Prusa Core One Heater

Important. I will not publish a circuit diagram here. Working with high voltage is dangerous and should only be done with the appropriate expertise.

Although I have provided a thermal fuse, I strongly recommend that you do not leave the device unattended due to the risk of fire and that you take precautions.

I have tried to make everything as safe as possible, but I am not responsible for any damage.

Heating is provided by a 200 watt/230V PCB element with a 220V fan.

A control system with an external sensor automatically regulates the temperature to the desired range.

The 120-degree fuse cuts off the power in case of overheating, e.g., if the fan fails.

Required:

- PTC heating element with fan (INSULATED) 220V 200W  https://de.aliexpress.com/item/1005007808891618.html?spm=a2g0o.order_list.order_list_main.56.5ce85c5faKhppV&gatewayAdapt=glo2deu

- Control system    https://de.aliexpress.com/item/1005006952222408.html?spm=a2g0o.order_list.order_list_main.51.5ce85c5faKhppV&gatewayAdapt=glo2deu

- Thermal fuse https://www.amazon.de/dp/B0DS4LKF4T?ref=ppx_yo2ov_dt_b_fed_asin_title

- Temperature-resistant silicone cable

- 2x Wago 221/5  https://www.amazon.de/Wago-Hebelverbindungsklemme-St%C3%BCck-Packung-BLV221415/dp/B071LPMGMB/260-9904306-1537515?pd_rd_w=MvlJ4&content-id=amzn1.sym.a3262f15-f867-491e-909e-9c5989acfe7d&pf_rd_p=a3262f15-f867-491e-909e-9c5989acfe7d&pf_rd_r=S4THVWR67CN7RA8VA758&pd_rd_wg=aXONb&pd_rd_r=6f8bf462-8f60-45a2-bc60-08a6f95d233b&pd_rd_i=B071LPMGMB&th=1

The side panel is available at a relatively low price from Prusa.

Use the drilling template to cut out the holes.

Insert 4 M3 nuts into the housing to secure the channel.

I secured them with a little superglue.

Then melt 4 M3 fusion nuts into the top of the channel and 2 into the housing to secure the heating element.

Feed the fan cables through the small hole to the controller.

Insert the thermal fuse into the base plate. Shape the bars so that they fit into the recesses and are a few mm away from the plate. The hot air should be able to flow around the fuse.

Insert the heater and feed the cables through the slot to the control unit. Insert the base plate and fasten it with 2 M3 screws.

Screw the duct to the housing with 4x M3 screws.

There are 2 recesses for 5 Wago terminals at the rear of the housing. After wiring, screw the lower panel to the housing from the inside using 4 M3 screws.

Now screw the cover to the channel at the top.

For the sensor, I drilled another hole at the back and laid the cable through the cable channel to the two fans where the original sensor is located.

If you have any questions, please feel free to contact me.