2 Fan Ducts.]]
 
</ul></div>
 
 
 
==Disassembling the Hot End==
 
<span style="color:red; font-weight:bold">Why is this happening? Surely the whole head just goes in the bin? All we want is to get the fans off..?</span>
 
*Remove Bowden tube from carriage by pushing down on the release collar.
 
*Unscrew the single fastener in the heater block with a phillips screwdriver.
 
*Remove the PT100 temperature sensor(smaller diameter) and the heater cartridge (larger diameter) with some small pliers.
 
*Remove the 4 screws that hold the end cooling fan onto the heat sink.
 
<div><ul>
 
<li style="display: inline-block; vertical-align: top"> [[File:Heater-Block-Screw.jpg|left|thumb|Unscrew the fastener in the heater block.]]
 
<li style="display: inline-block; vertical-align: top"> [[File:Remove-Cartridges.jpg|left|thumb|Pull out the PT100 thermocouple and heater cartridges]]
 
<li style="display: inline-block; vertical-align: top"> [[File:End-of-Loom.jpg|left|thumb|This should now be the carriage end of your loom]]
 
</ul></div>
 
*Trace the cooling fan wires back to through the loom and disconnect at the first plug (about 200mm away).
 
 
 
==Remove the Hot End Heating Components==
 
In this guide we are using a fully assembled E3D HotEnd which already has the a heating element and higher performance PT100 sensor installed.
 
 
 
* Turn the machine onto it's right side so that you can access the underside where you will see the white electronics board.
 
* Unscrew the 4x screws of the board with a hex key with access from the inside of the machine.
 
<span style="color:red; font-weight:bold">We need a photo of the 4 screws that need to be removed.</span>
 
<div><ul>
 
<li style="display: inline-block; vertical-align: top"> [[File:Removing-electronics-board.jpg|left|thumb|Access electronics board mounting screws from inside.]]
 
</ul></div>
 
*Careful not to loose the black plastic board spacers, remove the screws and rotate the board so the USB/power switch etc come easily away from the rear of the machine.
 
*Disconnect the PT100 temperature sensor plug and the heater cartridge wires. The heater wires are removed by pushing in the orange plungers on the green terminals with a flat screwdriver.
 
<div><ul>
 
<li style="display: inline-block; vertical-align: top"> [[File:Disconnect-Temp-Sensor.jpeg|left|thumb|Remove the PT100 thermocouple plug.]]
 
<li style="display: inline-block; vertical-align: top"> [[File:Disconnect-Heater.jpg|left|thumb|Disconnect the two heater wires from the terminals.]]
 
</ul></div>
 
* Once the heating components are removed from the board, it's easier to pull the larger cartridge through the wiring loom from the extruder end of the loom, and the smaller PT100 cartridge through the loom from the electronics end.
 
 
 
=Recap=
 
 
 
By now you should have these parts removed but saved for later :
 
*Cable Clips.
 
*2 x part fans.
 
*8 x part fan screws.
 
 
 
And these parts removed and available as "spares" :
 
*UM2 heater cartridge.
 
*UM2 PT100 temperature sensor.
 
*UM2 heat sink fan.
 
*UM2 metal double fan ducts.
 
*UM2 heat sink, heat block and nozzle.
 
*UM2 XY Carriage in 3 pieces.
 
*Some screws.
 
<div><ul>
 
<li style="display: inline-block; vertical-align: top"> [[File:Parts-removed.jpg|left|thumb|Parts removed at this stage]]
 
<li style="display: inline-block; vertical-align: top"> [[File:Parts-removed2.jpg|left|thumb|Parts removed at this stage]]
 
</ul></div>
 
 
 
=Assembly=
 
 
 
It is now time to work in reverse order, only you need to replace the UM2 parts with their E3D alternatives as well as using the 3D printed replacements.
 
==Assembling the Hot End Heating Components==
 
*Prepare the end of the heater wires by stripping back some cable insulation and the fibreglass sheathing.
 
*Plug the heater wires into the electronics board in the same place as the previous UM2 version.
 
*Plug in the PT100 thermocouple wires into the same place as the previous UM2 version.
 
*While the rear of the board is exposed, move the hot end cooling fan wires from the 5V pins to the 24V source as shown to provide the correct voltage for the E3D HotEnd heatsink fan. The positive pin is the one nearest the main power plug input on the side.
 
*Push the cartridges back though the wiring loom to the carriage end.
 
<div><ul>
 
<li style="display: inline-block; vertical-align: top"> [[File:Wires Stripped.jpg|left|thumb|Heater wires stripped and prepared.]]
 
<li style="display: inline-block; vertical-align: top"> [[File:Plug-In-Heater-Wires.jpeg|left|thumb|Re-position fan power from 5V to 24V and also connect heater wires.]]
 
<li style="display: inline-block; vertical-align: top> [[File:Plug-in-PT100-Thermocouple.jpg|left|thumb|Plug in the PT100 thermocouple.]]
 
</ul></div>
 
 
 
<br style="clear:both;">
 
 
 
==Assembling the XY Carriage==
 
 
 
The new printed XY Carriage is in 4 layers, Layer 1 is the bottom and layer 4 is the top. Layers 1 and 2 are the same part however layer 2 is orientated upside down. The HotEnd should be positioned in the front left quadrant of the smooth rod's crossover.
 
<div><ul>
 
<li style="display: inline-block; vertical-align: top"> [[File:Carriage-Layer1.jpg|left|thumb|Insert V6 HotEnd into hole in layer 1 and slide along groove mount first.]]
 
<li style="display: inline-block; vertical-align: top"> [[File:Carriage-Layer2.jpg|left|thumb|Layer 2 should slot over layer one and sandwich the bearing in place.]]
 
<li style="display: inline-block; vertical-align: top> [[File:Carriage-Layer3.jpg|left|thumb|Layer 3 should fit under the upper bearing.]]
 
<li style="display: inline-block; vertical-align: top> [[File:Carriage-Layer4.jpg|left|thumb|Layer 4 will sandwich the upper bearing onto layer 3.]]
 
<li style="display: inline-block; vertical-align: top> [[File:Carriage-All-Layers.jpg|left|thumb|Layers 1-2 can slide under layers 3-4 until the 4 long thumbscrews can be inserted down the corner holes.]]
 
</ul></div>
 
<br style="clear:both;">
 
* Insert the four long thumbscrews down the corner holes making sure there are washers under the heads.
 
* Install thumbscrews in the two front positions and one of the back positions. At the bottom of the screws use the M3 washers and Nuts.
 
** The missing screw at the back will give us space to attach the E3D HotEnd cooling fan duct later.
 
 
 
===HotEnd Cabling===
 
Time to take the opportunity to feed some cabling through the carriage for the HotEnd heater, thermocouple, HotEnd cooling fan and part cooling fans. The cabling should be fed before the HotEnd fan duct is in place.
 
* Feed the heater and PT100 cartridges down through the top hole.
 
* Feed the part cooling fan wires and the Hotend cooling fan wires from underneath up out the top and connect to the same loom connectors as the original UM2 versions.
 
* Clip the HotEnd fan and duct to the heatsink, carefully paying attention to not trap any wires. For this you will need to raise one of the rear thumb screws that you left un-nutted from above. Once clipped in, add this final washer and nut to the thumb screw.
 
  
==Assembling the Fan Ducts==
+
===E3D Titan Installation===
 +
For more information on the E3D Titan installation process, please visit the [http://wiki.e3d-online.com/wiki/Titan_Assembly E3D Titan Wiki Page].
 +
<!--We might have to modify this as we are supplying the pre assembled motor and pinion, maybe also worth explaining the motor wiring in this case-->
  
* Add another layer of nuts to the thumb screws until they sit around 5mm from the top of the threads to keep them out of the way. The will later be used to clamp the top of the printed fan ducts.
+
#Pass the M3x12mm screw through the hole in the curved groove of the Titan. Hold the supplied stepper motor in place where the original one was mouted with the connector side facing downwards towards the bottom of the printer. Secure the Titan and motor by passing the screw though the Ultimaker body as shown and tightening it into the motor. [[File:UT_Titan_Mount_1.jpeg|centre|800px]]
* Add each fan duct in turn, using 2x M3 washers on the top of the hole on each side.
+
#Mount the gear (with the longer shaft facing outwards), bowden adaptor (with the grey collet on the top side) and filament guide into the Titan body as shown. [[File:UT_Titan_Step_1.jpeg|centre|800px]]
* Finish off by adding the final layer of M3 washers and M3 nuts.  
+
#Screw the idler nut onto the idler screw, then slide the spring onto the screw. [[File:UT_Idler_Screw.jpeg|centre|500px]]
* Adjust the height of the fan ducts by adjusting the nut positions.
+
#Slide the idler lever onto the motor shaft then seat the idler screw and spring as shown. [[File:UT_Titan_Idler_Lever.jpeg|centre|800px]]
* Tighten up the nuts to hold the fan in position.  
+
#Slot the Titan lid onto the body assembly, this may require the body to be rotated to line up the motor shaft with its hole. The black gears shaft may also need to be pushed slightly to slot in. Screw the shorter M3x25mm screw into the top left corner hole in the Titan. [[File:UT_Titan_Short_Screw.jpeg|centre|500px]]
* Screw the part cooling fans to the printed fan ducts. The sticker on the fan must point into the duct so that air flows over the print.  
+
#Screw the longer M3x35mm screws into the other three holes. Make sure not to over-tighten the screw passing through the gear as this could damage the bearings during use. [[File:UT_Titan_Longer_Screws.jpeg|centre|500px]]
[[File:Assembled-Fan-Ducts.jpg|left|thumb|When finished, your fan ducts should be sandwiched with nuts on the thumb screws like this.]]
+
#Slide the bowden tube into the bowden adaptor, when secure it should not be able to be pulled out. [[File:UT_Bowden_Tube_2.jpeg|centre|500px]]
<br style="clear:both;">
 
  
==Moving the X Home Limit Switch==
+
==Electronics==
 +
===Accessing the Control Board===
 +
#Push the bed up to the top of the Ultimaker by pressing on it gently from below.
 +
#Carefully turn the Ultimaker onto its left side remembering that the old motor is still free to slide.
 +
#Remove the two screws pictured below being careful not to lose their corresponding nuts. This should allow the electronics cover to be removed. [[File:Electronics_Cover_Removal.jpeg|centre|800px]]
 +
#Remove the four screws shown below holding on the control board. Be careful not to lose the standoffs between the screws and the board. [[File:UT_Control_Board_Screws.jpeg|centre|800px]]
  
<span style="color:red; font-weight:bold">Why does this need to happen? Can't we flip the assembly to move the HE to the right hand side and thus remove this step entirely?</span>
+
===Wiring===
 +
#Once the electronics board is free from the frame we can begin removing the wiring of the original heoad. We wish to remove the wires from the pins labelled : TMP1, E1, Fan PWM, 5V. Using a flathead screwdriver, press down on the orange tabs for the two wires labelled HTR1 and pull the corresponding wires out. These connectors are shown below. [[File:UT_wiring_Removal.jpeg|centre|800px]]
 +
#Remove the old wiring loom by feeding the loose wires through the hole in the base of the printer. These can then be pulled out through the hole below the extruder.
 +
#Insert the new wiring loom though, through the hole beneath the extruder then through the hole in the base of the printer. Tuck the the loom behind the Titan underneath the idler lever. [[File:UT_wiring_insertion.jpeg|centre|800px]]
 +
#Plug in the extruder motor cable and run its wire through the hole in the base of the printer. [[File:UT_stepper_wire.jpeg|centre|500px]]
 +
#Insert the extruder motor cable into E1, this should only go in one way. [[File:UT_E1.jpeg|centre|500px]]
 +
#Insert the wire labelled 'Hotend Temp' into the 'TEMP1' socket. This can go either way around. [[File:UT_PT100.jpeg|centre|500px]]
 +
#Insert the wires labelled 'Heater' into the two sockets with the label 'HEATER1', when secure these should not be able to be pulled out. The wires can go either way around. [[File:UT_heater.jpeg|centre|500px]]
 +
#Inset the wire labelled 'Part Cooling Fan' into the 'FAN PWM' socket, this should only go in one way around. [[File:UT_part_fan.jpeg|centre|500px]]
 +
#Insert the wire labelled 'Heatsink Fan' into the '24V' pins shown below by the heater cables. This should go with the black negative wire on the outside of the board. [[File:UT_heatsink_fan.jpeg|centre|500px]]
  
Due to the modified geometry of the XY carriage it is necessary to reposition the X home limit switch by 10mm. It is found inside at the rear left top of the machine .
+
===Finishing Up===
*Remove the existing X home limit switch by unscrewing the two screws.
+
#Run the four electronics board screws through their holes and place the four standoffs onto them on the other side. Place the electronics board above them being careful not to trap any wires and screw the in the four screws to secure the board. [[File:UT_Board_Replace.jpeg|centre|800px]]
*Placing the limit switch in the new printed holder.
+
#Run the two electronics cover screws though their holes. Position the electronics cover into place by aligning its tabs into the sides of the printer, be careful not to trap any loose wires, the wires shown below should run through the small cutout in the cover. Place the bolts onto the screws and tighten to secure the cover. [[File:UT_Cover_Replace.jpeg|centre|800px]]
*Re-attach screws into new plastic holes in holder.
+
#Replace the motor cover again being sure not to trap any wires and screw its two screws in from the back of the printer to secure it. [[File:UT_Motor_Cover_Replace.jpeg|centre|800px]]
<div><ul>
+
This completes the physical part of the installation.
<li style="display: inline-block; vertical-align: top> [[File:Limit-Switch-Removal.jpg|left|thumb|Unscrew X home limit switch.]]
 
<li style="display: inline-block; vertical-align: top> [[File:Printed_X_Limit_Switch_Extender.jpeg|left|thumb|Place limit switch in printed holder.]]
 
<li style="display: inline-block; vertical-align: top> [[File:Limit-Switch-Installed.jpg|left|thumb|Screw into holes in new holder.]]
 
</ul></div>
 
<br style="clear:both;">
 
  
==Switching out the Extruder==
+
=Firmware and Printing Settings=
 +
You must update the Ultimaker firmware for the upgrade to function correctly. To update the firmware, '''Cura Version 15''' or earlier is required. This can be downloaded [https://ultimaker.com/en/products/cura-software/list here].
  
*Retract all of the filament from the extruder.
+
#Begin by downloading the appropriate E3D Ultimaker 2 Series Upgrade Kit Firmware for your printer.
*Push down on the collar to remove Bowden tube from extruder.
+
##[[https://github.com/e3donline/E3DUltimaker/blob/master/Marlin_E3D_Ultimaker_2.hex E3D Ultimaker 2/2+ Firmware]]
*Remove the 4 screws which holds the extruder onto the body of the motor.
+
<!--##[[File:Marlin_E3D_Ultimaker_2_Extended_Extended+.hex|E3D Ultimaker 2 Extended/Extended+ Firmware]]-->
*Remove the knurled drive from the motor shaft by unscrewing the set screw. If you cannot remove the knurled drive from the existing extruder motor then it will have to be swapped out with a new NEMA 17 motor
+
#Switch on your Ultimaker and plug it into your computer, if you have not already done so, factory reset the printer by following the factory reset steps in the [[#Preparation|Preparation]] section. do not run through the startup wizard just yet.
*Pre-assemble the E3D-Extruder according to the official documentation: [[Titan_Assembly]]
+
#Load up Cura as you normally would for printing on the Ultimaker. Make sure you have the correct printer selected by going to the '''Machine''' menu and selecting your printer. If it is not present, got to '''Machine''' > '''Add new machine...''' and run through the steps selecting your printer from the list.
*Fit extruder to the motor and screw through the rear panel.
+
#Navigate to the '''Machine''' menu, then click '''Install custom firmware...'''. Click OK to dismiss any warnings which pop up. [[File:UT_firmware_1.png|centre|800px]]
<div><ul>
+
#Navigate to  and open the firmware hex file downloaded from the above link. [[File:UT_firmware_2.png|centre|800px]]
<li style="display: inline-block; vertical-align: top> [[File:UM2-Original-Extruder.jpg|left|thumb|Remove the 4 screws.]]
+
#When the firmware update is complete the printer should restart. Run through the startup wizard steps on the printer to calibrate your printer to the new head.
<li style="display: inline-block; vertical-align: top> [[File:UM2-Knurled-Drive.jpg|left|thumb|Remove the knurled drive from the motor shaft.]]
 
<li style="display: inline-block; vertical-align: top> [[File:Fitted-E3D-Extruder.jpeg|left|thumb|Fitted E3D-Extruder.]]
 
</ul></div>
 
  
<br style="clear:both;">
+
==Firmware Changes==
 
+
The edits required to the Ultimaker 2 firmware after updating to the E3D HotEnd and Extruder combo are outlined here. If you have downloaded the modified firmware directly, you do not require to do this step. These are taken directly from the original guide by Steve wood, which can be found [http://wiki.e3d-online.com/wiki/E3D-v6_on_Ultimaker_2 here].<br />
=Firmware Changes=
 
Edits are required to the Ultimaker 2 firmware after updating to the E3D HotEnd and Extruder combo.<br />
 
 
These updates are built upon a download from the [https://github.com/Ultimaker/Ultimaker2Marlin official firmware] taken on 29th January 2016.<br />
 
These updates are built upon a download from the [https://github.com/Ultimaker/Ultimaker2Marlin official firmware] taken on 29th January 2016.<br />
 
There are 3 options for uploading the necessary firmware changes into your Ultimaker 2:
 
There are 3 options for uploading the necessary firmware changes into your Ultimaker 2:
#You can upload custom firmware via the Cura slicing software, if this is your preferred option then you can [http://www.thingiverse.com/download:2088491 download a previously compiled custom firmware] for this.<br />
+
#You can upload custom firmware via the Cura slicing software, if this is your preferred option then you can [https://github.com/e3donline/E3DUltimaker/blob/master/Marlin_E3D_Ultimaker_2.hex download a previously compiled custom firmware] for this.<br />
#Here are the modified [http://www.thingiverse.com/download:2088495 Marlin source files.] for compiling yourself using the Arduino software.
+
#Here are the modified [https://github.com/e3donline/E3DUltimaker Marlin source files.] for compiling yourself using the Arduino software. This is the preferred option as it enables you to upload the latest version of the firmware relevant to your machine.  
 
#If you are running your own modified firmware and want to know what lines to change in the "configuration.h" file then here are the edits:
 
#If you are running your own modified firmware and want to know what lines to change in the "configuration.h" file then here are the edits:
  
Line 215: Line 154:
  
 
  // default steps per unit for Ultimaker2 and E3D Extruder
 
  // default steps per unit for Ultimaker2 and E3D Extruder
  #define DEFAULT_AXIS_STEPS_PER_UNIT  {80.0,80.0,200,456}
+
  #define DEFAULT_AXIS_STEPS_PER_UNIT  {80.0,80.0,200,417.5}
 
  #define DEFAULT_MAX_FEEDRATE          {300, 300, 40, 20}    // (mm/sec)
 
  #define DEFAULT_MAX_FEEDRATE          {300, 300, 40, 20}    // (mm/sec)
 
  #define DEFAULT_MAX_ACCELERATION      {9000,9000,100,3000}    // X, Y, Z, E maximum start speed for accelerated moves. E default values are good for skeinforge 40+, for older versions raise them a lot.
 
  #define DEFAULT_MAX_ACCELERATION      {9000,9000,100,3000}    // X, Y, Z, E maximum start speed for accelerated moves. E default values are good for skeinforge 40+, for older versions raise them a lot.
 
  
 
I turned off EEPROM support by commenting out the following lines, otherwise you will not see the changes:
 
I turned off EEPROM support by commenting out the following lines, otherwise you will not see the changes:
 
  //#define EEPROM_SETTINGS
 
  //#define EEPROM_SETTINGS
 
  //#define EEPROM_CHITCHAT
 
  //#define EEPROM_CHITCHAT
 +
This does require that the print surface be re-calibrated upon restart.
 +
 +
 +
The Bowden retraction settings should be changed if the filament change function is to work properly after the upgrade. These settings are found in the "UltiLCD2_menu_material.h" file. Here are the variables that need to be changed and their new value:
 +
 +
#define FILAMENT_REVERSAL_LENGTH      (FILAMANT_BOWDEN_LENGTH + 150)
 +
 +
#define FILAMENT_REVERSAL_SPEED      75
 +
 +
#define FILAMENT_INSERT_FAST_SPEED    75  // Speed during the forward length
  
'''A Warning : '''The later Ultimaker 2 firmware (after v14.09) has a temperature "safety feature" built in, which has been notoriously sensitive. It seems like it is overly sensitive and an E3D HotEnd doesn't conform to it's expected heat up and cool down cycles. The result is a common "ERROR - STOPPED Heater error" on the display panel and a failed print. The part cooling fans can often trigger this error because they can blow air onto the nozzle heater block and cause temperature fluctuations.<br />
+
'''A Warning : '''The later Ultimaker 2 firmware (after v14.09) has a temperature "safety feature" built in, which has been notoriously sensitive. It seems like it is overly sensitive and an E3D HotEnd doesn't conform to it's expected heat up and cool down cycles. The result is a common "ERROR - STOPPED Heater error" on the display panel and a failed print. The part cooling fans can often trigger this error because they can blow air onto the nozzle heater block and cause temperature fluctuations. Although the silicon sock provided in the kit should reduce this, it is still a recurring issue.<br />
 
<div><ul>
 
<div><ul>
 
<li style="display: inline-block; vertical-align: top"> [[File:Stop-Heater-Error.jpeg|thumb|left|The fabled "ERROR - STOPPED Heater error".]] </li>
 
<li style="display: inline-block; vertical-align: top"> [[File:Stop-Heater-Error.jpeg|thumb|left|The fabled "ERROR - STOPPED Heater error".]] </li>
Line 239: Line 187:
 
  //            Stop(STOP_REASON_HEATER_ERROR);
 
  //            Stop(STOP_REASON_HEATER_ERROR);
  
=Gallery of Finished Conversion=
+
This concludes the upgrade process, you should now have a fully working E3D HotEnd on your Ultimaker 2 series printer!
<div>
+
 
[[File:UM2-Gallery1.jpg|left|thumb|]]
+
==E3D Edge Filament==
[[File:UM2-Gallery2.jpg|left|thumb|]]
+
The upgrade kit is supplied with a sample of E3D's Edge filament. In order to print with this material on the Ultimaker, a profile must be set up. This can be done in two ways:
[[File:UM2-Gallery3.jpg|left|thumb|]]
+
 
[[File:UM2-Gallery4.jpg|left|thumb|]]
+
Download the [[File:MATERIAL.TXT|E3D Edge Ultimaker Profile]] and place this onto an SD card. Insert this into your Ultimaker then navigate to '''MATERIAL > SETTINGS > Import form SD''' on the interface. EDGE should now be present in the list.
[[File:UM2-Gallery5.jpg|left|thumb|]]
+
 
[[File:UM2-Gallery6.jpg|left|thumb|]]
+
If you would prefer, you can create a custom material profile directly on the printer instead by following the instructions in the next section.
[[File:UM2-Gallery7.jpg|left|thumb|]]
+
 
[[File:UM2-Gallery8.jpg|left|thumb|]]
+
==Recommended Cura Settings==
</div>
+
This upgrade kit now allows you to print with a much wider range of materials. However, the standard Ultimaker settings might not prove satisfactory. In Cura 2.1.3, these can be found in the "Advanced" section. Here are our recommended settings for the most common materials used (0.4mm diameter standard nozzle):
 +
 
 +
'''Quality'''
 +
*Layer Height: 0.25mm
 +
*Initial Layer Height: 0.3mm
 +
*Line Width: 0.48
 +
'''Shell'''
 +
*Wall thickness: 1.2
 +
*Top/Bottom Thickness: 0.75
 +
*Horizontal Expansion: 0
 +
'''Infill'''
 +
*Infill Density: 25%
 +
*Infil Pattern: Grid
 +
*Disable Infill Before Walls
 +
'''Material'''
 +
*Enable Retraction
 +
*Retraction Minimum Travel: 1.5mm
 +
'''Speed'''
 +
*Print Speed: 50mm/s
 +
*Infill Speed: 40mm/s
 +
*Wall Speed: 25mm/s
 +
*Outer Wall Speed: 15mm/s
 +
*Inner Wall speed: 20mm/s
 +
*Travel Speed: 120mm/s
 +
*Initial Layer Speed: 15mm/s
 +
*Number of Slower Layers: 2
 +
'''Travel'''
 +
*Disable Combing
 +
'''Cooling'''
 +
*Enable Cooling Fans
 +
 
 +
==Recommended Material Settings==
 +
On your Ultimaker, go to '''MATERIAL > SETTINGS > Customize''' and input the following settings depending on the material you are planning on using.
 +
Then select '''Store as preset > New preset'''. Note this will be called something like 'CUSTOM1' rather than 'EDGE'.
 +
 
 +
'''E3D's Edge'''
 +
*Temperature: 240C
 +
*Heated buildplate: 80C
 +
*Diameter: 2.85mm
 +
*Fan: 100%
 +
*Flow %: 95%
 +
*Retraction Distance: 2.00mm
 +
 
 +
Standard materials also have slightly different optimal values with your E3D V6 hotend and Titan Extruder:
 +
 
 +
'''PLA'''
 +
*Temperature: 220C
 +
*Heated buildplate: 60C
 +
*Diameter: 2.85mm
 +
*Fan: 100%
 +
*Flow %: 95%
 +
*Retraction Distance: 2.00mm
 +
 
 +
'''ABS'''
 +
*Temperature: 240C
 +
*Heated buildplate: 100C
 +
*Diameter: 2.85mm
 +
*Fan: 100%
 +
*Flow %: 95%
 +
*Retraction Distance: 2.00mm

Revision as of 10:37, 27 September 2016

Ultimaker 2 with E3D Upgrade Kit.

This page provides a full guide to installing the E3D Ultimaker 2 Upgrade Kit, including the E3D Titan Extruder and V6 HotEnd into your Ultimaker 2 Series 3D printer.

This upgrade kit is compatible with:

  • Ultimaker 2/ Ultimaker 2 Extended
  • Ulimaker 2+/ Ultimaker 2 Extended+

This article is a companion to the Video Guide by Thomas Sanladerer showing the upgrade process. It is recommended to follow this page and his guide in tandem. Read the Preparation section before beginning the installation process.

Ensure your printer is switched off, disconnected from the power supply and cooled down before handling.

This guide is based on work originally written by Steve Wood of Gyrobot, many thanks for his contribution.

Requirements

Upgrade Kit Contents

Kit Contents
  • E3D Titan Extruder Kit
    • 3mm Groove Mount Bowden Adaptor
    • PTFE Bowden Tubing
    • NEMA 17 Stepper Motor with Cable
  • E3D V6 HotEnd 3mm Bowden - 24V, 30W, PT100
    • Wiring Loom and Braided Sleeve
    • V6 Nozzle Fun Pack
    • V6 Silicone Sock
  • Printed Parts
    • Four Layer Adaptor Body
    • 2x Fan Duct
    • Bowden Depressor Tool
  • Fixings
    • 12 x M3 Nut
    • 16 x M3 Washer
  • E3D Edge Sample Filament
  • Allen Keys

Tools Required

  • Pliers or 7mm Hex Wrench
  • Small Phillips-Head Screwdriver
  • Allen Keys (Included)

Preparation

  1. Begin by removing the filament from the printer in the normal manner used for Changing Filament but do not insert a new spool, simply continue through the process pressing OK at each stage.
  2. Wait for the HotEnd to cool back down, you can check this by going to MAINTENANCE > ADVANCED > Heatup nozzle. If the second temperature (eg. 27C/0C) is not already at 0C, rotate the dial to set this, wait for the first temperature to reach room temperature (eg. 27C/0C).
  3. Factory reset your printer by scrolling to MAINTENANCE > ADVANCED > Factory Reset and press YES. When the setup wizard loads, do not run through it, instead switch the printer off.
    UT Reset.jpeg
  4. Disconnect the power supply.

Installation

Printhead

Ultimaker Printhead Dissassembly

  1. Lower the bed by pressing down on it gently until it reaches the bottom.
  2. Unscrew both of the part cooling fans from the Ultimaker head, save the screws as we will use them later.
    Fan Unscrew.jpeg
  3. Remove the bowden clip from the bowden collet.
    Bowden Clip Removal.jpeg
  4. Press down on the bowden collet with your fingernails or the bowden removal tool, then pull upwards on the tube, it should slide out.
    Bowden Removal.jpeg
  5. Unscrew the four long thumbscrews holding the Ultimaker printhead together, keep these as we will use them later.
    Screw Removal.jpeg
  6. Carefully remove the rail from it's bracket on the left side by pulling up on it using the bracket for leverage.
    Rail Removal Dual.jpeg
  7. The lower and upper sections of the Ultimaker printhead should now be free from the assembly.
    Upper-Lower Section Free.jpeg
  8. Gently lift the rail and slide out the middle section from its bearings. The head assembly should now be free from the rails. If wires remain tangled, one side of the other rail may need to be unclipped from its bracket in a similar manner to free them.
    Middle Section Free.jpeg
  9. Detach all of the connectors from the Ultimaker head, keep the two 30x30mm part cooling fans as we will use them in the next section.
    Cable Disconnection.jpeg

E3D Printhead Assembly

  1. Take the two 30x30mm part cooling fans we saved from the Original Ultimaker Printhead. Screw these into the two printed fan ducts with the label on the inside and the wiring exiting from the tallest side of the duct as shown.
    Fan Screw.jpeg
  2. Carefully turn the printer onto its right side.
  3. Slot the first section of the new printhead into the lower bearing as shown.
    Layer 1.jpeg
  4. Pass the cables for the two part cooling fans and the heatsink fan though the wiring hole in the first section of the printhead, hold these in place for the next few steps.
    Fan Cables.jpeg
  5. Pass the wires though the second section (light grey) of the printhead as show then slot it over the bearing. Pass the wires thought the third (dark grey) section as shown.
    Layer 2-3.jpeg
  6. Gently lift the upper rail and slot the third section into the upper bearing as shown. Slot the rail back into its bracket when complete.
    Layer 3.jpeg
  7. Pass the wires though the top (black) section and slot it over the upper bearing.
    Layer 4.jpeg
  8. Slot the four long thumb screws from the original Ultimaker printhead through the four holes in the new printhead with washers between the screws and printed parts as shown.
    UT Screw Dual.jpeg
  9. Connect the wiring loom to the cables from the printhead, each connector should only go in one way.
    UT Connectors.jpeg
  10. Add a washer then nut to the other side of the bolts and tighten with pliers or a hex wrench.
    UT Nuts 1.jpeg
  11. Add another nut to each bolt then slot the heatsink fan onto the back of the heatsink with the cutout side of the fan bracket facing towards the top. The bottom flat surface of the fan bracket should align with the bottom of the heatsink. The wires should be routed around the sides of the bracket as shown below (viewed from the top right), running through the fan bracket cutout channel when installed.
    UT heatsink fan detailed.jpeg
  12. Add a washer to each bolt then slot the part cooling fan assemblies onto the bolts as shown, onto the left and right sides.
    UT Nuts 2 Part Fan.jpeg
  13. Add a final washer and nut to secure the part cooling fan assemblies and tighten. Ensure they do not go below the level of the nozzle to avoid fouling during printing.
    UT Nuts 3.jpeg
  14. Insert the new bowden tube into it's collet as shown. When properly seated it should not be able to be pulled out.
    UT Bowden Dual.jpeg
  15. Slide the braided sleeve down over the connectors and into the top of the printhead.
    UT Braided Sleeve.jpeg
  16. Remove the bowden clips from the original Ultimaker wiring loom and attach them to the braided sleeve and bowden tube of the new loom as shown.
    UT Bowden Clips Dual.jpeg

Extruder

Ultimaker Extruder Dissembly

  1. Remove the two screws shown below from the back of the Ultimaker.
    Motor Cover Screws.jpeg
  2. It should now be possible to remove the motor cover.
    Motor Cover Removal.jpeg
  3. Remove the bowden clip form the original Ultimaker extruder using your fingernail or a screwdriver.
    UT Extruder Bowden Clip.jpeg
  4. Hold the motor in place from the front and remove the four screws in the extruder shown below. The motor and extuder should now become free. Rest the motor at the bottom of the Ultimaker for now.
    UT Extruder Removal.jpeg

E3D Titan Installation

For more information on the E3D Titan installation process, please visit the E3D Titan Wiki Page.

  1. Pass the M3x12mm screw through the hole in the curved groove of the Titan. Hold the supplied stepper motor in place where the original one was mouted with the connector side facing downwards towards the bottom of the printer. Secure the Titan and motor by passing the screw though the Ultimaker body as shown and tightening it into the motor.
    UT Titan Mount 1.jpeg
  2. Mount the gear (with the longer shaft facing outwards), bowden adaptor (with the grey collet on the top side) and filament guide into the Titan body as shown.
    UT Titan Step 1.jpeg
  3. Screw the idler nut onto the idler screw, then slide the spring onto the screw.
    UT Idler Screw.jpeg
  4. Slide the idler lever onto the motor shaft then seat the idler screw and spring as shown.
    UT Titan Idler Lever.jpeg
  5. Slot the Titan lid onto the body assembly, this may require the body to be rotated to line up the motor shaft with its hole. The black gears shaft may also need to be pushed slightly to slot in. Screw the shorter M3x25mm screw into the top left corner hole in the Titan.
    UT Titan Short Screw.jpeg
  6. Screw the longer M3x35mm screws into the other three holes. Make sure not to over-tighten the screw passing through the gear as this could damage the bearings during use.
    UT Titan Longer Screws.jpeg
  7. Slide the bowden tube into the bowden adaptor, when secure it should not be able to be pulled out.
    UT Bowden Tube 2.jpeg

Electronics

Accessing the Control Board

  1. Push the bed up to the top of the Ultimaker by pressing on it gently from below.
  2. Carefully turn the Ultimaker onto its left side remembering that the old motor is still free to slide.
  3. Remove the two screws pictured below being careful not to lose their corresponding nuts. This should allow the electronics cover to be removed.
    Electronics Cover Removal.jpeg
  4. Remove the four screws shown below holding on the control board. Be careful not to lose the standoffs between the screws and the board.
    UT Control Board Screws.jpeg

Wiring

  1. Once the electronics board is free from the frame we can begin removing the wiring of the original heoad. We wish to remove the wires from the pins labelled : TMP1, E1, Fan PWM, 5V. Using a flathead screwdriver, press down on the orange tabs for the two wires labelled HTR1 and pull the corresponding wires out. These connectors are shown below.
    UT wiring Removal.jpeg
  2. Remove the old wiring loom by feeding the loose wires through the hole in the base of the printer. These can then be pulled out through the hole below the extruder.
  3. Insert the new wiring loom though, through the hole beneath the extruder then through the hole in the base of the printer. Tuck the the loom behind the Titan underneath the idler lever.
    UT wiring insertion.jpeg
  4. Plug in the extruder motor cable and run its wire through the hole in the base of the printer.
    UT stepper wire.jpeg
  5. Insert the extruder motor cable into E1, this should only go in one way.
    UT E1.jpeg
  6. Insert the wire labelled 'Hotend Temp' into the 'TEMP1' socket. This can go either way around.
    UT PT100.jpeg
  7. Insert the wires labelled 'Heater' into the two sockets with the label 'HEATER1', when secure these should not be able to be pulled out. The wires can go either way around.
    UT heater.jpeg
  8. Inset the wire labelled 'Part Cooling Fan' into the 'FAN PWM' socket, this should only go in one way around.
    UT part fan.jpeg
  9. Insert the wire labelled 'Heatsink Fan' into the '24V' pins shown below by the heater cables. This should go with the black negative wire on the outside of the board.
    UT heatsink fan.jpeg

Finishing Up

  1. Run the four electronics board screws through their holes and place the four standoffs onto them on the other side. Place the electronics board above them being careful not to trap any wires and screw the in the four screws to secure the board.
    UT Board Replace.jpeg
  2. Run the two electronics cover screws though their holes. Position the electronics cover into place by aligning its tabs into the sides of the printer, be careful not to trap any loose wires, the wires shown below should run through the small cutout in the cover. Place the bolts onto the screws and tighten to secure the cover.
    UT Cover Replace.jpeg
  3. Replace the motor cover again being sure not to trap any wires and screw its two screws in from the back of the printer to secure it.
    UT Motor Cover Replace.jpeg

This completes the physical part of the installation.

Firmware and Printing Settings

You must update the Ultimaker firmware for the upgrade to function correctly. To update the firmware, Cura Version 15 or earlier is required. This can be downloaded here.

  1. Begin by downloading the appropriate E3D Ultimaker 2 Series Upgrade Kit Firmware for your printer.
    1. [E3D Ultimaker 2/2+ Firmware]
  2. Switch on your Ultimaker and plug it into your computer, if you have not already done so, factory reset the printer by following the factory reset steps in the Preparation section. do not run through the startup wizard just yet.
  3. Load up Cura as you normally would for printing on the Ultimaker. Make sure you have the correct printer selected by going to the Machine menu and selecting your printer. If it is not present, got to Machine > Add new machine... and run through the steps selecting your printer from the list.
  4. Navigate to the Machine menu, then click Install custom firmware.... Click OK to dismiss any warnings which pop up.
    UT firmware 1.png
  5. Navigate to and open the firmware hex file downloaded from the above link.
    UT firmware 2.png
  6. When the firmware update is complete the printer should restart. Run through the startup wizard steps on the printer to calibrate your printer to the new head.

Firmware Changes

The edits required to the Ultimaker 2 firmware after updating to the E3D HotEnd and Extruder combo are outlined here. If you have downloaded the modified firmware directly, you do not require to do this step. These are taken directly from the original guide by Steve wood, which can be found here.
These updates are built upon a download from the official firmware taken on 29th January 2016.
There are 3 options for uploading the necessary firmware changes into your Ultimaker 2:

  1. You can upload custom firmware via the Cura slicing software, if this is your preferred option then you can download a previously compiled custom firmware for this.
  2. Here are the modified Marlin source files. for compiling yourself using the Arduino software. This is the preferred option as it enables you to upload the latest version of the firmware relevant to your machine.
  3. If you are running your own modified firmware and want to know what lines to change in the "configuration.h" file then here are the edits:
// increase the maximum temperature for the E3D V6 HotEnd
#define HEATER_0_MAXTEMP 400
// PID values for Ultimaker2 with E3D HotEnd
#define  DEFAULT_Kp 36.59
#define  DEFAULT_Ki 3.65
#define  DEFAULT_Kd 91.72
// travel extents have reduced slightly for E3D HotEnd
#define X_MAX_POS 215 // For E3D HotEnd
#define Y_MAX_POS 210 // For E3D HotEnd
#define INVERT_E0_DIR true   // for direct drive extruder v9 set to true, for geared extruder set to false
// default steps per unit for Ultimaker2 and E3D Extruder
#define DEFAULT_AXIS_STEPS_PER_UNIT   {80.0,80.0,200,417.5}
#define DEFAULT_MAX_FEEDRATE          {300, 300, 40, 20}    // (mm/sec)
#define DEFAULT_MAX_ACCELERATION      {9000,9000,100,3000}    // X, Y, Z, E maximum start speed for accelerated moves. E default values are good for skeinforge 40+, for older versions raise them a lot.

I turned off EEPROM support by commenting out the following lines, otherwise you will not see the changes:

//#define EEPROM_SETTINGS
//#define EEPROM_CHITCHAT

This does require that the print surface be re-calibrated upon restart.


The Bowden retraction settings should be changed if the filament change function is to work properly after the upgrade. These settings are found in the "UltiLCD2_menu_material.h" file. Here are the variables that need to be changed and their new value:

#define FILAMENT_REVERSAL_LENGTH      (FILAMANT_BOWDEN_LENGTH + 150)
#define FILAMENT_REVERSAL_SPEED       75
#define FILAMENT_INSERT_FAST_SPEED    75   // Speed during the forward length

A Warning : The later Ultimaker 2 firmware (after v14.09) has a temperature "safety feature" built in, which has been notoriously sensitive. It seems like it is overly sensitive and an E3D HotEnd doesn't conform to it's expected heat up and cool down cycles. The result is a common "ERROR - STOPPED Heater error" on the display panel and a failed print. The part cooling fans can often trigger this error because they can blow air onto the nozzle heater block and cause temperature fluctuations. Although the silicon sock provided in the kit should reduce this, it is still a recurring issue.

  • The fabled "ERROR - STOPPED Heater error".

The following lines in the "configuration.h" file control the parameters of this "safety feature". I have tried many combinations of these values with little effect.

#define MAX_HEATING_TEMPERATURE_INCREASE 10
#define MAX_HEATING_CHECK_MILLIS (30 * 1000)

If you want to disable this feature like it was back in v14.09 then you can comment out the following lines in the "temperature.cpp" file at your own risk:

// Commented out for UM2 because too sensitive for E3D HotEnd           
//            disable_heater();
//            Stop(STOP_REASON_HEATER_ERROR);

This concludes the upgrade process, you should now have a fully working E3D HotEnd on your Ultimaker 2 series printer!

E3D Edge Filament

The upgrade kit is supplied with a sample of E3D's Edge filament. In order to print with this material on the Ultimaker, a profile must be set up. This can be done in two ways:

Download the E3D Edge Ultimaker Profile and place this onto an SD card. Insert this into your Ultimaker then navigate to MATERIAL > SETTINGS > Import form SD on the interface. EDGE should now be present in the list.

If you would prefer, you can create a custom material profile directly on the printer instead by following the instructions in the next section.

Recommended Cura Settings

This upgrade kit now allows you to print with a much wider range of materials. However, the standard Ultimaker settings might not prove satisfactory. In Cura 2.1.3, these can be found in the "Advanced" section. Here are our recommended settings for the most common materials used (0.4mm diameter standard nozzle):

Quality

  • Layer Height: 0.25mm
  • Initial Layer Height: 0.3mm
  • Line Width: 0.48

Shell

  • Wall thickness: 1.2
  • Top/Bottom Thickness: 0.75
  • Horizontal Expansion: 0

Infill

  • Infill Density: 25%
  • Infil Pattern: Grid
  • Disable Infill Before Walls

Material

  • Enable Retraction
  • Retraction Minimum Travel: 1.5mm

Speed

  • Print Speed: 50mm/s
  • Infill Speed: 40mm/s
  • Wall Speed: 25mm/s
  • Outer Wall Speed: 15mm/s
  • Inner Wall speed: 20mm/s
  • Travel Speed: 120mm/s
  • Initial Layer Speed: 15mm/s
  • Number of Slower Layers: 2

Travel

  • Disable Combing

Cooling

  • Enable Cooling Fans

Recommended Material Settings

On your Ultimaker, go to MATERIAL > SETTINGS > Customize and input the following settings depending on the material you are planning on using. Then select Store as preset > New preset. Note this will be called something like 'CUSTOM1' rather than 'EDGE'.

E3D's Edge

  • Temperature: 240C
  • Heated buildplate: 80C
  • Diameter: 2.85mm
  • Fan: 100%
  • Flow %: 95%
  • Retraction Distance: 2.00mm

Standard materials also have slightly different optimal values with your E3D V6 hotend and Titan Extruder:

PLA

  • Temperature: 220C
  • Heated buildplate: 60C
  • Diameter: 2.85mm
  • Fan: 100%
  • Flow %: 95%
  • Retraction Distance: 2.00mm

ABS

  • Temperature: 240C
  • Heated buildplate: 100C
  • Diameter: 2.85mm
  • Fan: 100%
  • Flow %: 95%
  • Retraction Distance: 2.00mm