Velleman K8200 Assembly Manual Download Page 1

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000 - TOOLS REQUIRED FOR BUILDING THE K8200

•

COMBINATION SNAP RING PLIERS

(VTSRP)

•

CLASSIC CIRCLIP PLIERS FOR OUTER RINGS (SHAFTS)

(WH26790)

•

ALLEN KEYS 1.5-6 mm - RING WITH 8 PCS

(1620-8)

•

WRENCH SET - OPEN END - 6 – 22 mm - 8PCS

(1420-R8)

•

CERAMIC SOLDERING IRON 30W / 230V

(STC30N)

Summary of Contents for K8200

Page 1: ...DING THE K8200 COMBINATION SNAP RING PLIERS VTSRP or CLASSIC CIRCLIP PLIERS FOR OUTER RINGS SHAFTS WH26790 ALLEN KEYS 1 5 6 mm RING WITH 8 PCS 1620 8 WRENCH SET OPEN END 6 22 mm 8PCS 1420 R8 CERAMIC SOLDERING IRON 30W 230V STC30N ...

Page 2: ... 60 40 1 mm 100g SOLD100G WIHA SOFTFINISH CABINET SCREWDRIVER SLOTTED 3 x 100 mm WH00687 5 ELECTRICAL CUTTER STRIPPER VT109 or VT109N 3 DIGIT DIGITAL MULTIMETER DVM840 DIGITAL CALLIPER 150 mm 6 0 01 mm DCA150 ...

Page 3: ... TAPE RULE 3 m HRUT3PRO 6 PC PLASTIC TUNING NEEDLE SET VTPT 5 PC DIAMOND FILE SET VTDF2 ...

Page 4: ...e threaded rod put the parts together in this order 1 x M6 locking nut 1 x M6 small washer The mounting bracket oriented as in the picture below 1 x M6 small washer 2 x M6 nut 1 x M6 small washer 1 x M6 large washer 1 x M6 small washer 2 x M6 nut 2 x M6 nut 1 x M6 small washer 1 x M6 large washer 1 x M6 small washer 1 x M6 locking nut ...

Page 5: ...Leave some extra thread on the left around 10 mm or 0 39 ...

Page 6: ...Then tighten all the nuts the result should look like this Put this part aside you will need it later in the build ...

Page 7: ...CARRIAGE Take the X CARRIAGE out of the box Take the bag labelled with 3 out of the box you should have these parts Now take 4 pieces as shown in the picture below out of the bag containing the plastic parts BEARING CLAMP X ...

Page 8: ...bolt and an M5 toothed washer through the X CARRIAGE as shown in the picture Take notice of the orientation of the aluminium plate The red arrow shows a little hole make sure this hole lines up as in the picture ...

Page 9: ...below Flip the X CARRIAGE and put a M5 flat washer and an M5 nut on the M5 bolt as in the picture Do not tighten this nut ...

Page 10: ... the BEARING CLAMP X pieces over the washer and nut as shown in the pictures below Hand tighten this assembly This part should be able to move freely but not fall off later in the build we will tighten this piece ...

Page 11: ...The assembly should look like this ...

Page 12: ...Repeat this 3 times in the positions shown on the pictures Remember do not fully tighten these bolts Just hand tighten them Now take the circlip pliers a circlip and an LM10UU linear bearing ...

Page 13: ...Use the circlip pliers to carefully fit the circlip around the LM10UU linear bearing Slide the bearing with one circlip inside one of the BEARING CLAMP X pieces ...

Page 14: ...Use the circlip pliers to carefully fit the circlip around the LM10UU linear bearing and lock it in the BEARING CLAMP X piece ...

Page 15: ... all the BEARING CLAMP X pieces have a bearing with circlips Take the bag labelled with 4 out of the box you should have these parts Notice the plastic piece ADJUST SCREW BRACKET you can find this in the bag containing the plastic parts ...

Page 16: ...Insert a small M3 nut in the ADJUST SCREW BRACKET as shown in the picture ...

Page 17: ...Insert the M4 bolt with a toothed washer as in the picture Notice the red arrow it shows a detail that is only on one side of the X CARRIAGE You need to insert the bolt on this side ...

Page 18: ...It should look like this ...

Page 19: ...Place the ADJUST SCREW BRACKET with the small M3 nut inside over this bolt as in the picture Put an M4 washer and M4 nut on this bolt and tighten everything ...

Page 20: ...Put an M3 nut and M3 toothed washer over the long bolt and screw it in the M3 nut that is inside the plastic piece ...

Page 21: ...Take the bag labelled with 5 out of the box you should have these parts Notice the plastic piece ADJUST SCREW BRACKET you can find this in the bag containing the plastic parts ...

Page 22: ...Also take 4 pieces BEARING CLAMP Y as shown in the picture below out of the bag containing the plastic parts ...

Page 23: ...Insert the M4 bolt with an M4 toothed washer as shown in the BED SUPPORT plate smaller aluminium plate Notice the orientation of the aluminium plate Make sure it is exactly as in the picture ...

Page 24: ...Insert a small M3 nut inside the ADJUST SCREW BRACKET ...

Page 25: ...Place this over the M4 bolt Notice the orientation of the BED SUPPORT plate Make sure it is exactly as in the picture Place a M4 washer and an M4 nut on the bolt and tighten everything ...

Page 26: ...Screw the long M3 bolt with an M3 toothed washer and an M3 nut in the ADJUST SCREW BRACKET as shown in the picture ...

Page 27: ...Slide an LM8UU linear bearing in the BEARING CLAMP Y piece as shown in the picture Repeat this 3 more times ...

Page 28: ...Use the circlip pliers to carefully fit the circlip around the LM8UU linear bearing ...

Page 29: ......

Page 30: ......

Page 31: ...Take an M5 bolt and an M5 toothed washer and insert them in the BED SUPPORT plate as follows Flip the plate and use an M5 washer and an M5 bolt Do not tighten this nut ...

Page 32: ...Slide a BEARING CLAMP Y piece over the washer and bolt as follows Repeat this process 3 more times the assembly should look like this ...

Page 33: ...This piece will be referred as the BED SUPPORT CARRIAGE later in the manual ...

Page 34: ...se pieces BIG Y ROD CLAMP Y ROD CLAMP RIGHT and Y ROD CLAMP LEFT as shown in the picture below out of the bag containing the plastic parts Take the bag labelled with 6 out of the box you should have these parts ...

Page 35: ...Use the long M6 bolts with M6 toothed washers as follows ...

Page 36: ......

Page 37: ...Slide the BIG Y ROD CLAMP part over the bolts and washer on the side with the 3 M6 bolts Tighten the 3 M6 bolts ...

Page 38: ...Out of the bag labelled with 7 get two smooth rods with a diameter of 8 mm 0 31 and a length of 32 5 cm 12 8 ...

Page 39: ...Slot the two rods in the BIG Y ROD CLAMP part Slide the BED SUPPORT CARRIAGE over these two rods Notice the orientation ...

Page 40: ...Slide the two smaller plastic pieces Y ROD CLAMP LEFT and Y ROD CLAMP RIGHT over the bolt and washer and make sure that the rods slot nicely in these parts ...

Page 41: ......

Page 42: ...Tighten these bolts firmly Make sure there is enough clearance between the points marked with a red arrow ...

Page 43: ......

Page 44: ... right you can tighten the bolts that keep the LM8UU linear bearings in place Ensure a smooth motion while tensioning these bolts When the motion is not fluid loosen the bolts and start over tensioning them Use the M5 bolt and the large M5 washer as follows ...

Page 45: ...And the small M5 washer and an M5 locking nut on the other end Do not tighten the locking nut Just put it on so it won t fall off We will come back to this part in a few steps ...

Page 46: ...Take the bag labelled with 8 out of the box you should have these parts Search the piece MOTOR MOUNT as shown in the picture below out of the bag containing the plastic parts ...

Page 47: ...Take 1 motor out of the package labelled 9 ...

Page 48: ...Use the 2 M3 bolts with an M3 washer to bolt the MOTOR MOUNT to the motor Notice the orientation of the wires Insert the 2 M4 bolts as follows ...

Page 49: ...ollows on the X CARRIAGE and use 2 M4 toothed washers and M4 bolts to secure the motor Make sure that the motor is mounted level and on a 90 angle with the rods and that the wires are through the large hole of the X CARRIAGE ...

Page 50: ......

Page 51: ...Take the bag labelled with 10 out of the box you should have these parts ...

Page 52: ...Cut the belt once ...

Page 53: ... 127 teeth This measurement is critical We advise to count the teeth and also measure the distance before cutting The other half should be approx 86 cm 33 9 For this stage in the build we shall need the piece of 63 5 cm 25 Store the piece of 86 cm 33 9 for later use ...

Page 54: ...Take these pieces BELT CLAMP A and BELT CLAMP B as shown in the picture below out of the bag containing the plastic parts ...

Page 55: ...Take the pulley and the small M3 locking bolt ...

Page 56: ...Screw the bolt into the pulley ...

Page 57: ...Slide the pulley over the motor shaft as shown and tighten the small locking bolt ...

Page 58: ...Loosen the bolt and washer on the BIG Y ROD CLAMP you mounted earlier ...

Page 59: ...Place the small aluminium bracket as shown in the picture and tighten the assembly ...

Page 60: ... the M5 bolt the 625 bearing 6 M5 washers and 2 large M5 washers to assemble the following Use an M5 locking nut and an M5 washer and mount the assembly as shown in the picture Do not tighten this assembly ...

Page 61: ...Take the long M5 bolt the belt and the 2 plastic pieces BELT CLAMP A and BELT CLAMP B ...

Page 62: ...Assemble them as shown in the picture Take notice that the belt sits between the clamps exactly as in the picture ...

Page 63: ...Use an M5 washer and bolt to secure this assembly to the BED SUPPORT CARRIAGE as shown in the pictures ...

Page 64: ...Loop the belt around the pulley and around the 625 BEARING Now tighten the bolt with the 625 BEARING as shown in the pictures to put tension on the belt ...

Page 65: ......

Page 66: ...Take the bag labelled with 11 out of the box you should have these parts ...

Page 67: ...Search the piece MICROSWITCH MOUNT as shown in the picture below out of the bag containing the plastic parts ...

Page 68: ...Insert 2 M3 bolts with M3 washers as shown ...

Page 69: ...Add a micro switch and 2 M3 toothed washer and 2 M3 bolts Tighten these bolts ...

Page 70: ......

Page 71: ...Cut 10 mm 0 39 of the lever of the micro switch be careful not to cut too much ...

Page 72: ...Slot the remaining M3 bolt in the X CARRIAGE as in the picture ...

Page 73: ...Use an M3 toothed washer and an M3 bolt to hold it in place Do not tighten this bolt ...

Page 74: ...re that the screw on the BED support carriage actuates the micro switch as shown in the pictures below If this is not the case you can loosen the 4 bolts that hold the BEARING CLAMP Y pieces in place move the BED SUPPORT PLATE left or right and tighten the bolts again ensuring a fluid motion ...

Page 75: ...Tighten the bolt that holds the MICROSWITCH MOUNT in place ...

Page 76: ...You have now finished the second chapter of your build You should have a completed X CARRIAGE as shown in the picture below ...

Page 77: ...BLING BASE FRAME Take one ALUMINIUM PROFILE of 450 mm 17 7 out of the box Take two ALUMINIUM PROFILES of 416 mm 16 4 out of the box Take the bag labelled with 14 out of the box You should have 14 ANGULAR MOUNTS ...

Page 78: ...Slide 2 of these ANGULAR MOUNTS in each side of the ALUMINIUM PROFILE of 450 mm 17 7 ...

Page 79: ......

Page 80: ...Slide an ALUMINIUM PROFILE of 416 mm 16 4 on each side of the ALUMINIUM PROFILE of 450 mm 17 7 ...

Page 81: ...Tighten all the bolts firmly and make sure all angles are 90 and all ALUMINIUM PROFILES are flush ...

Page 82: ...You should have this ...

Page 83: ...Take the bag labelled with 15 out of the box You should have these parts Take the bag labelled with 16 out of the box You should have a bag with 34 square nuts ...

Page 84: ...y be an M5 nut on the bolt Screw a regular M5 nut an M5 flat washer and a square M5 nut on the foot Repeat this 4 times Do not tighten these nuts Slide these assemblies into the ends of each 416 mm 16 4 ALUMINIUM PROFILE ...

Page 85: ...Tighten the nuts firmly as in the picture below ...

Page 86: ...The frame should look like this ...

Page 87: ...Take two rods out of the bag labelled with 7 These rods should have a diameter of 10 mm 0 39 and a length of 450 mm 17 7 Slide the two rods into the linear bearings as shown in the pictures below ...

Page 88: ......

Page 89: ...Now take 4 pieces as shown in the picture below out of the bag containing the plastic parts ROD CLAMP X Slide the 4 ROD CLAMP X pieces over the ends of each rod ...

Page 90: ...Take all the M5 bolts out of the bag labelled with 17 ...

Page 91: ...Insert these bolts in each of the ROD CLAMP X pieces as follows ...

Page 92: ......

Page 93: ...Screw an M5 square nut on each of the bolts Do not tighten these nuts The X CARRIAGE should look like this ...

Page 94: ...Now slide the X CARRIAGE into the frame as shown in the pictures below Do this with the side of the motor first ...

Page 95: ......

Page 96: ...Now slide 2 square M5 nuts into the right ALUMINIUM PROFILE as shown ...

Page 97: ...Slide one square M5 nut into the left ALUMINIUM PROFILE as shown ...

Page 98: ...UNT on the end of the frame Make sure the X CARRIAGE is level and parallel inside the frame Also check if the BEARING CLAMP X pieces are still in the right place The bolts holding these pieces in place should still be just hand tightened Now slide an ANGULAR MOUNT on each ALUMINIUM bar on the open side of the frame ...

Page 99: ...Take one ALUMINIUM PROFILE of 450 mm 17 7 out of the box and slide it down the two ANGULAR MOUNTS ...

Page 100: ...Now slide the ALUMINIUM PROFILE and the 2 ANGULAR MOUNTS inside the frame ...

Page 101: ...If the ALUMINIUM PROFILE is flush with the rest of the frame you can tighten all the bolts of the ANGULAR MOUNTS ...

Page 102: ......

Page 103: ... BEARING CLAMP X pieces are still in the right place you can tighten these bolts holding them in place Make sure the X CARRIAGE can move freely Check if the X CARRIAGE is centred you should measure approx 93 50 mm 3 68 on each side ...

Page 104: ...Now tighten the bolts on de ROD CLAMP X pieces securing the X carriage in place ...

Page 105: ...BEARING CLAMP Y pieces and the LINEAR BEARINGS in the BEARING CLAMP X pieces You can slide these bearings a few millimetres out of the way when there is not enough clearance The 2 carriages should now move freely along the full length of all the rods ...

Page 106: ......

Page 107: ...004 ASSEMBLING THE LEFT UPRIGHT OF THE FRAME Take one ALUMINIUM PROFILE of 500 mm 19 7 out of the box ...

Page 108: ...Slide two ANGULAR MOUNTS from the box in the end of the ALUMINIUM PROFILE of 500 mm 19 7 Slide this assembly in the left profile of the BASE FRAME ...

Page 109: ...Slide it further down the profile until its centre is at 16 cm 6 3 from the edge of the base frame ...

Page 110: ...Tighten the bolts on the ANGULAR MOUNTS Take all the parts out of the bag labelled with 21 ...

Page 111: ...Now take 4 pieces as shown in the picture below out of the bag containing the plastic parts ROD CLAMP Z BIG Notice how the round hole must be 10 mm 0 39 in diameter ...

Page 112: ...Take two rods out of the bag labelled with 7 These rods should have a diameter of 10 mm 0 39 and a length of 345 mm 13 6 ...

Page 113: ...Use 4 square M5 nuts to assemble the following ...

Page 114: ...Slide 2 of these down the left upright ALUMINIUM PROFILE as shown in the pictures below ...

Page 115: ...Now slide two ROD CLAMP Z BIG pieces over the bolts as shown in the pictures below ...

Page 116: ...Make sure that the ROD CLAMP Z BIG pieces are as far down as possible and then tighten the bolt Do not over tighten this bolt ...

Page 117: ...Put the two rods in the ROD CLAMP Z BIG pieces ...

Page 118: ...Take all the parts out of the bag labelled with 19 ...

Page 119: ...Now take 4 pieces as shown in the picture below out of the bag containing the plastic parts BEARING CLAMP Z BIG ...

Page 120: ...Slide 4 linear bearings into the 4 BEARING CLAMP Z BIG pieces ...

Page 121: ...Use the circlip pliers to carefully fit the circlips around the both sides of the 4 LM10UU LINEAR BEARINGS ...

Page 122: ......

Page 123: ...Take all the parts out of the bag labelled with 20 ...

Page 124: ...Use the 2 M4 countersunk screws to attach the small ALUMINIUM PROFILE to the Z CARRIAGE FRONT piece ...

Page 125: ...Note the red markings Make sure the orientation is correct Use the M4 nuts and M4 toothed washers as shown in the picture below ...

Page 126: ...Slide an M4 washer over the long M4 bolt Repeat this 8 times ...

Page 127: ...T piece and the Z CARRIAGE back piece Make sure that the orientation of the pieces is exactly as in the picture watch the red arrows carefully Put the remaining bolts in place and use an M4 washer and an M4 locking nut on each bolt Do not tighten the bolts ...

Page 128: ...Slide the 4 BEARING CLAMP Z BIG pieces between the 2 aluminium plates and over the bolts ...

Page 129: ...Slightly tighten the bolts We will fully tighten these bolts at a later step in the building process ...

Page 130: ...Slide this assembly over the upright 2 rods Pay attention to the orientation ...

Page 131: ...Now slide the two remaining ROD CLAMP Z BIG pieces over the rods ...

Page 132: ...Take two of these bolts you assembled earlier Slide these bolts in the upright profile so they fit in the ROD CLAMP Z BIG pieces ...

Page 133: ...Tighten these bolts Do not over tighten ...

Page 134: ...Making sure that this Z CARRIAGE can move freely up and down you can firmly tighten all the bolts that were previously only slightly tightened ...

Page 135: ...005 ASSEMBLING THE RIGHT UPRIGHT OF THE FRAME Take one ALUMINIUM PROFILE of 500 mm 19 7 out of the box Slide two ANGULAR MOUNTS from the box in the end of the ALUMINIUM PROFILE of 500 mm 19 7 ...

Page 136: ...Slide this assembly in the right profile of the BASE FRAME Slide it down the profile until its centre is at 16 cm 6 3 from the edge of the base frame ...

Page 137: ......

Page 138: ...Tighten the bolts on the ANGULAR MOUNTS Take all the parts out of the bag labelled with 22 ...

Page 139: ...Now take the piece as shown in the picture below out of the bag containing the plastic parts BEARING CLAMP Z SMALL ...

Page 140: ...Take all the parts out of the bag labelled with 23 ...

Page 141: ...t of the bag labelled with 7 This rod should have a diameter of 8 mm 0 39 and a length of 300 mm 11 8 Now take the 2 pieces as shown in the picture below out of the bag containing the plastic parts ROD CLAMP Z SMALL ...

Page 142: ...Slide an M5 washer over the M5 bolt and screw a square M5 nut on Repeat this 2 times ...

Page 143: ...Slide one of these bolts in the right upright ALUMINIUM PROFILE ...

Page 144: ...Slide one of the ROD CLAMP Z SMALL pieces over this bolt and make sure you tighten this bolt so that this piece sits at about 6 cm 2 36 of the base frame ...

Page 145: ...Insert the rod into the ROD CLAMP Z SMALL piece ...

Page 146: ...Slide an LM8UU LINEAR BEARING into the BEARING CLAMP Z SMALL piece Use the circlip pliers to carefully fit the circlips around the both sides of the LM8UU LINEAR BEARING ...

Page 147: ......

Page 148: ...piece over the rod as shown in the picture below Slide one of the M5 bolts with washer and square nut and slide it down the ALUMINIUM PROFILE and slide a ROD CLAMP Z SMALL over this bolt It should fit over the rod ...

Page 149: ......

Page 150: ...ASSEMBLING THE EXTRUDER ARM Take one ALUMINIUM PROFILE of 395 mm 15 6 out of the box Take the FAN HOLDER BRACKET out of the bag labelled with 25 also take 4 square M5 nuts bag 16 and 2 ANGULAR MOUNTS bag 14 ...

Page 151: ...Slide the 2 ANGULAR MOUNTS into one end of the ALUMINIUM PROFILE of 395 mm 15 6 Slide 2 square M5 nuts into the ALUMINIUM PROFILE as shown in the picture below ...

Page 152: ...Slide the FAN HOLDER BRACKET and 1 square M5 nut into the ALUMINIUM PROFILE Notice the orientation of each part ...

Page 153: ...Now insert another square M5 nut on the opposite side of the fan holder bracket Notice the orientation ...

Page 154: ...Now slide the ALUMINIUM PROFILE into the BEARING CLAMP Z SMALL piece ...

Page 155: ...Now slide the two ANGULAR MOUNTS into the Z CARRIAGE Be careful that while doing this none of the square M5 nuts slide out of the angular profile ...

Page 156: ...Make sure there is about 5 mm of a gap from the top of the Z CARRIAGE and the top of the ANGULAR MOUNT ...

Page 157: ...Tighten all the bolts on the ANGULAR MOUNTS ...

Page 158: ...Now take the last ALUMINIUM PROFILE it should be one of 450 mm 17 7 Take 4 ANGULAR MOUNTS out of bag 14 ...

Page 159: ...Slide 2 ANGULAR MOUNTS on each end of the ALUMINIUM PROFILE ...

Page 160: ...Slide this assembly in the top of the frame ...

Page 161: ......

Page 162: ...Slide the ALUMINIUM PROFILE down until the tops of the ANGULAR MOUNTS are flush with the tops of the frame ...

Page 163: ......

Page 164: ...Tighten all the bolts on the angular mounts Slide the two square nuts on the opposite of each other in the extruder arm towards the BEARING CLAMP Z SMALL piece ...

Page 165: ...Use the 2 M5 bolts and 2 M5 washers to screw the BEARING CLAMP Z SMALL piece to the EXTRUDER ARM ...

Page 166: ......

Page 167: ...Tighten these bolts while making sure the Z CARRIAGE and the EXTRUDER ARM move freely ...

Page 168: ...007 ASSEMBLING THE Z MOTOR AND THREADED ROD Take a motor out of the package labelled with 9 Take the parts out of the bag labelled with 26 ...

Page 169: ...Now take the piece as shown in the picture below out of the bag containing the plastic parts Z ROD GUIDE ...

Page 170: ...Slide 2 square M5 nut into the left upright ALUMINIUM PROFILE as shown in the pictures below ...

Page 171: ......

Page 172: ...Use 2 M5 bolts and 2 M5 toothed washers to bolt the Z MOTOR BRACKET to the frame ...

Page 173: ...Make sure the bracket bottom is at MAXIMUM 4 5 cm 1 77 from the bottom frame It should be between 4 cm 1 57 and 4 5 cm 1 77 Tighten the 2 bolts and make sure that the bracket is perfectly horizontal ...

Page 174: ...Take the 2 M3 bolts and 2 M3 toothed washers and bolt the motor to the bracket Tighten these bolts firmly ...

Page 175: ...Screw an M8 bolt followed by an M8 washer an M8 toothed washer an M8 washer and the MOTOR CONNECTOR as shown in the picture below Tighten everything firmly ...

Page 176: ...Take the small locking bolt Screw it in the MOTOR CONNECTOR Do not screw this bolt in completely ...

Page 177: ...Place the MOTOR CONNECTOR over the motor shaft Make sure that the shaft goes as far as it can Now tighten the small locking bolt ...

Page 178: ...Now take these pieces as shown in the picture below out of the bag containing the plastic parts Z FOLLOWER A and Z FOLLOWER B Take the parts out of the bag labelled with 27 ...

Page 179: ...Slide the Z FOLLOWER A piece over the rod as shown in the picture Watch the orientation ...

Page 180: ...Screw the M8 nut over the rod and take the 2 M5 bolts and 2 M5 washers and screw them into the Z CARRIAGE Slide the Z FOLLOWER B piece over the rod as shown in the picture Watch the orientation ...

Page 181: ...Tighten the MOTOR CONNECTOR to make sure there is no play ...

Page 182: ...tach the Z FOLLOWER A piece to the CARRIAGE Do not fully tighten these bolts Turn the rod until the M8 bolt sits snugly into the Z FOLLOWER A piece Snap the Z FOLLOWER B piece into the Z FOLLOWER A piece ...

Page 183: ...Take the 2 M4 bolts and 2 M4 washers and screw them into the top of the Z FOLLOWER assembly as shown in the picture below ...

Page 184: ...Use 2 M4 nuts to keep the two Z FOLLOWER pieces together ...

Page 185: ...Tighten these bolts Now fully tighten the bolts that attach the Z FOLLOWER assembly to Z CARRIAGE assembly ...

Page 186: ...Screw an M8 locking bolt on the rod followed by an M8 washer ...

Page 187: ...Slide a 608 bearing into the Z ROD GUIDE piece Slide this assembly over the rod ...

Page 188: ...Take an M5 bolt an M5 washer and a square M5 nut Slide this assembly into the left upright ALUMINIUM PROFILE as shown in the picture below ...

Page 189: ...Slide the assembly over the Z ROD GUIDE and tighten the bolt so that it is fixed but still possible to slide up and down ...

Page 190: ...Slide this bolt and Z ROD GUIDE down until the 608 bearing meets the M8 washer Screw an M8 locking nut over the rod as shown in the picture ...

Page 191: ......

Page 192: ...The build should now look like this ...

Page 193: ......

Page 194: ...008 ASSEMBLING THE X DRIVETRAIN Take the parts out of the bag labelled with 28 Take the piece of 86 cm 3 39 belt you cut earlier ...

Page 195: ...Take the parts out of the bag labelled with 29 ...

Page 196: ...Take the two X BELT CLAMPS 4 M4 bolts 4 M4 toothed washers and 4 M4 nuts Bolt the X BELT CLAMPS as shown to the X CARRIAGE Notice the orientation of all the components ...

Page 197: ......

Page 198: ...Take the short M5 bolt and an M5 toothed washer and screw the X PULLEY BRACKET to the square nut on the left side of the base frame you put there earlier Do not fully tighten the bolt ...

Page 199: ......

Page 200: ...Take the large M5 bolt 6 small M5 washers 2 large M5 washers and 1 625 bearing And assemble the following ...

Page 201: ...Use an M5 locking nut and an M5 washer to bolt this assembly to the X PULLEY BRACKET as shown in the picture below ...

Page 202: ......

Page 203: ...m the X BELT CLAMPS and the X pulley should be in one line Slide the X PULLEY BRACKET until it is in one line with the two X BELT CLAMPS and then tighten the bolt holding it to the base frame Make sure it is perfectly horizontal ...

Page 204: ...Take two short M5 bolts and two M5 toothed washers and screw the X MOTOR BRACKET to the 2 square nuts on the right side of the base frame you put there earlier Do not fully tighten the bolts ...

Page 205: ...Take the small M3 locking bolt and screw it into the X TOOTHED PULLEY Do not screw it in completely ...

Page 206: ...Slide the toothed pulley over the shaft of the motor and tighten the small M3 bolt Watch the orientation of the pulley closely and make sure it is flush at the top ...

Page 207: ...Take the 2 M3 bolts and the M3 toothed washers and use them to bolt the motor in place ...

Page 208: ...The pulley of the motor should be in line with the 2 X BELT CLAMP pieces Slide it in place and tighten the bolts Make sure it is completely level ...

Page 209: ...Now clamp the end of the belt into the leftmost X BELT CLAMP Tighten the nuts ...

Page 210: ...Thread the belt around the pulley ...

Page 211: ...Loop the belt through the Y belt and around the motor pulley ...

Page 212: ...Clamp the end of the belt between the X BELT CLAMP on the right Pull tension on the belt before tightening the nuts on the X BELT CLAMP ...

Page 213: ......

Page 214: ......

Page 215: ...arts LARGE GEAR SMALL GEAR EXTRUDER BASE EXTRUDER SPRING MOUNT FILAMENT GUIDER EXTRUDER BEARING CLAMP A EXTRUDER BEARING CLAMP B Attention there is one SMALL GEAR with a small threaded hole on the side this is the one you need there are also 3 SMALL GEARS in a separate bag without the small threaded hole on the side these are spare parts Do not use one of these 3 ...

Page 216: ...Take 4 M3 nuts and push them into the EXTRUDER BASE as shown below ...

Page 217: ...Take the EXTRUDER MOUNT PLATE and 4 M3x16 bolts ...

Page 218: ...Bolt the EXTRUDER MOUNT PLATE to the EXTRUDER BASE Watch the orientation of the pieces closely Do not fully tighten these bolts ...

Page 219: ...Take 2 M4 bolts and 2 M4 washers Bolt the FRONT AND BACK EXTRUDER PLATE to the EXTRUDER BASE Watch the orientation of the parts closely ...

Page 220: ......

Page 221: ...Use 2 M4 locking nuts and 2 M4 washers Do not tighten the nuts ...

Page 222: ...Use the M5 butterfly bolt and an M5 nut as shown in the picture below together with the EXTRUDER SPRING MOUNT ...

Page 223: ...Slide this assembly into the FRONT AND BACK EXTRUDER PLATE Tighten the bolts that hold the FRONT AND BACK EXTRUDER PLATE together ...

Page 224: ...Tighten the bolts that hold the EXTRUDER MOUNT PLATE to THE EXTRUDER BASE ...

Page 225: ...Use an M5 locking nut and screw it on the end of the butterfly bolt Screw this bolt further down so there is about 3 to 5 mm 0 12 to 0 2 of thread from the butterfly bolt visible ...

Page 226: ...Push 2 M3 nuts into the EXTRUDER BEARING CLAMP A piece ...

Page 227: ...Take a 608 bearing out of the bag with 3 bearings and put it between the EXTRUDER BEARING CLAMP A and the EXTRUDER BEARING CLAMP B ...

Page 228: ......

Page 229: ...Take the 2 M3x20 bolts and bolt the two halves together ...

Page 230: ...If the bolts stick out a bit you should grind them down ...

Page 231: ...Use a small file and grind the bolts down Make sure that none of the grindings end up in the 608 BEARING ...

Page 232: ...If the bolts are almost flush with the plastic they will be ok ...

Page 233: ...Now screw the small locking bolt M4 x 5 in the small gear Do not screw it in completely ...

Page 234: ...otor out of the package labelled with 9 and slide the small gear over the shaft Slide it down until there is just place for a piece of paper between the motor and the small gear Then tighten the small locking bolt ...

Page 235: ...Now take the 2 metal spacers and two M3 x 16 bolts ...

Page 236: ...Slide the two bolts into the EXTRUDER BASE piece as shown in the picture below ...

Page 237: ...Tightly screw the metal spacers on these bolts ...

Page 238: ...Slide the BEARING CLAMP assembly into the extruder assembly ...

Page 239: ...Use a long M4 bolt and an M4 washer to lock the BEARING CLAMP assembly in place ...

Page 240: ...Use an M4 washer and an M4 bolt to slightly tighten this bolt ...

Page 241: ...Take the small M5 washer and the spring ...

Page 242: ...Place the spring into the cavity of the BEARING CLAMP assembly Slide the washer over the butterfly bolt ...

Page 243: ...Carefully force the spring over the butterfly bolt Take 2 long M4 bolts and 2 M4 washers Slide these two bolts in the two holes at the top of the extruder housing ...

Page 244: ...Take the filament guide piece and slide it over these bolts Watch the orientation of this piece ...

Page 245: ...Take 2 M4 washers and 2 M4 locking bolts to slightly tighten these bolts ...

Page 246: ...R 2 608 BEARINGS 2 M8 washers and the HOBBED BOLT Slide the HOBBED BOLT into the LARGE GEAR so that the head of the HOBBED BOLT fits snugly in the cavity of the LARGE GEAR Slide the 3 M8 washers over the bolt followed by a 608 BEARING ...

Page 247: ...Slide this assembly into the extruder housing Watch the orientation carefully ...

Page 248: ......

Page 249: ...Slide a 608 BEARING over the other end of the HOBBED BOLT Slide an M8 washer to cover the 608 BEARING ...

Page 250: ...Screw an M8 locking nut on the HOBBED BOLT ...

Page 251: ...Tighten this bolt but make sure that the large gear turns smoothly The extruder housing should look like this ...

Page 252: ...Take a long M4 bolt and an M4 washer ...

Page 253: ...Place it as shown in the picture below Tighten this bolt slightly ...

Page 254: ...Take the 3 M3 x 6 bolts ...

Page 255: ...Bolt the motor to the extruder housing Do not fully tighten these bolts ...

Page 256: ...Position the motor so the teeth of the gears interlock as shown in the picture below Then you can fully tighten the bolts ...

Page 257: ...Take 2 M3 x 25 bolts and 2 M3 washers ...

Page 258: ...into the spacers for later use the extruder itself will be mounted with these bolts Take the 2 M5 bolts the two large M5 washers and 2 M5 toothed washers Place these bolts and washers as shown in the pictures below ...

Page 259: ...Notice the 2 large M5 washers ...

Page 260: ...square M5 nuts in the bottom of the extruder arm profile you put there before Bolt the extruder to these two nuts Do not tighten these bolts fully Notice the orientation the extruder housing should be facing forward ...

Page 261: ...Slide the housing so the centre of the HOBBED BOLT sits at 20 cm 0 79 of the Z CARRIAGE ...

Page 262: ...Now make sure the extruder housing sits level and there is about a 1 mm 0 04 gap between the extruder arm profile and the back of the motor ...

Page 263: ...Now you can tighten the bolts that hold the extruder in place ...

Page 264: ...010 ASSEMBLING THE HEATED BED Take all the parts out of the bag labelled with 32 Now take the pieces as shown in the picture below out of the bag with all the plastic parts THUMB SCREWS ...

Page 265: ...Take the 4 countersunk M4 bolts and put them through the BED PLATE ...

Page 266: ...Use 4 M4 toothed washers and 4 M4 nuts ...

Page 267: ...Tighten all these bolts firmly Take all the parts out of the bag labelled with 33 Take extra care with the bag with the small NTC thermistor ...

Page 268: ...Lay the CARDBOARD ISOLATOR on top of the BED PLATE and align the holes Watch the orientation of the bedplate carefully ...

Page 269: ...Now take the HEATED BED PCB and the NTC THERMISTOR ...

Page 270: ...Tin one pad ...

Page 271: ...Place the NTC THERMISTOR with one side on the pad while you apply heat it does not matter which side a thermistor is not polarized Make sure you do not heat the thermistor for too long ...

Page 272: ...Now tin the other pad and other side of the NTC THERMISTOR ...

Page 273: ...A soldered NTC THERMISTOR should look like this Place the HEATED BED PCB on the BED PLATE Watch the orientation carefully ...

Page 274: ...Insert the 4 countersunk M3 bolts in the 4 holes ...

Page 275: ...Use 4 M3 washers and 4 M3 nuts to secure the HEATED BED PCB to the BED PLATE Tighten these 4 bolts firmly ...

Page 276: ...Insert an M4 nut into 4 THUMB SCREWS ...

Page 277: ...Screw these THUMB SCREWS onto the 4 BED PLATE bolts all the way down ...

Page 278: ...Now place the bed onto the X CARRIAGE Make sure all the 4 bolts slide through the BED SUPPORT PLATE Notice the orientation ...

Page 279: ...Insert an M4 nut into 4 THUMB SCREWS ...

Page 280: ...Put an M3 toothed washer on each of the THUMB SCREWS and screw these on each of the BED PLATE bolts as shown in the pictures below ...

Page 281: ......

Page 282: ......

Page 283: ...011 FINISHING THE FRAME Take all the parts out of the bag labelled with 35 You will also need the COIL SUPPORT you assembled earlier ...

Page 284: ...Now take 2 pieces as shown in the picture below out of the bag containing the plastic parts PROFILE MOUNTS ...

Page 285: ...Slide these PROFILE MOUNTS in the right upright ALUMINIUM PROFILE as shown in the pictures below ...

Page 286: ...Next slide the COIL SUPPORT in the same profile and align it with the horizontal ALUMINIUM PROFILE Tighten it firmly ...

Page 287: ...Place an END CAP on every open ALUMINIUM PROFILE end ...

Page 288: ......

Page 289: ......

Page 290: ......

Page 291: ...012 MOUNTING THE Z X END STOPS Take all the parts out of the bag labelled with 39 Now take the piece as shown in the picture below out of the bag containing the plastic parts ADJUST SCREW BRACKET ...

Page 292: ...Slide an M3 nut into the ADJUST SCREW BRACKET piece as shown below ...

Page 293: ...Take the M4 bolt and an M4 washer and bolt the ADJUST SCREW BRACKET piece to the Z CARRIAGE as shown in the pictures Use an M4 toothed washer and an M4 nut to bolt everything together firmly ...

Page 294: ......

Page 295: ...Use the long M3 screw with an M3 nut and an M3 toothed washer as shown in the picture ...

Page 296: ...Take all the parts out of the bag labelled with 38 Slide the M3 bolt with an M3 washer and an M3 toothed washer through the micro switch as shown in the pictures ...

Page 297: ...Bolt the micro switch to the Z MOTOR BRACKET use an M3 bolt Make sure it is level ...

Page 298: ...Take all the parts out of the bag labelled with 41 ...

Page 299: ...Slide the M3 bolt with an M3 toothed washer through the micro switch ...

Page 300: ...Put the M4 washer on the other end Bolt the micro switch to the X motor as shown in the pictures below ...

Page 301: ...Make sure that the micro switch is in line with the screw on the X CARRIAGE If not you will have to reposition both X PULLEY BRACKET and X MOTOR BRACKET ...

Page 302: ......

Page 303: ...013 MOUNTING THE FAN Take all the parts out of the bag labelled with 36 Bend the FAN HOLDER as in the pictures below The angles should be roughly the same ...

Page 304: ......

Page 305: ......

Page 306: ......

Page 307: ...Take the M3 bolt with an M3 washer ...

Page 308: ...Slide it through the fan and add the FAN HOLDER ...

Page 309: ...Add an M3 toothed washer and an M3 nut ...

Page 310: ...Take the M4 bolt and an M4 washer Slide it through the FAN HOLDER and mount it to the FAN HOLDER BRACKET you put earlier on the extruder arm with an M4 nut and an M4 toothed washer ...

Page 311: ......

Page 312: ...Tighten this bolt make sure that the FAN HOLDER is vertical ...

Page 313: ...Tighten the bolt on the fan make sure that the fan is level Slide the FAN HOLDER BRACKET closer to the extruder and tighten it firmly ...

Page 314: ...Place the wire as follows ...

Page 315: ......

Page 316: ...014 MOUNTING THE CONTROLLER BOARD Take all the parts out of the bag labelled with 34 and 37 ...

Page 317: ...Slide 2 of the small plastic rings over the bolts Watch the orientation of the plastic rings ...

Page 318: ...Make sure that the plastic PROFILE MOUNTS are approx 105 mm 4 13 apart ...

Page 319: ...Slide the bolts through the controller board as shown in the pictures below Watch the orientation of the controller board closely ...

Page 320: ...Slide a spacer over each bolt Screw the bolts into the PROFILE MOUNTS ...

Page 321: ......

Page 322: ...The board should be oriented as follows ...

Page 323: ......

Page 324: ...015 WIRING THE EXTRUDER MOTOR AND FAN Take the MULTI COLOURED FLATCABLE out of the bag labelled with 40 Cut a piece of 100 cm 39 4 This length is critical measure twice before cutting ...

Page 325: ...Detach rip them of the outer Brown and Red coloured wires from the pack over the whole length Keep these apart you will need these later ...

Page 326: ...cm 0 79 Group 1 Blue Green Yellow Orange Group 2 Red Brown Group 3 Black White Group 4 Grey Violet Blue Group 5 Green Yellow Orange Strip the wires from group 4 and group 5 5 mm and twist the wires in a group together as shown in the picture ...

Page 327: ...Strip the wires from group 3 5 mm 0 2 Do not twist these together ...

Page 328: ...Strip the wires from group 2 5 mm 0 2 Do not twist these together Strip the wires from group 1 5 mm 0 2 Do not twist these together ...

Page 329: ...Tin all the wires Take extra care when tinning the wires from group 4 and 5 since these are twisted together they need a bit more tin to make sure they all stay together ...

Page 330: ...Place this end of the cable next to the extruder with group 1 closest to the extruder housing Secure the cable with a large tie strip from the bag labelled with 40 ...

Page 331: ...e sure that the extruder arm is at its lowest point an then secure the cable to the horizontal profile at the top with a large tie strip as shown in the picture Use only the length of cable needed not more ...

Page 332: ...Next secure the cable with a large tie strip next to the right upright profile ...

Page 333: ...Fold the cable as shown in the pictures below and secure the cable with a large tie strip ...

Page 334: ...On this end of the cable detach 2 cm 0 79 the Blue Green Yellow Orange wires as a group ...

Page 335: ...Strip the 4 wires 5 mm 0 2 and tin them Take a board to wire connector with 4 wires out of the bag labelled with 40 ...

Page 336: ...Plug the female connector in the male connector labelled with E MOTOR on the controller board ...

Page 337: ...hrink tubing of 1 5 cm 0 59 long and 1 large piece of the biggest heat shrink tubing of 4 cm 1 57 You can find the heat shrink tubing in the bag labelled with 40 Slide the biggest piece of heat shrink tubing over the 4 wires from the connector ...

Page 338: ...Slide the 4 small pieces of heat shrink tubing over the 4 wires of the connector ...

Page 339: ...o the 4 wires of the flat cable you tinned earlier Watch the colours closely Flat cable Connector wires Blue Yellow Green Orange Yellow Red Orange Brown Slide the small heat shrink tubes over the solder joints and heat them up so they shrink ...

Page 340: ...Now slide the big piece of heat shrink tubing over the 4 small pieces heat the big piece so it covers and protects the 4 heat shrunk joints ...

Page 341: ...Take a board to wire connector with 2 wires out of the bag labelled with 40 ...

Page 342: ...Plug the female connector in the male connector labelled with FAN on the controller board Detach 2 cm the Red and Brown wires from the flat cable as a group ...

Page 343: ...Strip and tin these two wires ...

Page 344: ......

Page 345: ... shrink tubing of 1 5 cm 0 59 long and 1 large piece of the medium size heat shrink tubing of 4 cm 1 57 You can find the heat shrink tubing in the bag labelled with 40 Slide the medium size heat shrink tubes over the 2 wires of the connector ...

Page 346: ...Slide the 2 small heat shrink tubes over the 2 wires of the connector ...

Page 347: ... from the connector to the 2 wires of the flat cable you tinned earlier Watch the colours closely Flat cable Connector wires Red Red Brown Brown Slide the 2 small heat shrink tubes over the solder joints and heat them up ...

Page 348: ......

Page 349: ...Now slide the medium size piece of heat shrink tubing over the 2 small pieces heat the medium size piece so it covers and protects the 2 heat shrunk joints ...

Page 350: ...Take a board to wire connector with 2 wires out of the bag labelled with 40 Plug the female connector in the male connector labelled with THERM1 on the controller board ...

Page 351: ...Detach 2 cm 0 79 the Black and White wires from the flat cable as a group ...

Page 352: ...Strip the two wires 5 mm 0 2 and tin them ...

Page 353: ... shrink tubing of 1 5 cm 0 59 long and 1 large piece of the medium size heat shrink tubing of 4 cm 1 57 You can find the heat shrink tubing in the bag labelled with 40 Slide the medium size heat shrink tubes over the 2 wires of the connector ...

Page 354: ...l heat shrink tubes over the 2 wires of the connector Solder the 2 wires from the connector to the 2 wires of the flat cable you tinned earlier Watch the colours closely Flat cable Connector wires Black Red White Brown ...

Page 355: ...Slide the 2 small heat shrink tubes over the solder joints and heat them up ...

Page 356: ...Now slide the medium size piece of heat shrink tubing over the 2 small pieces heat the medium size piece so it covers and protects the 2 heat shrunk joints ...

Page 357: ...Next detach 2 cm 0 79 the Orange Yellow Green and Blue Violet Grey as groups ...

Page 358: ...Strip the wires 5 mm 0 2 and twist them together per group ...

Page 359: ...Tin the wires together per group Take a board to wire connector with 4 wires out of the bag labelled with 40 ...

Page 360: ...abelled with HEATER1 on the controller board Cut 2 small pieces of the medium size heat shrink tubing of 1 5 cm 0 59 long and 1 large piece of the biggest heat shrink tubing of 4 cm 1 57 You can find the heat shrink tubing in the bag labelled with 40 ...

Page 361: ...Slide the big heat shrink tubes over the 4 wires of the connector ...

Page 362: ...Slide 1 medium size heat shrink tubes over the Yellow and Orange wire and 1 medium size heat shrink tube over the Red and Brown wire ...

Page 363: ...Next twist and tin the ends of the Yellow and Orange wires together Also twist and tin the ends of the Red and Brown wires together ...

Page 364: ... cable you tinned earlier Watch the colours closely and respect the groups Flat cable Connector wires Orange Yellow Green Red and Brown Blue Violet Grey Yellow and Orange Slide the medium size heat shrink tubes over the solder joints and heat them up so they shrink ...

Page 365: ...w slide the big piece of heat shrink tubing over the 2 medium size pieces heat the big piece so it covers and protects the 2 heat shrunk joints Secure all the joints with 2 large tie strips to the profile ...

Page 366: ......

Page 367: ...Use some small tie strips bag 40 to group the wires together ...

Page 368: ...Turn you attention to the other end of the flat cable again Take the wires of the extruder motor and tin them ...

Page 369: ...Cut 4 small pieces of the small heat shrink tubing of 1 5 cm 0 59 long and 1 large piece of the biggest heat shrink tubing of 4 cm 1 57 You can find the heat shrink tubing in the bag labelled with 40 ...

Page 370: ...Slide the big heat shrink tube over the 4 wires of the motor Slide the 4 small heat shrink tubes over the 4 wires of the motor ...

Page 371: ...Tin all the wires ...

Page 372: ...to the 4 wires of the flat cable you tinned earlier Watch the colours closely Flat cable Motor wires Blue Blue Green Red Yellow Green Orange Black Slide the small heat shrink tubes over the solder joints and heat them up so they shrink ...

Page 373: ...Now slide the big piece of heat shrink tubing over the 4 small pieces heat the big piece so it covers and protects the 4 heat shrunk joints ...

Page 374: ...Now take the 2 wires of the fan and tin them ...

Page 375: ...t 2 small pieces of the smallest heat shrink tubing of 1 5 cm 0 59 long and 1 large piece of the medium size heat shrink tubing of 4 cm 1 57 You can find the heat shrink tubing in the bag labelled with 40 ...

Page 376: ...Slide the medium size heat shrink tube over the 2 wires of the fan Slide the 2 small heat shrink tubes over the 2 wires of the connector ...

Page 377: ...Solder the 2 wires from the fan to the 2 wires of the flat cable you tinned earlier Watch the colours closely Flat cable Fan wires Red Red Brown Black ...

Page 378: ...Slide the small heat shrink tubes over the solder joints and heat them up so they shrink ...

Page 379: ...Now slide the big piece of heat shrink tubing over the 2 small pieces heat the big piece so it covers and protects the 2 heat shrunk joints ...

Page 380: ...Use a small tie strip to keep the cables together ...

Page 381: ...Use a small tie strip to guide the cable of the fan ...

Page 382: ...We will return to this flat cable again in a later chapter to hook up the extruder itself ...

Page 383: ...ABLE out of the bag labelled with 40 Cut a piece of 100 cm 3 94 This length is critical measure twice before cutting Detach rip them of the outer Blue Green Yellow Orange Red and Brown colour wires from the pack over the whole length We will use these colours for this chapter ...

Page 384: ...Detach the Brown and Red wire for 2 cm 0 79 Strip and tin the wires ...

Page 385: ...Cut 4 medium size pieces of the smallest heat shrink tubing of 1 5 cm 0 59 long ...

Page 386: ...Slide the 2 medium size pieces of heat shrink tubing over the Red and Brown wires of the flat cable Tin the two outer contacts of the Z micro switch ...

Page 387: ...Solder the Red and Brown wires to the contacts ...

Page 388: ...Slide the heat shrink tubes over the contacts and heat them up ...

Page 389: ...motor a bit and thin them Cut 4 small pieces of the smallest heat shrink tubing of 1 5 cm 0 59 long and 1 large piece of the biggest heat shrink tubing of 4 cm 1 57 You can find the heat shrink tubing in the bag labelled with 40 ...

Page 390: ...Slide the biggest piece of heat shrink tubing over the 4 wires from the motor Slide the 4 small pieces of heat shrink tubing over the 4 wires of the motor ...

Page 391: ...Solder the 4 wires from the motor to the 4 wires of the flat cable you tinned earlier Watch the colours closely Flat cable Motor wires Blue Blue Green Red Yellow Green Orange Black ...

Page 392: ...Slide the small heat shrink tubes over the solder joints and heat them up so they shrink ...

Page 393: ...Now slide the big piece of heat shrink tubing over the 4 small pieces heat the big piece so it covers and protects the 4 heat shrunk joints ...

Page 394: ...Use two small tie strips to hold the wires in place as shown in the picture below ...

Page 395: ...Slide the flat cable in the hollow space of the profile run it through the back of the printer as shown in the picture below ...

Page 396: ...Take a board to wire connector with 3 wires out of the bag labelled with 40 ...

Page 397: ...Cut the middle wire away at the connector ...

Page 398: ...Plug the female connector in the male connector labelled with ZSTOP on the controller board ...

Page 399: ...Strip all the wires from the flat cable that comes from the Z motor ...

Page 400: ...t 2 small pieces of the smallest heat shrink tubing of 1 5 cm 0 59 long and 1 large piece of the medium size heat shrink tubing of 4 cm 1 57 You can find the heat shrink tubing in the bag labelled with 40 ...

Page 401: ...Slide the medium size heat shrink tubes over the 2 wires of the connector Slide the 2 small heat shrink tubes over the 2 wires of the connector ...

Page 402: ...Solder the 2 wires from the connector to the 2 wires of the flat cable you tinned earlier Watch the colours closely Flat cable Connector wires Red Red Brown Brown ...

Page 403: ...Slide the 2 small heat shrink tubes over the solder joints and heat them up ...

Page 404: ...Now slide the medium size piece of heat shrink tubing over the 2 small pieces heat the medium size piece so it covers and protects the 2 heat shrunk joints ...

Page 405: ...Take a board to wire connector with 4 wires out of the bag labelled with 40 Plug the female connector in the male connector labelled with Z MOTOR on the controller board ...

Page 406: ...est heat shrink tubing of 1 5 cm 0 59 long and 1 large piece of the big heat shrink tubing of 4 cm 1 57 You can find the heat shrink tubing in the bag labelled with 40 Slide the big heat shrink tubes over the 4 wires of the connector ...

Page 407: ...tubes over the 4 wires of the connector Solder the 4 wires from the connector to the 4 wires of the flat cable you tinned earlier Watch the colours closely Flat cable Connector wires Blue Yellow Green Orange Yellow Red Orange Brown ...

Page 408: ...Slide the small heat shrink tubes over the solder joints and heat them up so they shrink ...

Page 409: ...Now slide the big piece of heat shrink tubing over the 4 small pieces heat the big piece so it covers and protects the 4 heat shrunk joints ...

Page 410: ...Use small tie strips to group the cables together ...

Page 411: ...Tuck the excess cable into the void in the profiles The controller board should now look like this ...

Page 412: ......

Page 413: ...RING THE X AXIS MOTOR AND MICRO SWITCH Take a board to wire connector with 4 wires out of the bag labelled with 40 Plug the female connector in the male connector labelled with X MOTOR on the controller board ...

Page 414: ...Cut the wires of the X axis motor down to about 15 cm 5 9 ...

Page 415: ...m 0 2 and tin them Cut 4 small pieces of the smallest heat shrink tubing of 1 5 cm 0 59 long and 1 large piece of the biggest heat shrink tubing of 4 cm 1 57 You can find the heat shrink tubing in the bag labelled with 40 ...

Page 416: ...Slide the big heat shrink tube over the 4 wires of the connector Slide the 4 small heat shrink tubes over the 4 wires of the connector ...

Page 417: ...Solder the 4 wires from the motor to the 4 wires of the connector you tinned earlier Watch the colours closely Connector cable Motor wires Yellow Blue Orange Red Red Green Brown Black ...

Page 418: ...Slide the small heat shrink tubes over the solder joints and heat them up so they shrink ...

Page 419: ...Now slide the big piece of heat shrink tubing over the 4 small pieces heat the big piece so it covers and protects the 4 heat shrunk joints ...

Page 420: ...Tuck the excess cable into the void in the profiles Take a piece of Red and Brown wire that you detached from the flat cable earlier Strip the ends 5 mm 0 2 and tin them ...

Page 421: ...Tin the contact points of the X micro switch Be careful and don t touch the belt with the hot soldering iron ...

Page 422: ...Cut 2 small pieces of the smallest heat shrink tubing of 1 5 cm 0 59 long Slide them over the ends of the Red and Brown wire you tinned earlier ...

Page 423: ...Solder the wires to the contact points of the micro switch slide the heat shrink tubes over the contacts and shrink them Use small tie strips to hold the Red and Brown wire in place ...

Page 424: ...Take a board to wire connector with 3 wires out of the bag labelled with 40 ...

Page 425: ...Cut the middle wire away at the connector ...

Page 426: ...Plug the female connector in the male connector labelled with XSTOP on the controller board ...

Page 427: ...Cut the Red and Brown wire from the X micro switch so that it can connect to the wires of the connector you just plugged in Strip 5 mm 0 2 and tin the ends of these wires ...

Page 428: ...t 2 small pieces of the smallest heat shrink tubing of 1 5 cm 0 59 long and 1 large piece of the medium size heat shrink tubing of 4 cm 1 57 You can find the heat shrink tubing in the bag labelled with 40 ...

Page 429: ...Slide the medium size heat shrink tubes over the 2 wires of the connector ...

Page 430: ... shrink tubes over the 2 wires of the connector Solder the 2 wires from the Red and Brown wire to the 2 wires of the flat connector you tinned earlier Watch the colours closely Flat cable Connector wires Red Red Brown Brown ...

Page 431: ...Slide the 2 small heat shrink tubes over the solder joints and heat them up ...

Page 432: ...slide the medium size piece of heat shrink tubing over the 2 small pieces heat the medium size piece so it covers and protects the 2 heat shrunk joints Use a few small tie strips to hold the wires together ...

Page 433: ......

Page 434: ...d be 1 meter 39 4 long Detach the following groups for about 2 cm 0 79 Group 1 Brown Red Group 2 Orange Yellow Green Blue Group 3 Violet Grey White Black Group 4 Brown Red Orange Yellow Green Blue Strip and thin the first 3 groups Make sure you twist the wires from group 2 and 3 together ...

Page 435: ...Twist the wires from group 2 and 3 together before soldering them together ...

Page 436: ... THERM Group 2 and 3 should go through the hole marked with HEATER Now insert the tinned pieces of the wires into the small holes the wires from Group 1 go into the holes that correspond with THERM not polarized and the wires from Group 2 and 3 go into the holes that correspond with HEATER not polarized ...

Page 437: ...Solder the end of the wires to the bottom of the board Take extra care when soldering these points to not damage a part of the printer with the hot soldering iron ...

Page 438: ...Detach Group 4 23 cm 9 06 from the wires that are now connected to the HEATED BED PCB ...

Page 439: ...ten the wires of Group 1 2 and 3 Make sure the bed can move to its full extent without the wire catching or stretching It s good practice to give it some bends as shown in the picture so that it folds nicely when the bed is moving ...

Page 440: ...Fold the cable as shown in the picture below Thread the cable through the hole ...

Page 441: ...Notice where the cable splits ...

Page 442: ...Split the wires as shown in the picture You should have a group with the following wires Blue Green Yellow Orange and a group with the following Red Brown ...

Page 443: ...t the group with the following wires Blue Green Yellow Orange and the wires of the motors so they can connect Look at the picture below for guidance Strip 5 mm 0 2 the wires as shown in the pictures below ...

Page 444: ...Tin the wires ...

Page 445: ...rink tubing of 1 5 cm 0 59 long and 1 large piece of the biggest heat shrink tubing of 4 cm 1 57 You can find the heat shrink tubing in the bag labelled with 40 Slide the biggest piece of heat shrink tubing over the 4 wires from the flat cable ...

Page 446: ...pieces of heat shrink tubing over the 4 wires of the motor Solder the 4 wires from the motor to the 4 wires of the flat cable Watch the colours closely Flat cable Motor wires Blue Blue Green Red Yellow Green Orange Black ...

Page 447: ...Slide the small heat shrink tubes over the solder joints and heat them up so they shrink ...

Page 448: ...e the big piece of heat shrink tubing over the 4 small pieces heat the big piece so it covers and protects the 4 heat shrunk joints Then use a small tie strip to keep the wires in place as shown in the picture ...

Page 449: ...Slide the Red and Brown wire through the hole as shown in the picture below ...

Page 450: ...Fold the cable as shown in the pictures below and secure it with small tie strips ...

Page 451: ...Secure the cable firmly so it is parallel to the frame ...

Page 452: ...Cut the Red and Brown wire as shown in the pictures below ...

Page 453: ...Strip 5 mm 0 2 and tin the wires ...

Page 454: ...Cut 4 medium size pieces of the smallest heat shrink tubing of 1 5 cm 0 59 long Slide the 2 medium size pieces of heat shrink tubing over the Red and Brown wires of the flat cable ...

Page 455: ...Tin the two outer contacts of the Y micro switch ...

Page 456: ...Solder the Red and Brown wires to the contacts Slide the heat shrink tubes over the contacts and heat them up ...

Page 457: ...Now move the X CARRIAGE as far away as possible from the controller board Lead the flat cable as shown in the picture and secure it with a large tie strip ...

Page 458: ...Lead the flat cable further along the ALUMINIUM PROFILES while securing it with large tie strips Notice how the cable folds in the corner and disappears under the ALUMINIUM PROFILE ...

Page 459: ...Fold and secure the cable as shown in the picture below Take a board to wire connector with 4 wires out of the bag labelled with 40 ...

Page 460: ...Plug the female connector in the male connector labelled with Y MOTOR on the controller board ...

Page 461: ...Blue Green Yellow Orange and tin them Cut 2 small pieces of the smallest heat shrink tubing of 1 5 cm 0 59 long and 1 large piece of the big heat shrink tubing of 4 cm 1 57 You can find the heat shrink tubing in the bag labelled with 40 ...

Page 462: ...Slide the big heat shrink tubes over the 4 wires of the connector Slide the 4 small heat shrink tubes over the 4 wires of the connector ...

Page 463: ...Solder the 4 wires from the connector to the 4 wires of the flat cable you tinned earlier Watch the colours closely Flat cable Connector wires Blue Yellow Green Orange Yellow Red Orange Brown ...

Page 464: ...Slide the small heat shrink tubes over the solder joints and heat them up so they shrink ...

Page 465: ...Now slide the big piece of heat shrink tubing over the 4 small pieces heat the big piece so it covers and protects the 4 heat shrunk joints ...

Page 466: ...Strip 5 mm 0 2 the Red and Brown wire from the flat cable and tin the ends ...

Page 467: ...Take a board to wire connector with 3 wires out of the bag labelled with 40 ...

Page 468: ...Cut the middle wire away at the connector Plug the female connector in the male connector labelled with YSTOP on the controller board ...

Page 469: ... shrink tubing of 1 5 cm 0 59 long and 1 large piece of the medium size heat shrink tubing of 4 cm 1 57 You can find the heat shrink tubing in the bag labelled with 40 Slide the medium size heat shrink tubes over the 2 wires of the connector ...

Page 470: ...Slide the 2 small heat shrink tubes over the 2 wires of the connector ...

Page 471: ... from the connector to the 2 wires of the flat cable you tinned earlier Watch the colours closely Flat cable Connector wires Red Red Brown Brown Slide the 2 small heat shrink tubes over the solder joints and heat them up ...

Page 472: ......

Page 473: ...Now slide the medium size piece of heat shrink tubing over the 2 small pieces heat the medium size piece so it covers and protects the 2 heat shrunk joints ...

Page 474: ...Take a board to wire connector with 4 wires out of the bag labelled with 40 Plug the female connector in the male connector labelled with HEATER2 on the controller board ...

Page 475: ...Twist and tin the ends of the Yellow and Orange wires together and twist and tin the ends of the Red and Brown wires together ...

Page 476: ......

Page 477: ...Next detach 2 cm 0 79 the Orange Yellow Green Blue and Violet Grey White Black as groups Strip 5 mm 0 2 the ends twist them together per group and tin the ends together per group ...

Page 478: ......

Page 479: ...ze heat shrink tubing of 1 5 cm 0 59 long and 1 large piece of the biggest heat shrink tubing of 4 cm 1 57 You can find the heat shrink tubing in the bag labelled with 40 Slide the big heat shrink tubes over the 4 wires of the connector ...

Page 480: ...eat shrink tube over the Red and Brown wire Solder the 6 wires from the connector to the 4 wires of the flat cable you tinned earlier Watch the colours closely and respect the groups Flat cable Connector wires Orange Yellow Green Blue Red and Brown Violet Grey White Black Yellow and Orange ...

Page 481: ...Slide the medium size heat shrink tubes over the solder joints and heat them up so they shrink ...

Page 482: ...w slide the big piece of heat shrink tubing over the 2 medium size pieces heat the big piece so it covers and protects the 2 heat shrunk joints Secure all the joints with 2 large tie strips to the profile ...

Page 483: ...Take a board to wire connector with 2 wires out of the bag labelled with 40 ...

Page 484: ...abelled with THERM2 on the controller board Cut 2 small pieces of the smallest heat shrink tubing of 1 5 cm 0 59 long and 1 large piece of the medium size heat shrink tubing of 4 cm 1 57 You can find the heat shrink tubing in the bag labelled with 40 ...

Page 485: ...Slide the medium size heat shrink tubes over the 2 wires of the connector Slide the 2 small heat shrink tubes over the 2 wires of the connector ...

Page 486: ...Strip the two wires 5 mm 0 2 that are left over Red and Brown and tin them ...

Page 487: ...Solder the 2 wires from the connector to the 2 wires of the flat cable Watch the colours closely Flat cable Connector wires Black Red White Brown ...

Page 488: ...Slide the 2 small heat shrink tubes over the solder joints and heat them up ...

Page 489: ...Now slide the medium size piece of heat shrink tubing over the 2 small pieces heat the medium size piece so it covers and protects the 2 heat shrunk joints ...

Page 490: ...Use small tie strips to keep the cables together ...

Page 491: ......

Page 492: ......

Page 493: ...EXTRA care with the small NTC THERMISTOR It is very fragile If on the other hand you have the parts shown in the picture below NTC Thermistor not shown in this picture you will have to assemble the heater block first Note how the heater cartridge and the heater block are not assembled in the picture below ...

Page 494: ...ant development it is also possible that you have a bag with an alternate LARGER version of the NTC and a heater block with an extra hole as shown below Do not panic we will handle both versions in the manual below ...

Page 495: ...To assemble the heater block select these parts Insert the small grub screw into the heater block ...

Page 496: ...he heater cartridge as shown in the picture below Make sure the orientation is correct note the small holes on the side of the heater block This is how it should look for the heater block without the extra hole ...

Page 497: ...This is how it should look for the heater block with the extra hole ...

Page 498: ...is point on the manual will use pictures of the heater block assembly with the heater cartridge sealed into the heater block Both versions with grub screw and the one with red sealant have the same function Next slide the white plastic spacer into the aluminium bracket You may need to use some force ...

Page 499: ...Slide the copper barrel into the white spacer Watch the orientation closely Screw on the white plastic barrel ...

Page 500: ...Take the heater block again it does not matter if you have the version with the small grub screw they are the same Slide the 2 sleeves of the cartridge ...

Page 501: ...E sleeve in halve and slide the small pieces back over the heater cartridge FOR THE SMALL NTC Cut the TWO sleeves in halve and slide two small pieces back over the heater cartridge Cut the wires of the heater cartridge in half ...

Page 502: ...Strip 5 mm 0 2 all the ends of the wires you have cut Take the two loose wires ...

Page 503: ...FOR THE SMALL NTC INSTRUCTIONS FOR THE LARGE NTC ARE BELOW SKIP THESE INSTRUCTIONS IF YOU HAVE THE LARGE NTC Carefully wrap one leg of the NTC onto the bare wire Solder it in place ...

Page 504: ...Carefully wrap the other leg of the NTC onto the second bare wire Solder it in place ...

Page 505: ... small washer and the small copper screw to lightly fasten the wires to the heater block Make sure that the glass bead of the NTC fits snugly in the small hole and that you don t over tighten the small screw this could cause a short circuit between the 2 wires ...

Page 506: ...Use a small tie strip to hold the wires of the NTC and the heater block together ...

Page 507: ...FOR THE LARGE NTC Cut 1 5cm of the legs of the NTC Solder the two loose wires to the legs of the NTC ...

Page 508: ...Slide the long sleeve over the NTC and the connections Slide the NTC through the hole in the heater block as shown ...

Page 509: ...Bend the leg of the NTC as shown in the picture Gently fix the wire to the heater block with the small washer and the small M2 5 screw ...

Page 510: ...Slide the big washer over the copper barrel Slide the heater block over the copper barrel Watch the orientation ...

Page 511: ...zle firmly Do not forget to screw the white plastic barrel back on firmly afterwards Warning If you do not tighten these pieces firmly enough you risk having a leaking extruder This is irreparable Then again if you use too much force you can strip the threads of the barrel rendering the piece useless We recommend tightening the nozzle with a torque of 3 5 Nm ...

Page 512: ...FOR THE LARGE NTC ...

Page 513: ...TC You should measure something between 70 to 100 KΩ depending how hot the NTC is If your measurement is way lower than it is possible that the NTC is shorting out Detach it check it and attach it again Unscrew the two bolts where the HOTEND needs to be mounted ...

Page 514: ...Slide these bolts and washer into the aluminium bracket ...

Page 515: ...of the extruder faces away from the fan Make sure this is correct Cut 2 small pieces of the medium size heat shrink tubing of 1 5 cm 0 59 long and 1 large piece of the biggest heat shrink tubing of 4 cm 1 57 You can find the heat shrink tubing in the bag labelled with 40 Slide the big heat shrink tubes over the 4 wires of the HOTEND ...

Page 516: ...Slide the 2 medium size heat shrink tubes over the 2 wires of the heater cartridge Make sure these are the wires of the heater cartridge and not the ones of the NTC ...

Page 517: ...Tin the wires of the heater cartridge Take the 2 groups with the following wires Group 1 Grey Violet Blue Group 2 Green Yellow Orange ...

Page 518: ...Solder the 2 wires of the heater cartridge to the 2 groups Slide the medium size heat shrink tubes over the solder joints and heat them up so they shrink ...

Page 519: ...Now slide the big piece of heat shrink tubing over the 2 medium size pieces heat the big piece so it covers and protects the 2 heat shrinked joints ...

Page 520: ...t 2 small pieces of the smallest heat shrink tubing of 1 5 cm 0 59 long and 1 large piece of the medium size heat shrink tubing of 4 cm 1 57 You can find the heat shrink tubing in the bag labelled with 40 ...

Page 521: ...Slide the medium size heat shrink tubes over the 2 wires of the NTC Make sure these are the wires of the NTC Slide the 2 medium size heat shrink tubes over the 2 wires of the NTC ...

Page 522: ...Tin the wires of the NTC ...

Page 523: ...Solder the 2 wires of the NTC to the Black and White wires of the flat cable Slide the small heat shrink tubes over the solder joints and heat them up so they shrink ...

Page 524: ...Now slide the medium size piece of heat shrink tubing over the 2 small size pieces heat is piece so it covers and protects the 2 heat shrinked joints ...

Page 525: ...Use 2 small tie strips to keep all the wires together ...

Page 526: ...hed In the next chapters we will speak about the basics of printing calibrating your printer more advanced settings and so on Make sure to read and understand these next chapters because they contribute a whole lot to the printing quality of the K8200 ...

Page 527: ......

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Velleman K8200, Assembly Manual

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