Mendel90 Kit Instructions

The build is broken down into sub assemblies that can be worked on sequentially by one person, or in parallel if there is more than one person building. For this reason each assembly begins on a new page so the instructions can be separated. All the diagrams can be viewed in openSCA allowing real time !ooming, rotating and panning to get the best view. "#$""$"% "&'()'"# First release of this manual. %#$""$"% %*'&%'*+ ,ade - cable "((mm longer. Added advice about temperatures. (*$"%$"% %%'"('#( Fi.ed missing - parts. Added Skienforge and bed sections. *($""$"% ")'*"'#( - bar clamps and / bearing mounts no longer have separate switch versions. %"$"%$"% (*'%&'"* T%.# belt and pulleys, new e.truder 0C1 and 2head mount. (%$("$"* %"'()'"# ,inor corrections and suggestions from users. "

Table of Contents
. ,endel3( 4it 5nstructions.................................................................................................................." ". 6eneral 1uild Tips.......................................................................................................................# Tools 7equired...........................................................................................................................8 7ecommended.......................................................................................................................8 Consumables ........................................................................................................................8 %. Frame Assembly..........................................................................................................................+ 9itamins.....................................................................................................................................+ 0rinted parts...............................................................................................................................+ Assembly....................................................................................................................................3 *. 1ed Fan Assembly....................................................................................................................."" 9itamins..................................................................................................................................."" 0rinted part..............................................................................................................................."" Assembly.................................................................................................................................."" &. : 5dler Assembly......................................................................................................................."% 9itamins..................................................................................................................................."% 0rinted......................................................................................................................................"% Assembly.................................................................................................................................."* #. : ,otor Assembly....................................................................................................................."& 9itamins..................................................................................................................................."& 0rinted parts............................................................................................................................."& Assembly.................................................................................................................................."# ). - ,otor Assemblies..................................................................................................................."3 9itamins..................................................................................................................................."3 0rinted parts............................................................................................................................."3 Assembly..................................................................................................................................%( 8. - A.is Assembly........................................................................................................................%% 9itamins...................................................................................................................................%% 0rinted parts.............................................................................................................................%% Sub;assemblies.........................................................................................................................%% Assembly..................................................................................................................................%* +. / idler assembly.........................................................................................................................%# 9itamins...................................................................................................................................%# 0rinted parts.............................................................................................................................%# Assembly..................................................................................................................................%# 3. / motor assembly......................................................................................................................%) 9itamins...................................................................................................................................%) 0rinted parts.............................................................................................................................%) Assembly..................................................................................................................................%) "(. / Carriage Assembly...............................................................................................................%8 9itamins...................................................................................................................................%8 0rinted parts.............................................................................................................................%8 Assembly..................................................................................................................................%+ "". / <eatshield Assembly............................................................................................................%3 9itamins...................................................................................................................................%3 Assembly..................................................................................................................................%3 "%. 0rint bed assembly...................................................................................................................*" 9itamins...................................................................................................................................*" Sub;assemblies.........................................................................................................................*" 1ed =iring...............................................................................................................................*% %

Assembly..................................................................................................................................*& "*. / A.is Assembly......................................................................................................................*# 9itamins...................................................................................................................................*# 0rinted parts.............................................................................................................................*# Sub;assemblies.........................................................................................................................*# Assembly..................................................................................................................................*) "&. : Carriage Fan Assembly........................................................................................................*+ 9itamins...................................................................................................................................*+ 0rinted parts.............................................................................................................................*+ Assembly .................................................................................................................................*+ "#. : Carriage Assembly...............................................................................................................*3 9itamins...................................................................................................................................*3 0rinted parts.............................................................................................................................*3 Assembly .................................................................................................................................&( "). <ot end assembly.....................................................................................................................&" 9itamins...................................................................................................................................&" Assembly..................................................................................................................................&" "8. >.truder connection pcb assembly..........................................................................................&* 9itamins...................................................................................................................................&* Assembly.................................................................................................................................&* "+. >.truder ,otor Assembly........................................................................................................&& 9itamins...................................................................................................................................&& 0rinted parts.............................................................................................................................&& Sub;assemblies.........................................................................................................................&& Assembly..................................................................................................................................&# "3. >.truder Assembly...................................................................................................................&) 9itamins...................................................................................................................................&) 0rinted parts.............................................................................................................................&) Sub;assemblies.........................................................................................................................&) Assembly..................................................................................................................................&8 %(. : A.is Assembly.....................................................................................................................#( 9itamins...................................................................................................................................#( Sub;assemblies.........................................................................................................................#( Assembly..................................................................................................................................#" %". Spool holder assembly.............................................................................................................#* 9itamins...................................................................................................................................#* 0rinted parts.............................................................................................................................#* Assembly..................................................................................................................................#& %%. 0S? assembly..........................................................................................................................## 9itamins...................................................................................................................................## 0rinted parts.............................................................................................................................## =iring.......................................................................................................................................#) Summary..................................................................................................................................#8 Assembly..................................................................................................................................#+ %*. >lectronics Assembly...............................................................................................................#3 9itamins...................................................................................................................................#3 0rinted 0arts.............................................................................................................................#3 Assembly..................................................................................................................................#3 %&. Software...................................................................................................................................)* ,arlin Firmware......................................................................................................................)* *

Arduino 5 >.............................................................................................................................)* 0ronterface...............................................................................................................................)* %#. Testing......................................................................................................................................)& 2umpers....................................................................................................................................)& 0ower up..................................................................................................................................)& @imit switches..........................................................................................................................)& ,otors......................................................................................................................................)& <eaters.....................................................................................................................................)# Fan............................................................................................................................................)# %). Calibration...............................................................................................................................)) 1ed @evelling...........................................................................................................................)) >.truder Calibration.................................................................................................................)8 - <ome 0oint...........................................................................................................................)8 First 0rint..................................................................................................................................)+ Slicing with Skeinforge............................................................................................................)3 %8. Aperating 5nstructions..............................................................................................................8( <eated 1ed...............................................................................................................................8( Changing filament....................................................................................................................8( 7emoval...............................................................................................................................8( 5nsertion...............................................................................................................................8" ifferent types of filament .................................................................................................8" Cleaning the hobbed bolt.........................................................................................................8%

&

1. General Build Tips

: is left $ right. / is backwards $ forwards. - is up $ down. 1ar lengths' The longest and shortest bars are the / bars. Af the two pairs left, the longer ones are the : a.is and the shorter two the - a.is. The longer belt is for : and the shorter one is for /. e;grease the rods and black screws that come with packing grease. All screws have a plain washer where they meet the plastic, to spread the load and prevent the plastic being chewed up by the rotation of the screw head. ,ost fi.ings have a captive Byloc nut to prevent them vibrating loose. It is very important that the nut is fully seated in the nut trap while the screw is inserted. They are quite a tight fit, so sometimes it is necessary to pull or push them in with a long screw. The two ,* . &#mm screws in the kit are handy for this. The bar clamps should not be over tightened, i.e. do not close the gap fully or the parts will break. The / and - bars only need a light clamping force because the only force trying to slide them is the bearing friction. The : idler clamps need to withstand the belt tension so need to be reasonably tight but at the motor end the bars butt up against the motor housing. =ashers tend to have a smooth side and a side with a burr from being stamped out. ,ake sure the smooth side faces bearings and belts. 7ibbon clamp notation is Cnumber of wiresDEChole si!eD. There are three lengths' the short ones are "& way for the : a.is, the medium ones are %( way for the - a.is and the long ones are %) way for the bed. An B suffi. denotes with nut traps. 1 denotes no slot.

The polypropylene strips are pre;cut to the correct width but need cutting to length. Cut the ".)mm, %.&mm and *.%mm heat shrink sleeving into "#mm lengths. Cut the ).&mm into two *(mm and two "#mm lengths. All the bolts are shown as being black in the diagrams but the ones supplied in the kit may be black or silver.

Tools Required
Spanners' #mm, #.#mm, 8mm F "*mm. Allen keys' ".#mm, %.#mm, *mm F )mm. 0- " 0o!idriv screw driver. Small flat blade and small 0o!idriv screw driver Gfor ,el!i screw terminalsH. 9ice Gto close 5 C =ire cutters. =ire strippers. Soldering iron. igital callipers type connectorH.

Recommended

,ulti;meter with thermocouple attachment ial gauge =ire brush

Consumables

Ail, lithium grease, glass cleaner, lint free wipes.

2. Frame Assembly Vitamins

*) ,& cap screw . ")mm % ibond sheet "))mm . *+&mm . *mm " ibond sheet &)#mm . *+&mm . *mm " ibond sheet &)#mm . &"3mm . *mm *) Byloc nut ,& % A@ square tube "%.8 . "%.8 . ".)* . &((mm *+ =asher ,& . 3mm . (.+mm "( -iptie "((mm min length

Printed parts
10 fixing_block.stl 1 ribbon_clamp_20_44N.stl

1 ribbon_clamp_26_44N.stl

4 tube_cap.stl

Assembly

Bote that this view is from the back of the machine. ". 7emove the protective film from the ibond panels. They all have a matt side and a shiny side. The shiny side is up on the base, forward on the gantry and outside on the stays. %. 5nsert ,& nyloc nuts into each of the three nut traps in the fi.ing blocks Ga small pair of snipe nose pliers is useful for pressing them homeH. *. ?sing a *mm Allen key' attach three fi.ing blocks to the left and right stays with two ,& . ")mm screws each, noting that they go on the matt side that faces inwards. Stand the sheet on its edge on a flat surface and slide the block down to be flush with the edge before tightening the screws. Tighten Iust enough to nip the sheets together but don't over-tighten. &. Fit the remaining four fi.ing blocks along the bottom of the back of the gantry Glarge n shaped sheetH in the same way. #. Fi. the stays to the back of the gantry using one screw in each fi.ing block. Bote the shiny sides face outwards and the one with the fan hole is on the left hand side looking from the 3

front. Tighten the screws. ). Attach the two aluminium square tubes to the underside Gmatt sideH of the front of the base by placing a washer in the end of the tube, passing an ,& . ")mm screw up through the large hole in the underside of the tube, through the washer, through the base and into a washer and nyloc on the top.

8. Screw the gantry to the base using si. screws from below. Bote that the rear two screws go through the aluminium tubes in the same way as at the front. Align the stays with the back edge before tightening. +. Fit the four end caps to the tubes. 3. @oosely insert # pairs of !ip ties into the pairs of small holes in the gantry and base. "(. @oosely attach the two ribbon clamps. The longer one goes at the back of the base for the bed wires. The shorter one goes at the top of the gantry for the : a.is cable.

"(

3. Bed Fan Assembly

The bed fan is optional. 5t speeds up the cool down period when the parts are finished. 5t is not included in the kit but the hole is cut out so you may add it later if you wish. 5n the meantime Iust fit the fan guard.

Vitamins
& ,& cap screw . ")mm " Fan +(mm . *+mm Gnot includedH & Byloc nut ,& & =asher ,& . 3mm . (.+mm

Printed part
" fanEguard.stl

Assembly

,ake sure the fan is blowing inwards. This is usually indicated by an arrow on the frame and is often the side with the label. The four screws pass through a plain washer, the fan guard, the left stay, the fan Gif fittedH and finally a nyloc nut. There isnJt a washer behind the fan because fan frames tend not to have room for one. The ,el!i doesnJt have a second fan output but you can easily add one on a spare 5$A pin as described here' hydraraptor.blogspot.co.uk$%("%$(8$sanguinololu;fan;hack. 5t can be controlled with ,&%. ""

4. X Idler Assembly Vitamins

% 1all bearing )%& &mm . "*mm . #mm " ,& cap screw . &#mm % ,* he. screw . ")mm % @,+?? linear bearing % Byloc nut ,* " Byloc nut ,& % =asher ,* . 8mm . (.#mm % =asher ,& . 3mm . (.+mm % =asher ,# . %(mm . ".&mm

Printed
" .EidlerEbracket.stl

"%

Assembly

". 5nsert the two linear bearings by pushing the end which is towards the middle in first. Then slide it up against the divider in the middle before pushing in the other end. 5nsert a rod to check they are aligned well. %. 5nsert all the nyloc nuts into their nut traps. 5t can be easier to pull the ,* nuts for the bar clamps into their hard;to;reach traps using one of the longer screws from elsewhere in the design. *. Fit the ,* . ")mm he screws and washers loosely. &. ,ake the washer and bearing kebab on the long ,& bolt that forms the idler a.le, but leave it loose to allow the : bars to be inserted later.

"*

5. X

o!or Assembly
" 0olypropylene strip &#8mm . %#mm . (.#mm * ,* pan screw . +mm & Bo% pan wood screw . "*mm " T%.# pulley ") teeth " 7ibbon cable %( way "%%(mm " ,icroswitch & <eatshrink sleeving 5 %.&mm . "#mm & =asher ,%.# . #.3mm . (.#mm "* =asher ,* . 8mm . (.#mm

Vitamins
& ,* cap screw . ")mm % ,* cap screw . %(mm " "# way 5 C socket " ,& grub screw . )mm Gpre;fitted to pulleyH & ,* he. screw . ")mm % @,+?? linear bearing " B>,A"8 . &8.#mm stepper motor + Byloc nut ,* % Bitrile A;ring %.#mm . ".)mm

" 0olypropylene strip &("mm . "+mm . (.#mm * Star washer ,* . (.#mm

Printed parts
" dEshell.stl " dEshellElid.stl " ribbonEclampE"&E**.stl

" ribbonEclampE"&E**B1.stl

" ribbonEclampE%(E**.stl

" .EmotorEbracket.stl

"&

Assembly

". Cut the two polypropylene strips to the lengths shown in the vitamins list. %. 5nsert the linear bearings and bar clamp he screws as described above for the : idler assembly. Also insert the four ,* nyloc nuts for the ribbon clamps and the remaining two in the ribbonEclampE"&E**B1. *. Fit the pulley to the motor shaft ensuring the grub screw locates on the flat of the shaft. 0osition it so that *mm of the shaft protrudes beyond the pulley. &. Fit the motor with the wires pointing upwards and threaded through the big hole in the top of the bracket. Crop them so they are Iust long enough to be attached to the ribbon cable and then tucked back into the bracket. 7etain the surplus wire for connecting limit switches and the bed thermistor. #. Secure the motor with ,* . +mm pan screws, star washers and plain washers.

"#

). The ne.t task is attaching the %( way ribbon cable. 0eel back the first two wires at the red edge and the last four wires at the opposite edge. 5nsert the remaining fourteen wires into the first fourteen pins of the type socket. i.e. pin * of the cable mates with pin " of the socket. 0in + of the socket is unused. See the photo below' ;

0in " is top left in this photo, the unused pin + is at the bottom left. 8. Close the socket using a vice to make the 5 C connections. Clip the strain relief clip on the back but do not pass the cable through it Gstrain relief is provided by the printed parts but the clip is needed to lock the connector closedH. +. 5nsert into the dEshell in the orientation shown below.

")

3. Secure the connector by screwing on the dEshellElid with two Bo% . "*mm pan screws with ,%.# washers. "(. Clamp down the cable with the thinner polypropylene strip under it Gagainst the shellH using the ribbonEclampE"&E**B1, ,* . ")mm cap screws and ,* washers Gfrom the undersideH. "". Complete the connector by adding ,* . %(mm retaining screws and washers and then secure them in place with the rubber A rings. "%. 0eel back the ) loose wires along the length of the polypropylene strip until Iust past the end furthest from the connector. Then clamp the "& way cable and the wider strip in the ribbon clamp on the top of the : motor bracket with the red edge at the top using the ribbonEclampE"&E**, ,* . ")mm cap screws and ,* washers. Form the cable and strip into a loop as shown in the diagram above before tightening the clamp fully. This is necessary because the cable needs to be a bit longer than the strip to go round the outside of the curve. "*. 0ass the full %( way part of the cable through the ribbonEclampE%(E** at the rear of the motor bracket and clamp it with the second polypropylene strip on top using ,* . ")mm he screws and ,* washers. "&. Add loops of sticky tape Gnot providedH to fasten the middle of each cable to the middle of its cable strip. "#. 0ass the first two loose wires through the large hole in the top of the motor bracket and out through the small hole for the limit switch. Solder the switch on Guse the two outer pinsH and then mount it with two Bo% . "*mm pan wood screws with ,%.# washers. B.1. !he micro switch must be oriented with the button towards the bottom. "). Solder the remaining four lose wires to the motor wires using the heat shrink sleeving to cover the Ioins and then tuck them into the top motor bracket. ?se the following connection scheme' ; 7ibbon wire "8 7ibbon wire "+ 7ibbon wire "3 7ibbon wire %( : motor red : motor blue : motor green : motor black

Thread the heatshrink sleeving onto the motor wires before soldering and keep them well way from the Ioint so the heat of the soldering does not shrink them prematurely. Slide the heatshrink over the Ioints after they have cooled and shrink by holding them over the barrel of the soldering iron, close but not touching.

"8

"+

". #

o!or Assemblies

Vitamins
% ,* cap screw . ")mm + ,* cap screw . %(mm & ,& cap screw . ")mm % B>,A"8 . &8.#mm stepper motor "( Byloc nut ,* & Byloc nut ,& + ,* pan screw . +mm % 09C aquarium Tubing A )mm 5 &mm . ")mm "+ =asher ,* . 8mm . (.#mm & =asher ,& . 3mm . (.+mm + Star washer ,* . (.#mm

Printed parts
" !EmotorEbracketElhs.stl " !EmotorEbracketErhs.stl

& !Ecoupling.stl

"3

Assembly

". Fit all the nyloc nuts into their nut traps. %. Fit the ,* . ")mm cap screws to the bar clamps with plain washers. *. Attach the motor with the wires e.iting towards the back using four ,* . +mm pan screws, star washers and plain washers. &. egrease the motor shafts before fitting the plastic tubing but be careful not to degrease the bearings. 5t will be a tight fit. Stretching it by opening a pair of pliers inside can help, as can warming it.

#. ,ake sure the metal shaft of the motor protrudes slightly beyond the end of the tubing. ). 2oin the two halves of the couplings together using four ,* . %(mm cap screws and plain washers. 8. Fit the coupling loosely over the tubing for now. +. Twist the motor wires in pairs and feed them through the hole at the bottom of the gantry. 7ed $ blue are one pair and green $ black the other pair. The quickest way to twist them is by %(

using an electric drill. Tie a knot in the far end and put it in the chuck. The reason they are twisted is to minimise the radio frequency emissions. 3. Attach the motor assemblies to the gantry using ,& . ")mm cap screws. Bote that the motors rest on the base and the bar clamps face inwards. "(. 7oute the left motorJs wires through the mouse hole under the gantry, the rise up the outside of the left stay, pass through the lower hole in the left stay, a cable tie, across the back of the gantry, another cable tie and a slot in the right stay to get to the electronic bay. "". The right hand motorJs wires pass through a round hole near the bottom of the gantry to get to the electronics bay.

%"

7. Z Axis Assembly
Vitamins
% ,* cap screw . ")mm & ,& cap screw . ")mm % 1rass nut ,) % Byloc nut ,* & Byloc nut ,& % Bo% pan wood screw . "*mm % Smooth rod +mm . **)mm " ,icroswitch % Threaded rod ,) . %8"mm % =asher ,%.# . #.3mm . (.#mm % =asher ,* . 8mm . (.#mm & =asher ,& . 3mm . (.+mm

Printed parts
% !EbarEclamp.stl % !EscrewEpointer.stl

Sub-assemblies
" .EmotorEassembly " .EidlerEassembly % !EmotorEassemblies

%%

Assembly

". 5nsert the ,* nyloc nuts into the nut traps inside the bar clamps and ,& nylocs into their base. %. Fit ,* . ")mm cap screws and washers to the bar clamps. *. Attach the bar clamps to the top of the gantry using ,& . ")mm cap screws, note that they both face the same way. @eave the screws loose. 5f only one of the bar clamps has screws holes for the limit switch ensure that one is on the left. An later kits both parts are the same. &. Solder a pair of twisted blue wires Guse the e.cess cut from the : motorH to the outer two pins of the microswitch. The final length needs to be #*(mm after twisting so cut to )((mm and trim when connecting to the ,el!i. #. Fit the micro switch to the left hand bar clamp using Bo% . "#mm pan head wood screws. ".#. !he button should be towards the front of the machine. ). Thread the limit switch wires though the hole below the left hand bar clamp and route it along the top of the gantry in the holes and cable ties above the ones used for the motor wires. 8. Fit the - bars Gsmooth rodsH, inserting them through the : ends. Tighten the left hand bar clamp but leave the right hand one loose.

%*

+. Thread the ,) brass nuts onto the bottom of the lead screws Gthreaded rodH about #(mm of the way up. 3. Screw the - screw pointers on the bottom Iust high enough to clear the couplings. "(. 0ush each : end to the top and insert the lead screw from underneath far enough to allow the bottom end to go into the top of the couplings. "". Arient the couplings so that the flat on the motor shaft is facing towards the gap rather than the plastic. Tighten the couplings enough to grip the lead screws at the top and the tubing at the bottom. onJt close the couplings completely at the bottom as the tubing needs to remain fle.ibly. "%. Cut the polypropylene strip to the length shown in the vitamins table. "*. Clamp the %( way ribbon cable and its cable strip with the ribbon clamp at the top of the gantry and pass the remainder of the cable through the slot above it.

%&

$. % idler assembly Vitamins

% 1all bearing )%& &mm . "*mm . #mm " ,& cap screw . ")mm " ,& cap screw . *(mm % Byloc nut ,& # =asher ,& . 3mm . (.+mm % =asher ,# . %(mm . ".&mm

Printed parts
" yEidlerEbracket.stl

Assembly

Assemble as shown, easiest done on its side with the long a.le screw pointing upwards and slowly inserted as the washers and bearings are added. To get the last washer in you have to have the bolt Iust far enough up to retain the ,& washer as the penny washer slides over it.

%#

&. % mo!or assembly Vitamins

& ,& cap screw . ")mm " ,& grub screw . )mm " B>,A"8 . &8.#mm stepper motor & Byloc nut ,& & ,* pan screw . +mm " T%.# pulley ") teeth & =asher ,* . 8mm . (.#mm & =asher ,& . 3mm . (.+mm & Star washer ,* . (.#mm

Printed parts
" yEmotorEbracket.stl

Assembly

Assemble as shown above with the motor shaft protruding *mm from the pulley. The wires should e.it downwards.

%)

1'. % Carria(e Assembly Vitamins

"& ,* cap screw . ")mm % ,* cap screw . %(mm " ibond sheet %")mm . %")mm . *mm * @,+?? linear bearing ") Byloc nut ,* ") =asher ,* . 8mm . (.#mm * -iptie "((mm min length

Printed parts
" ribbonEclampE%)E**.stl " ribbonEclampE%)E**B.stl * yEbearingEmount.stl

" yEbeltEanchor.stl

" yEbeltEanchorEtoothed.stl

" yEbeltEclip.stl

" yEbeltEclipEtoothed.stl

%8

Assembly

This view is from the bottom of the bed which is the matt side of the ibond. >.cept for the cable clamps, the nuts go on the bottom and the screw heads and washers on top . The cable clamps have the heads on the bottom to avoid a clash with the / idler. ". 5nsert ,* nyloc nuts into all of the nut traps, including those in the top of the belt anchors. A long ,* screw can be used to pull them up to the top. %. Tie the bearings into the holders with the !ip ties, and screw the holders to the carriage using ,* . ")mm screws and washers. Bote that one side of the bearing holders has a tab to trigger the limit switch and that must face forwards Gthat is, away from the ribbon clampH. Alder versions of the bearing holder only have a tab on one of the three, so ensure that is the one on its own if that is the case. *. Align the two bearings on the left Gright on the pictureH by inserting a rod and lining up the tabs with the edge of the board before tightening the screws. @eave the third bearing loose. &. Fit the belt clamps loosely to retain the nuts using ,* . ")mm screws and washers, then fit the anchors to the carriage using ,* . ")mm screw and washers. Bote that the anchor with the tooth goes at the back and the belt clamp with the tooth at the front. #. Fit two wide ribbon clamps to the holes at the back of the board using ,* . %(mm screws and washers.

%+

11. % )ea!s*ield Assembly

The heatshield prevents heat radiating downwards from the bed heating the / carriage, which can make it warp due to the top surface e.panding more than the bottom. )mm corrugated cardboard is used as a cheap and effective insulator and aluminium foil tape on top reflects heat back towards the bed. 5t isnJt needed for printing 0@A and isnJt included in the kit. 5f you want to print A1S it can be added later as it Iust slides under the bed and is taped in place.

Vitamins
" Corrugated cardboard "3%mm . %")mm . )mm Gcut it from the bo. of the kitH. # Aluminium foil tape #(mm . %%)mm . (.(#mm

Assembly

Start by printing a paper template from the pdf drawing yEheatshield.pdf. Cut out the outline with scissors or a craft knife. 0lace the template over the cardboard and cut round with a straight edge and craft knife. Cut through the holes.

Apply the tape strips with some overlap. Turn it foil side down and trim round with a knife.

%3

*(

12. +rin! bed assembly Vitamins

& "3mm bulldog clip " 0C1 bed %"&mm . %"&mm & ,* cap screw . "(mm " 6lass sheet %"&mm . %(%mm . %mm & <e. male $ female pillar ,* . %(mm % <eatshrink sleeving 5 ".)mm . "#mm % <eatshrink sleeving 5 %.&mm . "#mm % <eatshrink sleeving 5 ).&mm . *(mm " >pcos 1#8+)"S"(&F&( "((4 "K thermistor Gpre;fittedH

" 0olypropylene strip %8"mm . **mm . (.#mm & =asher ,* . 8mm . (.#mm " 1lack wire *%$(.% length )*#mm " 7ibbon cable %) way *+"mm " 7ed wire *%$(.% length )%(mm

Sub-assemblies
" yEcarriageEassembly

*"

Bed Wiring
The thermistor comes pre;glued to the bed with 2;1 =eld, which is a high temperature thermally conductive epo.y. ". Separate all the %) ways of the ribbon cable and strip about "(mm of insulation. %. Twist the first "% wires together, leave two for the thermistor and then twist the last "% together. 5t is easier to twist bunches of three together and then twist four of those bunches to get all "% to meet. Alternatively roll the twelve wires into a tube before twisting. *. Apply solder to tin the twisted ends. &. Solder the two groups of "% wires to the 0C1 so that they lead off towards the middle, as shown below. 1e careful not to get solder down the holes in the 0C1 as that will prevent the glass from lying flat. >nsure the red wire is the one on the right.

#. 0ut the ".)mm heat shrink on the middle two wires and solder them to the thermistor. Shrink the sleeving with a heat gun or place it over the soldering iron very close but not touching.

*%

). Separate, strip and bunch the other end of the cable in the same way and solder the red and black *%$(.% wires as shown below and then sleeve with the ).&mm heat shrink.

8. ?se red and black wires trimmed from the : motor for the thermistor wiring. Twist them before soldering and sleeve with the %.&mm sleeving. Abserve the polarity above for minimum crosstalk with the heater. Cut them "((mm longer than the black heater wire.

**

Assembly

". Screw the pillars into the / carriage. The ibond has been tapped ,* but donJt over tighten as it is quite soft. Bote that the rear two pillars have a washer under them. The front two are initially spaced the same distance by using a washer as a temporary shim. They can then be adIusted up or down slightly to level the bed relative to the no!!le. %. The bed is installed with the cable at the back. 5t initially leads off forwards and then loops back on itself under the top ribbon clamp. 5t then doubles back under the / carriage through the lower cable clip. *. Screw the bed to the top of the pillars with the ,* . "( cap screws Gno washersH. &. 0ull the ribbon cable tight enough so that the loop under the bed does not touch the bed and clamp it together with the polypropylene strip Gwhich goes closest to the clampH. 5nstall the clips and the glass after the carriage has been mounted on the machine.

*&

13. % A,is Assembly Vitamins

" 1elt T%.# . )mm . ))*mm & ,* cap screw . ")mm + ,& cap screw . ")mm & Byloc nut ,* + Byloc nut ,& % Bo% pan wood screw . "*mm " Smooth rod +mm . %8(mm " Smooth rod +mm . &"8mm " ,icroswitch % =asher ,%.# . #.3mm . (.#mm & =asher ,* . 8mm . (.#mm + =asher ,& . 3mm . (.+mm

Printed parts
* yEbarEclamp.stl " yEbarEclampEswitch.stl

Sub-assemblies
" printEbedEassembly " yEidlerEassembly " yEmotorEassembly

*#

Assembly

". 5nsert the captive nyloc ,* nuts and ,* . ")mm cap screws in each of the / bar clamps. %. @oosely fit the two left hand / bar clamps to the base. Arient them so the rod is towards the outside of the machine. *. Twist together about 8#(mm of green wire trimmed from the : motor and solder to the outer two pins of the microswitch. Screw it to the yEbarEclampEswitch with Bo% pan wood screws and ,%.# washers with the button towards the top and facing the back of the machine. The wires need to e.it down the side of the bracket that is towards the back of the machine. &. Fit the right hand / bar clamps to the base but leave the screws loose. #. Thread the limit switch wires down the hole in the base close to the limit switch and run it through the nearest cable tie, along the underside of the base through a second cable tie, up through the hole in the base and then through the adIacent mouse hole in the right stay. ). Thread the / motor wires through the hole in the base and then screw the / motor bracket in place. 7un the wires in the cable ties and holes parallel to the limit switch wires. 8. Clamp the / belt Gthe shorter of the twoH in the front belt anchor with the teeth facing away *)

from the carriage. The end of the belt should proIect enough to have four complete teeth showing. +. 0ut a half twist in the belt and the thread it through the / idler assembly with the smooth side against the bearings and then clamp it in the rear clamp with the teeth facing the carriage. Again leave four complete teeth proIecting from the anchor. 3. Slide the / bars through the bar clamps and the carriage bearings. Tighten the clamps to grip the bars lightly but do not over-tighten them. Slide the carriage up and down to align the right hand bearing and bar clamps. Tighten the bearing first and then move it to each end and tighten the clamps. "(. 0ut the belt over the motor pulley and fasten the idler assembly to the base with enough tension on the belt to play a low note when plucked. >nsure the belt runs in the middle of the idler without touching the washers each side by adIusting the angle of the idler. "". Clamp the bedJs ribbon cable and polypropylene strip to the base with the ribbon clamp. The wires turn right and go through the cable ties and under the mouse holes in the right hand stay. The heater wires go through the rear tie and the larger hole.

*8

14. X Carria(e Fan Assembly Vitamins

& ,& cap screw . *(mm " Fan )(mm . "#mm & Byloc nut ,& & =asher ,& . 3mm . (.+mm

Printed parts
" .EcarriageEfanEbracket.stl " .EcarriageEfanEduct.stl

Assembly
". Assemble as shown below with the fan label downwards and the wires e.iting nearest the leftmost screw in the picture.

*+

15. X Carria(e Assembly Vitamins

% ,* cap screw . "(mm " ,* cap screw . %(mm % ,* cap screw . %#mm * @,+?? linear bearing " But ,* & Byloc nut ,* & =asher ,* . 8mm . (.#mm * -iptie "((mm min length " 1elt T%.# . )mm . +)(mm

Printed parts
" .EbeltEclamp.stl " .EbeltEgrip.stl

" .EbeltEtensioner.stl

" .Ecarriage.stl

*3

Assembly

". 5nsert the linear bearings and secure each one with a !ip tie. %. 0ut ,* nyloc nuts in the four nut traps. *. Add the two ,* . "(mm screws and washers for the fan mount but leave loose. &. Attach the : belt Glonger of the twoH to the left side .EbeltEclamp G7<S in the pictureH with the teeth facing upwards Gdownwards in the pictureH and four complete teeth proIecting from the clamp. Clamp with the ,* . %(mm cap screw and washer. #. 5nsert the ,* captive plain nut and ,* . %#mm cap screw for the belt tensioner and put the tensioning piece on the end of the screw with the flange towards the carriage. ). 0ut one half twist in the belt and feed it though the slot below the right hand clamp G@<S in the pictureH with the teeth facing downwards Gupwards in the pictureH. The twist direction should be such that the vertical stretch in the middle has the teeth facing inwards Gto avoid them catching on the fanH. 8. ouble back the belt over the tensioner Gas depicted in yellowH and clamp it with the .EbeltEgrip and an ,* . %#mm cap screw and washer with four complete teeth proIecting.

&(

1". )o! end assembly Vitamins

" 2<ead ,4# hot end " ?1#C #7)F #7) *= vitreous enamel resistor " >pcos 1#8#)(6"(&F "((4 "K thermistor % <eatshrink sleeving 5 ".)mm . "#mm % <eatshrink sleeving 5 %.&mm . "#mm " <eatshrink sleeving 5 ).&mm . )(mm % 7ed wire ")$(.% length "8(mm " -iptie "((mm min length

% 0TF> sleeving A ".%mm 5 (.8"mm . )%mm % 6reen wire 8$(.% length "&(mm

Assembly
The hot end come pre;assembled. The resistor and thermistor are cemented in with car e.haust putty. The heater is then run for a few hours below "((LC to bake out the water content of the cement without causing blistering due to steam bubbles. This is necessary because the wet cement will be slightly conductive and effect the sensitive thermistor inputs. Bote that the soldered Ioints on the resistor leads are inside the 0TF> sleeving rather than the heatshrink as they get too hot for the normal black heatshrink material. Surplus green wire from the motors is used for the thermistor leads.

&"

&%

1-. .,!ruder connec!ion pcb assembly Vitamins

" "# way 0C1 mount plug " % way ,ole. 44 header " * way ,ole. 44 header " >.truder connection 0C1 % & way terminal block

Assembly

Solder the connectors to the 0C1 as shown. Start with the shortest parts first and solder one pin in the middle then check it is flat and aligned Gbetter than mineMH before soldering the remaining pins.

&*

1$. .,!ruder Vitamins

o!or Assembly
% Bo% pan wood screw . "*mm % =asher ,%.# . #.3mm . (.#mm % =asher ,* . 8mm . (.#mm

% ,* cap screw . &#mm " ,* grub screw . )mm " B>,A"8 . &8.#mm stepper motor * But ,*

Printed parts
" dEmotorEbracket.stl " dEmotorEbracketElid.stl " wadesEsmallEgear.stl

Sub-assemblies
" e.truderEconnectionEpcbEassembly

&&

Assembly

Bote that the wires e.it the motor on the bottom edge Gleft in the pictureH. ". 7emove two of the motorJs screws and replace them with the longer ,* . &#mm screws and washers that fasten the dEmotorEbracket to the motor. %. 5nsert the 0C1 and the two ,* nuts in the nut traps and then screw down the lid pieces Gwhich hold connector and the nuts in placeH using Bo% . "#mm pan wood screws and ,%.# washers. *. Fit the gear to the motor leaving only a small gap. The grub screw needs to be tight to avoid working loose but not too tight it or it will crack the plastic gear. &. Cut the motor wires short, strip and tin them and then connect them to the terminals as follows' ; !erminal $%# &abel Motor 'ire ,4 ,6 ,1 ,7 &# 1lack 6reen 1lue 7ed

1&. .,!ruder Assembly Vitamins

* 1all bearing )(+ +mm . %%mm . 8mm * ,* cap screw . ")mm * ,* he. screw . "(mm % ,& he. screw . %(mm % ,& he. screw . #(mm " ,+ he. screw . )(mm, hobbed at %# * But ,* % But ,& % But ,+ " Smooth rod +mm . %%mm % Spring 8mm A , "mm gauge . "(mm long * =asher ,* . 8mm . (.#mm * =asher ,& . 3mm . (.+mm * Star washer ,* . (.#mm " Star washer ,+ . ".)mm

Printed parts
" wadesEblock.stl " wadesEgearEspacer.stl

" wadesEidlerEblock.stl

" wadesEbigEgear.stl

Sub-assemblies
" e.truderEmotorEassembly " hotEendEassembly

&)

Assembly

". 0ress fit the bearings into the e.truder with a vice or pull them in using the ,+ bolt and a nut. They are a tight fit to ensure there is no movement during reversals which would wear away the plastic. %. 5nsert the three ,* nuts into the slots near the base. 0ush the hot end into its socket and secure with three ,* . ")mm cap screws with ,* star washers and ,& washers that capture the top of the groove. The washers have to go in from the side before the screws go through them. 1e careful to get the screws vertical to ensure they donJt cross thread. 5t may be necessary to rotate the hot end to allow the screw heads to clear the !ip tie. ,ake sure it is aligned as shown before tightening the screws.

&8

*. 5nsert the two ,& nuts into the slots in the bearing block, one from above and one from below Gnot visible in the pictureH. &. 0ush the idler a.le through the bearing and snap it into the idler block. #. 0lace one of the ,& . %(mm bolts through the hole in the base of the block underneath the motor. ). @oosely attach the motor with three ,* . "(mm he. head screws trapping the ,& bolt in place. The 0C1 bracket should be on the side of the motor facing the hobbed bolt. 8. 0ush the ,+ hobbed bolt through the large gear and make sure it is fully seated. +. Add the spacer to the bolt and put it through the bearing block. Secure with an ,+ nut finger tight. Add the ,+ star washer and second nut to lock it in place. Finger tight is generally enough to stop it shaking loose. 3. 0ut the springs on the ,& . #(mm he. screws and thread them through the idler block into the bearing housing and into the trapped nuts. Tighten them until the end of the screw is flush with the back of the bearing housing. "(. Slide the motor up to engage the gears and rotate them to ensure they donJt bind or have too much backlash. @ock the motor in position by tightening the screws. "". 0ush some filament into the e.truder hard against hobbed bolt whilst turning the large gear &+

to pull it in. Some force on the filament is needed initially to open the idler but once you see it open the filament can be fed by Iust turning the gear. "%. This is the way the e.truder is loaded. Bormally one would wind it in by hand until it hits some resistance, then heat the e.truder and feed it with the motor. 5n this case Iust wind it up and down and check the gears donJt bind. The spring force pushes the bolt a little further back in the bearings, so you might need to slacken off the motor a bit. "*. Strip and tin the wires on the hot end. "&. Attach the red heater wires to the terminals marked <. "#. Attach the green thermistor wires to the terminals marked T.

&3

2'. X A,is Assembly Vitamins

% Smooth rod +mm . *+"mm % =ingnut ,&

Sub-assemblies
" e.truderEassembly " .EcarriageEassembly " .EcarriageEfanEassembly

#(

Assembly

". 0ut the : ends at the bottom of the - a.is. %. Make sure the ( bars are completely free of grease or the clamps won't grip. *. 7emove the idlerJs a.le bolt. &. Slide the : bars through the idler bracket, the : carriage and into the motor bracket as far as they will go. #. Tighten the : bar clamps while the a.is is at the bottom. )on't over tighten them, i.e. donJt close the gap entirely, Iust enough until you feel it grips the bar solidly. ). ,ove the a.is to the top and then tighten the top right - bar clamp. 8. 0ut the belt round the motor pulley and then re;attach the idler a.le with the belt around the idler. +. Tension the belt enough to play a low note when plucked. 3. 7un the carriage up and down a few times and check that the belt does not rub on the idler #"

washers. 5f it does then shim one side of the penny washer where it rests against the plastic with a few layers of paper until it runs true. "(. Attach the e.truder with the ,& wing nuts. 5f the right hand wing nut stops in a position where it sticks out beyond the carriage start again with the he. head in a different one of the si. possible positions. "". Slide the fan assemblyJs bracket onto the ,* screws on the front of the carriage and tighten them. "%. 0lug the fan into the * pin connector on the distribution 0C1. The red and black wires should line up with the FN and F; labels. "*. ,ate the type connectors and screw the captive ,* screws in the shell into the captive ,* nuts in the dEmotorEbracket.

#%

21. /pool *older assembly

The spool holder will hold a *(( . +#mm spool commonly used by filament suppliers for %.*kg reels. The spool is not included in the kit.

Vitamins
& 1all bearing )(+ +mm . %%mm . 8mm % ,& cap screw . ")mm & ,+ cap screw . *(mm " Foam sponge %(mm . %(mm . %(mm % Byloc nut ,& & Byloc nut ,+ " 0@A sample *mm %(m " 0TF> tubing A &.)mm 5 *.+&mm . 8#(mm % =asher ,& . 3mm . (.+mm + =asher ,+ . "8mm . ".)mm & =asher ,+ . *(mm . ".#mm

Printed parts
" dustEfilter.stl " feedEtubeEconnector.stl

% spoolEbracketEfemale.stl

% spoolEbracketEmale.stl

#*

Assembly

The male and female halves of the brackets press fit together. They are supplied fitted to make them more robust while being shipped. ". 5nsert the two ,& nyloc nuts into the nut traps in the male brackets. %. Screw the bearings to the brackets using the sequence of washers shown above. *. Cut a slit half way through the foam cleaning sponge and squash it into the bo. in the dust filter with the slot aligned with the holes for the filament. &. Clip the dust filter in the middle of one of the brackets, note the orientation. #. Thread the 0TF> tube through the cylinder at the top of the dust filter and wrap some "%mm wide sticky tape around the end to increase the diameter to about )mm. 0ull it back into the cylinder where it should be retained by the lip at the top end. ). Slide the dust cap over the other end of the 0TF> tube and add tape as above to secure it. 8. <ang the brackets over the top of the frame stays on the inside towards the front and secure each with an ,& . ")mm cap screw and washer. The one with the dust filter and feed tube goes on the left. #&

22. +/0 assembly Vitamins

" T<S"# Aluminium clad resistor "(7 " T<S"# Aluminium clad resistor &78 " 0S? e.g. A@05B>#(( & ,& cap screw . ")mm " 5>C mains lead & Byloc nut ,%.# & Byloc nut ,& & ,%.# pan screw . "%mm % );*% pan screw . 3.#mm " <eatshrink sleeving 5 "(mm . "#mm * <eatshrink sleeving 5 %.&mm . "#mm # <eatshrink sleeving 5 *.%mm . "#mm % <eatshrink sleeving 5 ).&mm . "#mm & =asher ,%.# . #.3mm . (.#mm ) =asher ,& . 3mm . (.+mm % Star washer ,& . (.+mm % -iptie "((mm min length

Printed parts
" at.ElongEbracket.stl " at.EshortEbracket.stl

##

Wiring

". Cut one of the black wires to a length of %&(mm and one of the red wires to %+(mm, strip them, add "#mm of *.%mm heatshrink and solder to the "(7 Ggold in the kitH dummy load resistor. %. Cut another black wire and the green wire to %*(mm, strip them, twist together, sleeve with "#mm of *.%mm sleeving and solder to one end of the &78 resistor. *. Cut the brown sense wire and one orange wires to %%(mm, strip them, twist together, sleeve with "#mm of *.%mm sleeving and solder to the other end of the &78 resistor. &. Cut the remaining si. red wires short GO#(mmH, strip, twist together and solder. Cover the end with "#mm of ).&mm heatshrink. #. Cut the remaining three orange wires short, strip, twist together and solder. Sleeve with "#mm of *.%mm heatshrink. ). Cut each of the purple, blue and grey wires short and sleeve them individually with "#mm of %.&mm heatshrink.

#)

8. Cut the si. yellow wires to a length of "3(mm, strip "#mm, twist and solder them together, cut off the point and sleeve with "#mm of ).&mm heatshrink leaving enough wire protruding to fit the terminal block on the ,el!i terminal. +. Cut the "% remaining black wires to a length of %"(mm, strip "#mm, twist and solder them together, cut off the point and sleeve with "#mm of "(mm heatshrink, leaving Iust enough wire protruding to fit the terminal block on the ,el!i. 5t will Iust fit if you donJt add too much solder. The reason for using all 12 wires is that the heater and motor currents cause a small voltage drop in the ground connection. Because it is connected to the mains earth inside the PSU the ground of the Melzi will be a little above earth potential. That causes current to flow in the USB lead to the P and can disrupt the communication. !eeping the ground resistance as low as possible reduces the problem. "t also ma#imises the voltage at the bed.

3. 0ut a cable tie round the black and yellow bundles plus all the short one. "(. 0ut a second cable tie on the si. wires going to the resistors, see the picture above.

Summary
%olour 1lack /ellow 7ed 1lack 1lack N 6reen 7ed Arange 1lue 0urple 6rey 'ires &ength *leeving "% ) " " % ) * " " " %"(mm "(mm "3(mm ).&mm %+(mm *.%mm %&(mm *.%mm %%(mm *.%mm %*(mm *.%mm O#(mm ).&mm O#(mm *.%mm O#(mm %.&mm O#(mm %.&mm O#(mm %.&mm 6B N"%9 #9 dummy load #9 dummy load return *.*9 dummy load $ *.*9 sense *.*9 dummy load return $ 0S? AB #9 ; unused *.*9 ; unused ;"%9 ; unused #9 standby ; unused 0ower good ; unused +unction

Arange N 1rown %

#8

Assembly

". 0ut four ,& nyloc nuts in the nut traps of the two brackets. %. Screw the brackets to the frame with ,& . ")mm cap screws and washers. *. 7un the wires from the right - motor, the / motor and the bed up the corner between the gantry and the right stay before fitting the 0S? between the brackets. &. Secure the 0S? with two );*% . 3.#mm pan screws, ,& star washers and ,& plain washers. #. Screw the resistors to the frame using four ,%.# . "%mm pan screws, ,%.#mm washers and ,%.#mm nyloc nuts.

#+

23. .lec!ronics Assembly Vitamins

& ,* cap screw . ")mm " ,el!i electronics & Byloc nut ,* " ,icro S card " ,icro S to ?S1 adapter % <eatshrink sleeving 5 %.&mm . "#mm " ?S1 A to ,ini 1 lead + =asher ,* . 8mm . (.#mm

Printed Parts
& pcbEspacer.stl

Assembly
B.1. The ,el!i is the most e.pensive part of the machine and can easily be damaged if the wiring is incorrect. 0lease double check before connecting the power. 5t is supplied loaded with ,arlin firmware configured for the ,endel3(, has the stepper motor current pots pre;set to (.#9, which gives ".%A and has had a full functional test on a Iig with motors, limit switches and dummy loads for the heaters and fans. The thermistor inputs have been tested using a known resistance. ?se static precautions when handling. Screw the ,el!i to the frame above the 0S? with the four ,* . ")mm cap screws, spacers and ,* nuts with plain washers both sides. The side of the ,el!i with the terminals goes towards the gantry. 1efore connecting each pair of wires check the resistance with a multi;meter ' ; Thermistors should measure roughly "((4P at room temperature. The e.truder heater should measure about #.+P. The bed heater should measure O".%P . !here should be no connection between the heaters and the thermistors . The limit switches should be a short circuit and open when they are pressed. The motors should be about ".3P between red and blue and between green and black but no connection between red and black.

The wires all terminate at screw terminals on the ,el!i board. The terminals are labelled on the edge of the 0C1. Connect the wires following the first two columns of the table below. Strip and tin them first. 6ive each wire a tug after screwing down the terminal to make sure it has grabbed the wire. A loose wire can cause a spark which can damage the ,el!i. Bote that there are no connections to FABN on the ,el!i and pin # of the ribbon cable.

#3

Mel,i %onnector
>T>,0 6B >T>,0 S56BA@ 1T>,0 6B 1T>,0 S56BA@ -STA0 6B -STA0 S56BA@ /STA0 6B /STA0 S56BA@ :STA0 6B :STA0 S56BA@ FAB ; FAB N <AT>B ; <AT>B N <AT1> ; <AT1> N 0A=>7 6B 0A=>7 N "%9 >;,ATA7 >;,ATA7 >;,ATA7 >;,ATA7 -;,ATA7 -;,ATA7 -;,ATA7 -;,ATA7 /;,ATA7 /;,ATA7 /;,ATA7 /;,ATA7 :;,ATA7 :;,ATA7 :;,ATA7 :;,ATA7

'ire
7ibbon & 7ibbon * 7ed 1lack 1lue 1lue 6reen 6reen 7ibbon % 7ibbon " GredH 7ibbon "%

*ignal
>.truder thermistor 6B

) connector pin
0in 3

>.truder thermistor signal 0in " 1ed thermistor 6B 1ed thermistor signal - limit switch 6B - limit switch signal / limit switch 6B / limit switch signal : limit switch 6B : limit switch signal Fan drive Fan "%9 0in "*

7ibbon 3, "(, "" >.truder heater drive 7ibbon ), 8, + Thick black Thick red 0S? 1lack 0S? /ellow 7ibbon "* 7ibbon "& 7ibbon "# 7ibbon ") - motor " red - motor % blue >.truder heater N"%9 1ed heater drive 1ed heater N "%9 0S? 6B 0S? N "%9 >.truder motor red >.truder motor blue >.truder motor green >.truder motor black - motor red - motor blue

0in &, #, "% 0in *, "(, ""

0in ) 0in "& 0in 8 0in "#

- motor " green - motor green - motor % black - motor black / motor red / motor blue / motor green / motor black 7ibbon "8 7ibbon "+ 7ibbon "3 7ibbon %( / motor red / motor blue / motor green / motor black : motor red : motor blue : motor green : motor black

)(

The - motors are wired in series, so connect red and green of the first motor and blue and black of the second motor to the ,el!i, connect blue on the first motor to red on the second motor and sleeve the Ioint with %.&mm . "#mm heatshrink. Connect black of the first motor to green on the second and sleeve with heatshrink.

For reference the ribbon cable has the following pin out' ; 'ire number " GredH % * & # ) 8 + 3 "( "" "% "* "& "# ") "8 "+ "3 %( *ignal : limit signal : limit 6B Thermistor signal Thermistor 6B 0robe Gnot currently usedH <eater N"%9 <eater N"%9 <eater N"%9 <eater ; <eater ; <eater ; Fan ; >.truder motor red >.truder motor blue >.truder motor green >.truder motor black : motor red : motor blue : motor green : motor black ) type connector pin

0in " 0in 3 0in % 0in "( 0in * 0in "" 0in & 0in "% 0in # 0in "* 0in ) 0in "& 0in 8 0in "#

The photo below shows a wired up machine. )"

)%

24. /o1!2are
The micro S card with the kit comes preloaded with software to operate the machine on =indows G@inu. versions of all the tools are available onlineH. After this has been copied to your 0C the card can be wiped and used to run the machine. 7unning 6 code from the card gives more consistent results than sending it over ?S1. @oading 6 code onto the card via the ,el!i is quite slow so a ?S1 S card reader is included in the kit to allow it to be loaded directly from the 0C. The following softwares are included' ;

Marlin Firm are

This is the source code for the firmware that is pre;loaded on the ,el!i. 5t is BopheadJs fork and is also available on 6it<ub https'$$github.com$nophead$,arlin. The pre;installed version is sufficient to test the machine but calibration involves tweaking the - a.is home position and the hobbed bolt diameter.

Arduino !"#
This is used to compile and load the firmware and is located in the Windows\arduino-1.0.1folder. Ance copied to your 0C it can be run simply by clicking on arduino.exe, no installation is needed. 5t is as downloaded from http'$$arduino.cc$en$,ain$Software with Iust the addition of the hardware\Melzi folder. =hen started it opens an empty sketch. ?se the File$Apen menu to open Marlin\Marlin\Marlin.ino. Click on the configuration.h tab and make your changes to Z_HOME_PO !"E_ #EP _PE$_MM and possibly change the baud rate. >verything else should work as is. =hen you are directed below to update the firmware do the following' ; >nsure the auto reset Iumper at the top of the ,el!i is fitted. ?se the Tools $ 1oard menu option to set the board to Q,el!i =$ ATmega"%+&p ")m<!R. ?se the Tools $ Serial 0ort option to select the correct ?S1 port. 0ress the play button. =ait for R one uploadingR to appear. Save your changes with the save button.

Pronterfa$e
This is a simple host application used to control the printer downloaded from http'$$koti.kapsi.fi$Okliment$printrun$ . Again it needs no installation. Simply copy the files and run Windows\%rintrun-win-Mar&01&slic'r\dist\%ronterface.exe. To configure it for the ,endel3( build volume and origin plus get some handy buttons for bed levelling copy %rintrunconf.ini over the one it creates when first run. This is located in ()\*ocu+ents"and" ettings\,serna+e on =in:0 and ()\,sers\,serna+e on =in8.

)*

25. Tes!in( %umpers

,ake sure the auto reset Iumper is installed at the top of the ,el!i. This is required for loading firmware but has to be removed for stand alone operation from the S card. The power Iumper in the middle of the board should be set to 97>6 to power the ,el!i from the 0S?. The ?S1 position can be useful for loading firmware before the board is installed but the #9 at the end of a ?S1 cable is a lot less accurate and more noisy then the regulator output.

Po er up
ouble check the "%9 supply to the board is the right way round, plug in the mains and switch on the 0S?. The 0S? fan should run. Connect the ?S1 lead to a 0C and a ?S1 connection should appear. An =indows, the 0C will need a ?S1 FT 5 driver for the serial port to appear. This can be found in the Arduino drivers folder. The board comes with ,arlin installed configured for %#(k1. Bote that non;standard baud rates have problems on some versions of @inu., so you may have to configure the firmware for ""#.%k1 and reinstall the firmware. Apen pronterface, set the baud rate and serial port and press QConnectR. After a few seconds the following should be displayed.
Connecting... start Printer is now online. echo:Marlin: 1.0.0 RC2 echo: Last Updated: 2012-07-27 | A thor: nophead echo: !ree Me"or#: 12$%2 Planner& ''er&#tes: 12(2 echo:Using )e'a lt settings: echo:*) card o+

&imit s it$'es
!eck t!at t!e limit s"itc!es are "orking "it! #11$. %!en no s"itc!es are triggere& t!ey s!oul& all rea& lo"'

,-"in:L #-"in:L .-"in:L o+

Check that manually triggering each switch causes the corresponding input to change from @ to < while the switch is held down. Also check that each a.is is able to hit its limit switch. For : the e.truder wing nut can get in the way. 5f this is the case simply rotate the he. head bolt in its socket. The - a.is must be reasonably level side to side so that the right hand side doesnJt hit the top of the a.is before the left side hits the limit switch. The micro;switches must be mounted in the correct orientation for the button to strike its intended target G: towards the bottom, / towards the top, towards the frontH.

Motors
0ut some oil on the - lead screws and lithium grease on the e.truder gears. A1S gears will run continuously for months with grease but wear out quickly when run dry. ,ove all of the a.es manually to somewhere near the centre. Then check that all the a.es move in the right direction by using the Iog buttons in 0roterface. Click on the Q"(R ring in the N: quadrant and check that the carriage moves "(mm towards the left, away from the limit switch. Then click the Q"(R ring in the ;: quadrant and check it moves back towards the switch. Since the limit switches have been verified to be working and the motor is running in the right direction it is now )&

safe to home by pressing the : home button Ghouse icon with an :H. 7epeat the procedure for the / a.is. N/ moves the bed backwards away from the switch and ;/ forwards towards the switch Bote that both the : and / a.es are backwards by normal conventions when viewed from the front of the machine. 1ecause the - limit switch is at the top the N- button should move the - a.is upwards towards its limit switch and ;- should move it back downwards. =hen all the a.es have been homed successfully enter 6":(/(-"((F*(((( to centre them. 5t should then be possible to use the Q"((R ring to move the : and / a.es to their e.tremes. The firmware soft limits should prevent them hitting the end. Check the the e.truder feeds forwards when the Q>.trudeR is pressed and backwards when the Q7everseR button is pressed.. ,arlin may prevent you from doing Jcold e.trusionJS you can override this with command ,*(%. ,ake sure you donJt have any filament loaded during this test.

(eaters
Tick the Q,onitor 0rinterR to show the temperature graph. The figures under the QCheck TempR button should show the hot end GTH and the bed G1H to be around room temperature. Set the Q<eater'R target temperature to %%(LC and press the QSetR button. The temperature of the hot end should rise and settle at %%(LC. 5f you have a thermocouple probe you can insert it inside the hot end and verify the temperature at this stage Gbefore the barrel is filled with plasticH. To do this you will need to remove the idler and stiffen the thermocouple wire by sleeving it with about "#(mm of 0TF> tubing with an outside diameter less than *mm. 0ressing the blue QAffR button should cause the temperature to slowly fall back to room temperature again. 7epeat the same procedure with the bed heater by setting it to )(LC.

Fan
Type ,"() to turn the fan on and ,"(8 to turn it off. This completes the testing.

)#

2". Calibra!ion Bed &e)elling

The best way to level the bed relative to the no!!le is to use a dial gauge mounted in place of the e.truder using this clamp. 5f you donJt have a dial gauge you can roll a spare piece of smooth rod or slide some paper or film under the no!!le and feel when it is Iust touching.

The two pillars at the back of the bed have a washer under them to ensure the front can be made both higher or lower than the back. Those pillars are tightened and not adIusted. Front ; back adIustment is achieved by adIusting the two pillars at the front. @eft ; right adIustment is done by turning the - lead screws. 5deally there would be only one mounting point at the front as only three points are needed to mount a stiff sheet like glass. <aving four makes the adIustment more tedious as they tend to bend the sheet and interact with each other. Start by sliding a washer under the front pillars to set them to the same height as the back. ,ove the gauge or no!!le to the middle of the back of the bed. Bote that level on the gauge, or nudge the a.is to Iust touch your feeler. This is the level that we want the whole bed to be at. ,ove to the back left corner and adIust the left lead screw to get the same level as the middle. ,ove to back right and adIust the back right lead screw. ,oving the gauge all the way across the back should now read the same height. Bow move to each of the front corners in turn and turn the pillar until the height is correct. @ock them in place by tightening the top screws through the bed. The whole bed should now be level but usually you need to repeat the procedure a few times due to the interaction of the four points.

))

#*truder Calibration
The > steps per mm should be adIusted so that when commanded to e.trude "((mm it actually feeds "((mm. This is done by placing a mark Ga piece of tape for instanceH on the filament "%(mm above the e.truder and telling it to feed "((mm at say )(mm$min. Then measure the distance to the mark to work out how much it actually e.truded. 5t depends on the diameter of the bolt hobbing and how far the plastic is pressed into it, i.e. how soft it is and the spring tension. <arder plastics will feed faster. ,ultiply the >EST>0SE0>7E,, in the firmware by "(( $ actual e.trusion and reload it. /ou also need to make sure the slicer knows what volume of plastic it actually gets for a "mm increment, and that depends on the diameter of your filament. ,easure the diameter using digital callipers and then input that figure into the slicing software. The Faberdashery sample provided will be very close to %.+#mm.

+ (ome Point
=hen using a top - limit switch you set the height of the machine in the firmware and thereby define T(T as Ttouching the bedT without having to actually crash the head into the bed. Ance the bed is levelled home -, and then nudge it down to meet an obIect of known height placed on the bed. A smooth rod is ideal as you can roll it backwards and forwards nudging the no!!le up and down and feel when it Iust touching. =hen the no!!le is Iust touching your feeler obIect, take the - value with ,""&. Subtract the height of the obIect from that and then subtract the result from the -E<A,>E0AS in the firmware. For e.ample, if it thinks it is at 8 when it is actually + then -E<A,>E0AS is too small by "mm. ?pdate the firmware and download it. The position should then be accurate when the machine is cold. To get it spot on start printing an obIect Gsee ne.t sectionH and stop it after it has done the outline. Cool the outline and measure its thickness in a few places and take the average. 5f it is say (.*%mm but the obIect was sliced with (.*mm layers then it is too high by (.(%mm so increase the -E<A,>E0AS by that amount. =hen the - home point has been set rotate the two - screw pointers so that they point directly at the - bars. Ane can now see if the lead screws get out of sync.

)8

First Print
". Clean the glass bed to remove any finger marks. %. The S card also contained a 6 code file' android_ex%ort.gcode. This should print well assuming your filament is close to the %.+)mm that it was sliced for. Apen it with the File $ Apen menu option of 0ronterface and then press the S button and select S ?pload. Alternatively copy it onto the S card with the ?S1 adapter and give it an upper;case name, + characters or less, and a .6 suffi.. *. ,ake sure the Q,onitor 0rinterR button is not ticked as that can affect print quality. &. 0ress the S button, select S print and then select the file. The machine should home and then place the no!!le on the bed preventing it from oo!ing while it warms up, print an outline and then print the obIect. #. =ait for the glass to cool and the obIect should then be easy to remove. 5t should look like this' ;

)+

*licing with *keinforge The android sample was sliced with Skeinforge Gdownloaded from http'$$fabmetheus.crsndoo.com$H, which was also on the S card in the Skienforge#( folder and the settings used to slice it are in the .s-einforge folder. 7unning Skeinforge requires 0ython %.8 to be installed and then run s-einforge.0\s-einforge_a%%lication\s-einforge.%/. Close it and find where it stores its setting. This will be ()\*ocu+ents"and" ettings\,ser0a+e\.s-einforge on :0, ()\,sers\,ser0a+e\.s-einforge on =in8 and probably 12.s-einforge in @inu.. Copy the .s-einforge folder supplied over the top before re;launching it. Settings you are likely to want to change are' ; Carve' @ayer <eight >dge =idth over <eight 5nset' 5nfill =idth over Thickness Fill' >.tra Shells 5nfill Solidity 5nfill 0attern Solid Surface @ayers imension' Filament iameter ,ultiply' Bumber of Columns Bumber of 7ows 7aft' Activate 7aft Gturns on supportH Bote that the temperatures are set in .s-einforge\alterations\start.gcode.

)3

2-. 3pera!in( Ins!ruc!ions (eated Bed

The purpose of the heated bed is twofold' to reduce warping and to make the first layer stick. 5n general molten plastics donJt stick well to cold smooth surfaces but they will stick to some hot surfaces. As each layer is laid down it cools and shrinks a little due to thermal contraction. The second layer welds on to the first layer and then tries to contract, putting stress on it. The ne.t layer does the same and eventually the cumulative stress becomes enough to overcome the adhesion of the first layer to the bed and the corners start to lift and curl up. 1y keeping the obIect warm the amount of contraction is reduced until the bed is switched off at the end and then all the layers cool to room temperature together. The ideal temperature for the surface of the bed is Iust below the glass transition temperature of the plastic GTgH. This is the temperature at which the plastic transitions from a rubbery state to a rigid or glass like state. As the plastic cools from the molten state all the way down to Tg it isnJt solid enough to stress the layer below. Stopping it cooling Iust below Tg means it doesnJt contract much at all past the point where it is solid enough to stress the layer below and it is rigid enough to support the layer above. The temperature of the bed is measured underneath, so the temperature at the surface of the glass is around "#LC lower. 0@A has a glass transition around ##LC, so 8(LC is a good temperature to set the bed to. 5t can be set to a higher temperature for the first layer to increase adhesion, but after that it must be below Tg. At the end of the build 0@A obIects will come lose when the temperature drops below about *#LC due to the different contraction rate of the plastic and the glass. A1S is more difficult because it has a higher glass transition and higher thermal e.pansion coefficient 5n addition it doesnJt stick well to bare glass. A bed set temperature of "%(LC;"*(LC is needed and the bed struggles to reach that temperature without insulation under it. Covering the top surface with a sheet of corrugated cardboard makes it warm up much faster. To make A1S stick to the glass it will need some form of coating. A thin layer of a dilute solution and A1S in acetone works. 0>T or 4apton tape gives more adhesion but the disadvantage is the obIects donJt come loose when the bed cools and need to be prised off.

C'anging filament
)o not to let the e truder run out of filament. 5f it does it will lose grip as soon as it gets past the hobbed bolt, making it difficult to remove as you cannot simply rewind it. /ou would have to remove the idler screws and grab the end with snipe nose pliers and pull it out while hot.
Remo4al

To change to a new reel of filament heat the e.truder to normal operating temperature then rewind "((mm at O"%(mm$min. =hen the bit that has been molten gets to the hobbed bolt there will come a point where it is too thin or soft to be gripped. At this point pull it with enough hand tension to stop it from slipping and keep up the tension until it is all the way out. )o not stop rewinding it when it is part way out. This can cause soft filament to e.pand into the entrance of the 2;<ead Gwhich is bigger than the filament pathH and Iam there as it free!es. 5f you are switching between a strong colour and a weaker one it can take a long time to flush through all the pigment. To minimise this you can remove 0@A at +(LC Gwhich is above its glass 8(

transition temperature but below its melting pointH. As it is therefore not a liquid but a rubbery solid, it will pull out in one piece leaving very little behind. 5t does stretch a lot though, so you need to rewind about "#(mm to get it all out. The same trick can by done with A1S at "#(LC. )o not leave the e truder hot without filament as the plastic residue inside will o.idise and become baked on to the inside of the melt chamber. Switch off the heater if you are not going to reload it immediately.
Inser!ion

To insert the new filament press the Q,otors offR button, push the filament into the e.truder while turning the big gear by hand. 5t is important to apply enough force to get the filament to open the idler without it slipping against the hobbed bolt. 5f the bolt slips against the plastic its teeth can get clogged.
5i11eren! !ypes o1 1ilamen!

0lease note different filaments require different temperatures. Bot only does the type of plastic, but even the colour, makes a big difference. The village green 0@A from Faberdashery that is supplied with the kit is happy at %%(LC but other colours vary. The pigments change how viscosity varies with temperature. <ere are some recommended temperatures for other colours of 0@A' ; Fire >ngine 7ed %((LC 1utter cream Arctic white @apis blue %%(LC %&(LC %#(LC

+ailure to use an appropriate temperature may cause the e truder to become blocked. =hen trying a new filament for the first time turn the e.truder motor off and try feeding it by hand turning the big gear. 5f the temperature is too low it will be very stiff to turn. 5f it is too high it will drip out the no!!le like syrup rather than forming a solid filament. Ather signs of it being too hot are discolouration or smoke. )on't select a temperature higher than -.0/% as it will damage the hot end.

8"

Cleaning t'e 'obbed bolt

5n normal use the hobbed bolt does not need cleaning. 5f the filament starts slipping for any reason, such as not enough spring tension, or the no!!le is blocked then its teeth can become clogged with plastic. 5t will then not give consistent grip until it is cleaned. 7emove the filament by the method described above. @ower the - a.is so the e.truder is below the gantry. ?ndo the ,+ nuts and remove the big gear and the hobbed bolt. Clean the bolt with a wire brush. 7eassemble and reload the filament.

8%