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    How to replace the door sensor (CORE One)

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    How to replace the door sensor (CORE One)

    How to replace the door sensor (CORE One)
    Relevant for:
    CORE One
    Last updated 2 days ago
    How to replace the door sensor (CORE One)
     Difficulty
    Difficult
     Steps
    27
     Available languages

    Step 1 Introduction

    Introduction
    Introduction
    Introduction
    ⬢This guide will take you through the Door Sensor replacement on your Prusa CORE One.
    ⬢All necessary parts are available in our eshop prusa3d.com.
    Note that you have to be logged in to have access to the spare parts section.
    Warning: You will be handling metal sheets in this guide. Be careful!

    Step 2 Tools necessary for this guide

    Tools necessary for this guide
    Tools necessary for this guide
    Tools necessary for this guide
    ⬢Please prepare tools for this guide:
    ⬢2mm Allen key
    ⬢2.5mm Allen key
    ⬢T10 Torx key
    ⬢Flush cutters are recommended as an optional tool.

    Step 3 Printer Preparation

    Printer Preparation
    Printer Preparation
    Printer Preparation
    ⬢On the printer, visit the menu Control and trigger the Auto Home.
    ⬢Turn the printer off using the switch on the back.
    ⬢Disconnect the printer from power.

    Step 4 Side Cover Removal

    Side Cover Removal
    Side Cover Removal
    Side Cover Removal
    ⬢Remove the five Nylon rivets holding the plastic side cover.
    ⬢We recommend using flush cutters to lift the top part of the rivet, unlocking it. Then, remove the bottom part of the rivet.
    ⬢Remove the plastic side cover.

    Step 5 Side Panel Removal

    Side Panel Removal
    Side Panel Removal
    ⬢Remove the marked Nylon rivets holding the Side Sheet Metal Panel.
    ⬢Remove the panel.

    Step 6 Front Panel Disengage

    Front Panel Disengage
    Front Panel Disengage
    Front Panel Disengage
    ⬢Lift the front sheet metal panel with the LCD upward on the right side to unhook it from the corner profile.
    The panel is held by magnets.
    ⬢

    Once unhooked from the corner profile, pull the panel forward slightly to keep it unhooked.

    Be very careful when moving the front panel assembly, as there are cables connected to the LCD. Ensure you do not disconnect or damage them!
    ⬢Move the front panel assembly to the right. Move it just so that you gain access to the two screws on the left.

    Step 7 Corner Profile Removal (Part 1)

    Corner Profile Removal (Part 1)
    Corner Profile Removal (Part 1)
    Corner Profile Removal (Part 1)
    ⬢On the side of the printer, remove the three screws holding the corner profile.
    ⬢From the front of the printer, remove only the two marked screws securing the corner profile.

    Step 8 Corner Profile Removal (Part 2)

    Corner Profile Removal (Part 2)
    Corner Profile Removal (Part 2)
    Corner Profile Removal (Part 2)
    Corner Profile Removal (Part 2)
    ⬢Leave the top screw holding the corner profile in place for now.
    ⬢Notice the door switch lever poking through an opening in the profile.
    ⬢

    Hold the printer’s door with one hand while removing the top screw holding the profile.

    After removing the screw, carefully unhook the corner profile from the top part, ensuring the door switch is not damaged during the process.

    ⬢Then, remove the corner profile along with the door, ensuring the lever of the door switch is not damaged.

    Step 9 Back Cover Removal (Part 1)

    Back Cover Removal (Part 1)
    Back Cover Removal (Part 1)
    Back Cover Removal (Part 1)
    ⬢On the inside of the printer, remove the two screws holding the back cover.
    ⬢On the back of the printer, slide the center cover downwards.
    If it’s difficult to move, use a screwdriver as a lever through the opening to assist.
    ⬢Ensure the four hooks on top of the cover are disengaged from the metal chassis.

    Step 10 Back Cover Removal (Part 2)

    Back Cover Removal (Part 2)
    Back Cover Removal (Part 2)
    Back Cover Removal (Part 2)
    Back Cover Removal (Part 2)
    ⬢Move the cover slightly towards the back.
    ⬢Pull the bottom part of the cover outward while tilting the top toward the printer. This will unhook it from the cable bundle behind.

    Step 12 Cable Disconnecting

    Cable Disconnecting
    Cable Disconnecting
    Cable Disconnecting
    ⬢Locate the door switch cable connected to the A_TEMP connector on the xBuddy board.
    ⬢Disconnect the cable from the connector.
    Note that the connector has a safety latch that must be pressed to disconnect it.
    ⬢Carefully cut the zip ties securing the cable bundle where the door switch connector cable is located.
    Proceed with extreme caution to avoid damaging any cables.

    Step 13 Cable Removal

    Cable Removal
    Cable Removal
    Cable Removal
    Cable Removal
    ⬢Guide the connector through the opening on top of the xBuddy cover.
    ⬢Guide the cable through the opening to the inside of the printer.
    ⬢From the inside of the printer, pull the cable until it goes through.
    Be careful. Do not damage the connector!

    Step 14 Sensor Removal

    Sensor Removal
    Sensor Removal
    Sensor Removal
    Sensor Removal
    ⬢Cut off the three zip-ties holding the cables to the Core XY assembly.
    ⬢Cut off the zip-tie holding the cable just below the door sensor.
    ⬢Using the 2mm Allen key, remove the M2.5x10 screw. Then remove the sensor.

    Step 16 Sensor Installation

    Sensor Installation
    Sensor Installation
    Sensor Installation
    Sensor Installation
    ⬢Slightly loosen the marked sensor calibration bolt. Two turns should be enough.
    ⬢Attach the new door sensor to the marked location, ensuring the lever is pointing upward. Fix the sensor in place using the M2.5x10 screw in the bottom opening only.
    ⬢While tightening the screw, push the sensor slightly towards the calibration screw in the back.
    ⬢Secure the sensor cable to the printed part with a zip-tie, then trim the excess zip-tie.
    Make sure to leave some slack in the cable near the sensor body.

    Step 17 Cable Attachment

    Cable Attachment
    Cable Attachment
    ⬢Guide the sensor cable together with the WLED cable under the Core XY metal profile.
    ⬢Secure the cable bundle under the metal profile using zip-ties in the marked spots. Trim any excess zip-tie.
    Proceed carefully to prevent damaging the cables!

    Step 18 Cable Guidance

    Cable Guidance
    Cable Guidance
    Cable Guidance
    Cable Guidance
    ⬢Guide the cable through the opening toward the back of the printer.
    ⬢Gently pull the cable out on the other side.
    ⬢Guide the cable into the xBuddy box.

    Step 19 Cable Connection

    Cable Connection
    Cable Connection
    Cable Connection
    Cable Connection
    ⬢Secure the cable bundle to the hooks inside the xBuddy box using two zip-ties.
    Avoid overtightening the zip-ties to prevent damage to the cables.
    ⬢Plug the door sensor cable to the connector labeled A_TEMP on the xBuddy board.
    ⬢Attach the xBuddy box cover using the 6 M3x4bT screws.

    Step 20 Back Cover Installation

    Back Cover Installation
    Back Cover Installation
    Back Cover Installation
    Back Cover Installation
    ⬢Cover the cables with the sheet metal part, making sure none of the cables is getting pinched.
    ⬢Push the cover up, so that the four tabs engage into the recesses.
    ⬢While pushing the cover up, fix it in place using two M3x4bT screws from the inside of the printer.

    Step 21 Corner Profile Installaton

    Corner Profile Installaton
    Corner Profile Installaton
    Corner Profile Installaton
    Corner Profile Installaton
    ⬢Now, reattach the corner profile with the door.
    We need to align the profile without damaging the door sensor lever.
    ⬢

    First, position the tabs with the threaded openings behind the top profiles on both the front as well as on the side. 

    While moving the profile, keep a close eye on the door switch!!

    ⬢Fix the profile using the top M3x4bT screw only, for now.
    ⬢Push the switch lever to verify if it fits the opening and clicks correctly, when pressed.

    Step 22 Corner Profile Attachment

    Corner Profile Attachment
    Corner Profile Attachment
    Corner Profile Attachment
    ⬢

    Fix the corner profile in place using the three M3x4bT screws on the left side.

    Ensure the tab on top of the corner profile is positioned behind the top part of the printer’s frame, as seen in the picture.
    ⬢Fix the corner profile using two M3x4bT screws on the front.

    Step 23 Front Panel Attachment

    Front Panel Attachment
    Front Panel Attachment
    Front Panel Attachment
    Front Panel Attachment
    ⬢Move the front panel to the left, until it engages into the corner profile.
    There are cables connected to the LCD. Ensure you do not disconnect or damage them!
    ⬢With the right side of the panel lifted, push it toward the printer until it is flush with the front of the printer.
    ⬢Then, move the right side of the panel down to engage it into the corner profile on the right side.
    ⬢Align the front panel with the printer’s frame.

    Step 24 Sensor Initial Calibration

    Sensor Initial Calibration
    Sensor Initial Calibration
    Sensor Initial Calibration
    Sensor Initial Calibration
    ⬢Close the printer’s door.
    When closing the door, the sensor should make an audible click, indicating it has been activated.
    ⬢If the sensor does not click, start tightening the calibration screw slowly, until the sensor clicks.
    ⬢Test the sensor by opening and closing the door. It should click each time the door closes.

    Step 25 Side Cover Installation

    Side Cover Installation
    Side Cover Installation
    Side Cover Installation
    ⬢Add the side sheet metal panel to the printer and align it with the opening.
    ⬢Secure the panel in place with 11 Nylon rivets in the marked spots.
    ⬢Add the plastic cover onto the top part and align it with the opening.
    ⬢Fix it in place using 5 Nylon rivets.

    Step 26 Sensor Test

    Sensor Test
    Sensor Test
    Sensor Test
    Sensor Test
    ⬢Connect the printer to power.
    ⬢Turn the printer on using the switch on the back.
    ⬢On the printer’s display, navigate to the menu Info > Sensor Info > Door Sensor
    ⬢Repeatedly open and close the printer’s door and check if the reading on the display changes accordingly between the open and closed states.

    Step 27 Finish

    Finish
    Finish
    Finish
    ⬢Congratulations. Your door sensor has been successfully replaced.
    ⬢If further adjustment is needed, you can access the door sensor calibration screw from inside the printer.
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