Kossel Delta Printer - Klipper Configuration

This repository contains the Klipper/Moonraker configuration for a Kossel delta printer (MKS SBASE v1.3 / LPC176x) running with Mainsail.

Hardware Configuration

• Printer: Kossel 3D Delta Printer
• Controller: MKS SBASE v1.3 (uses LPC176x) - MKS SBASE GitHub

• Kinematics: Delta
• Build Area: 110mm radius
• Hotend: Standard 0.4mm nozzle
• Bed: Heated bed with Honeywell thermistor
• Extruder: 1.75mm filament, 22.73mm rotation distance
• Display: RepRapDiscount 128x64 Full Graphic Smart Controller (ST7920)
• Probe: Z-probe with auto-bed leveling
• Accelerometer: FLY-ADXL345 USB for resonance testing

Configuration Files

printer.cfg

Main configuration file containing:

• Delta kinematics setup
• Stepper motor configuration (A, B, C towers + extruder)
• Hotend and heated bed configuration
• Probe settings for auto-bed leveling
• Input shaping for vibration reduction
• Display configuration
• Current control via MCP4451 digipots

moonraker.conf

Moonraker configuration file containing:

• Klippy socket path
• Update manager config (Mainsail + mainsail-config)

accelerometer.cfg

Accelerometer configuration for resonance testing:

• FLY-ADXL345 USB accelerometer setup
• Resonance testing configuration
• Reference: Mellow USB Accelerometer ADXL345 Documentation

macros.cfg

Convenience macros for common calibration tasks:

• RUN_PROBE_CALIBRATE
• RUN_PROBE_ACCURACY
• RUN_BASIC_DELTA_CALIBRATE

delta_analyze_enhanced.cfg

Macro wrapper for Klipper enhanced delta calibration:

• DELTA_ANALYZE_ENHANCED
• Stores the DELTA_ANALYZE measurement commands in one place
• Runs DELTA_ANALYZE CALIBRATE=extended with your recorded measurements

Key Settings

Delta Configuration

• Delta Radius: 103.174mm (auto-calibrated; see SAVE_CONFIG)
• Arm Length: 208.1mm
• Print Radius: 110mm
• Max Velocity: 200mm/s
• Max Acceleration: 10000mm/s²

Input Shaping

• Type: MZV
• Frequency: X=45.6Hz, Y=48.6Hz (see SAVE_CONFIG)

Using The Accelerometer (Resonance Testing)

The accelerometer is not always connected. In printer.cfg the include for accelerometer.cfg is intentionally commented out.

Enable it when the sensor is plugged in:

1. Connect the USB accelerometer
2. Edit printer.cfg and uncomment the line:
   • # [include accelerometer.cfg]
3. Restart Klipper

Verify the sensor is working:

ACCELEROMETER_QUERY

Measure baseline noise:

MEASURE_AXES_NOISE

Run resonance tests (example):

TEST_RESONANCES AXIS=X
TEST_RESONANCES AXIS=Y

Generate new input shaper values:

SHAPER_CALIBRATE
SAVE_CONFIG

Disable it again when done (so Klipper will start without the sensor):

• Re-comment the include accelerometer.cfg line in printer.cfg
• Restart Klipper

Probe Settings

• Z Offset: 24.33mm (see SAVE_CONFIG)
• Speed: 5mm/s
• Samples: 5 (median result)

Extruder

• Pressure Advance: 0.28
• Smooth Time: 0.04s
• Nozzle Diameter: 0.4mm
• Filament Diameter: 1.75mm

Probe Z-Offset Calibration

To calibrate the probe Z-offset:

1. Home the printer:

   G28
   

2. Move to center of build area:

   G0 X0 Y0 Z30
   

3. Test probe deployment:

   QUERY_PROBE
   

4. Perform manual Z-offset calibration:

   PROBE_CALIBRATE
   

   • Follow the on-screen prompts
   • Use a piece of paper to test nozzle-to-bed distance
   • Adjust until you feel slight drag when moving paper

5. Save the new Z-offset:

   SAVE_CONFIG
   

6. Verify the setting:

   GET_PROBE
   

Current Z-offset: 24.33mm (can be updated after calibration)

Installation / Layout

This repo is intended to live at ~/kossel-config on the Raspberry Pi, and you symlink Klipper's config directory to the repo.

Expected on the Pi:

• Repo: /home/anthony/kossel-config
• Mainsail macros: /home/anthony/mainsail-config/mainsail.cfg
• Klipper config directory: /home/anthony/printer_data/config (symlink to /home/anthony/kossel-config/config)

Note: config/printer.cfg includes Mainsail macros via an absolute path:

• config/printer.cfg includes /home/anthony/mainsail-config/mainsail.cfg

Provisioning (MainsailOS + Ansible)

The intended flow is now MainsailOS first, then a small Ansible pass to apply this repo.

1. Flash MainsailOS and enable SSH + Wi-Fi in Raspberry Pi Imager.
2. Boot the Pi once and let first-boot provisioning finish.
3. Run the Ansible playbook:

ansible-playbook ansible/klipper-setup.yml

Notes:

• The playbook forwards your SSH agent so the Pi can clone git@github.com:... without storing your private key on the Pi.
• KlipperScreen is installed by default as part of this playbook. Opt out with -e install_klipperscreen=false.
• By default the playbook installs the standard utility packages in this repo, runs apt full-upgrade, configures zsh, applies the Wi-Fi tuning in the playbook, and links printer_data/config to this repo.
• If ~/printer_data/config already exists, the playbook backs it up to ~/printer_data/config.pre-kossel-config and replaces it with a symlink to this repo.

Maintenance

• Run DELTA_CALIBRATE command if tower positions change
• Run DELTA_ANALYZE_ENHANCED after printing/measuring calibrate_size.stl for dimensional tuning
• Use TEST_RESONANCES with accelerometer for input shaping updates
• Re-tune PID values if temperature control issues occur
• Update probe Z-offset if bed leveling accuracy degrades

Delta Calibration Workflows

Basic delta calibration

Use either direct command or convenience macro:

DELTA_CALIBRATE
SAVE_CONFIG

or:

RUN_BASIC_DELTA_CALIBRATE
SAVE_CONFIG

Enhanced delta calibration (DELTA_ANALYZE)

1. Print calibrate_size.stl from the Klipper docs.
2. Measure center distances, outer distances, center pillar widths, and outer pillar widths.
3. Update values in config/delta_analyze_enhanced.cfg.
4. Run:

DELTA_ANALYZE_ENHANCED
SAVE_CONFIG

Note: The enhanced measurements are only valid for the current config state. If you rerun DELTA_CALIBRATE or otherwise change delta geometry, reprint and remeasure before running enhanced calibration again.

Filament Runout

This config has filament runout detection enabled. When a runout is detected, Klipper will execute PAUSE.

What happens on runout:

• The print pauses
• The toolhead parks (this config customizes the Mainsail PAUSE behavior to park at X0 Y0 with a small Z lift)

To recover:

1. Replace/load filament (and make sure it is actually feeding)
2. Heat the hotend if needed
3. Purge a little filament and clean the nozzle
4. In Mainsail, click RESUME (or run RESUME from the console)

Notes:

• Runout sensors are defined in printer.cfg as filament_switch_sensor filament_runout and filament_motion_sensor filament_motion (either can trigger a pause).
• RESUME is configured to check the runout sensor set in _CLIENT_VARIABLE.variable_runout_sensor and will refuse to resume if it still reports "no filament".

License

Licensed under the MIT License - see LICENSE.