1 COPPERHEAD 3D PRINTER ASSEMBLY GUIDE WELCOME

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2 1 COPPERHEAD 3D PRINTER ASSEMBLY GUIDE WELCOME Thank you for choosing the Copperhead 3D printer from Acadian Robotics. Please read through this manual first before setting up your machine. If you have any questions or comments regarding this guide please contact us at January 2015 version ASSEMBLY INSTRUCTIONS Tools required: Metric allen wrench set Needle nose pliers Large and small Philips head screwdriver Large and small flat head screwdriver Grounding wrist strip (for PCB protection) Small crescent wrench General notes: - Keep the hardware (nuts, bolts, washers) loose until the machine is fully assembled unless otherwise noted in the individual steps. - When testing the machine s components and wiring all connections should be securely fastened. - When installing wiring loosely secure the zip strips or cable claps unless otherwise noted in the individual steps. Do not let the wiring hand loose from components without supporting the wires with zip strips or wire clips. - When disconnecting the motors grab the sides of the white motor plug connector and gently jiggle the connector away from the motor. NEVER grab the wires to disconnect the motors.

3 2 COPPERHEAD 3D PRINTER ASSEMBLY GUIDE

4 3 COPPERHEAD 3D PRINTER ASSEMBLY GUIDE I. Pre-assembly Step 1: Bottom structure panel - Install the Z motor wire (66) to the bottom side of the bottom panel (10) using zip strips (36). Step 2: Shelf - Assemble the two shelf (14) pieces using (2) 8-32x7/8 black oxide bolts (37) and washers (40).

5 4 COPPERHEAD 3D PRINTER ASSEMBLY GUIDE Step 3: PCB mounting - Install the printed circuit board (PCB) (31) to the inside of the shelf (14). Do not overtighten the bolts. Tighten enough only to secure the PCB. Spacers (30) should be mounted between the shelf and PCB. Step 3: Top panel - Install the white LED strip (58) to the underside of the top panel (12). - Cooling fan (65) can be installed at a later step when installing the extruder. Cooling fan is an option component. It is mostly only used when printing with PLA material.

6 5 COPPERHEAD 3D PRINTER ASSEMBLY GUIDE Step 4: Left panel - Fasten the Z limit switch (32) to the Z switch angle (7). - Install the Z limit switch angle (16) [NOT THE ANGLE THAT FASTENS TO THE CARRIAGE] to the left panel (8). - Install the Z motor mount (26) to the left panel (8). Step 5: Right panel - Install the Z motor mount (26) to the right panel (9).

7 6 COPPERHEAD 3D PRINTER ASSEMBLY GUIDE Step 6: Motor assembly - Install the aluminium gears (29) to the Nema 17 motors (20). - Install the motor (20) to the motor mount (26) with (55). Step 7: X carriage - Install the Y rack (6), X motor mount (26), X motor (20), linear bearings (22), limit switch bolt (44), Y limit switch (32), and rod holders (23) to the X carriage.

8 7 COPPERHEAD 3D PRINTER ASSEMBLY GUIDE Step 7: X carriage wiring Step 7: Y carriage - Install the Y motor mount (26), Y motor (20), limit switch bolt (44), linear bearings (22), print bed (4) to the Y carriage (3). - Install and secure the Y carriage wiring from the print bed before attaching to the X carriage.

9 8 COPPERHEAD 3D PRINTER ASSEMBLY GUIDE - Do not tighten the linear bearings at this time. Fasten the nuts to the bolts just enough so they will not fall off the bolts. Step 8: Print bed to Y carriage - Install the print bed (4) to the Y carriage (3). Do not install the glass until assembly is fully complete. - This would be the best time to manually level the bed. Use the springs (19) and 2 nuts (44) to level the bed. Step 9: Y carriage wiring - Install the y carriage wiring but do not secure tight at this time.

10 9 COPPERHEAD 3D PRINTER ASSEMBLY GUIDE Step 10: Main carriage - Install the Z limit switch angle with switch (7), the X limit switch (32), rod holders (23), Z linear bearing blocks (15)with linear bearings (22), and the X rack (5) to the main carriage (1). - Leave the rod holder nuts loose until the machine is completely assembled. Do not over tighten the nuts. Snug them to secure in place. Step 10: Y carriage to the X carriage - Fasten the Y carriage (3) to the X carriage (2). - When inserting smooth rods through linear bearings DO NOT USE FORCE. Gently guide and push while twisting slowly to guide the rod through the linear bearings. It may help to lubricate the rods with a light based oil or WD-40.

11 10 COPPERHEAD 3D PRINTER ASSEMBLY GUIDE Step 11: X carriage (2) to the main carriage (1). II. Assembly Step 1: Place the bottom structure panel with the front edge flat on a flat surface. Step 2: Connect the two side panels to the bottom panel and shelf. Step 3: Remove the backlash nut (27) from the z rods and flip it 180 degrees on the Z threaded rod (21). - When removing the back lush nut from the Z threaded rod use caution as to not lose the spring that is housed inside the backlash nut. - When inserting the backlash nut the spring and holder should fit inside the backlash nut. Use pressure to twist the backlash nut onto the spring and holder. -Ensure that you do not cross thread the nut onto the rods. Figure 1 Figure 2

12 11 COPPERHEAD 3D PRINTER ASSEMBLY GUIDE Step 4: Install the Z motors into the Z motor mounts. Step 5: Guide the main carriage onto the Z motor threaded rods. Step 6: Insert Z smooth rods into the main carriage and into the shelf. - Do not use force when inserting the smooth rods. Step 7: Fasten the backlash nuts to the main carriage using (50, 51). Step 8: Install the Z rod holders (23) with spacer (15A) to the side panels. Step 9: Install the extruder assembly and cooling fan to the bottom of the top structure panel using (43,52,46). Step 10: Connect the top structure panel to the side panels. III. Final Assembly Step 1: PCB Wiring

13 12 COPPERHEAD 3D PRINTER ASSEMBLY GUIDE - Use caution when handling the PCB. Ensure that you are grounded as to not transmit any static to the PCB. - When inserting the extruder heater wire, cooling fan wire, and heatbed heater wire do not twist the bare ends of the wire together. It will make it more difficult to insert. Gently guide the wires into the pins and use a small flathead screwdriver to secure the wiring in place. - The wires for the extruder heater and heatbed heater can be inserted into the + or pins. The cooling fan wire needs to match the respective polarity for the cooling fan to work properly. - The limit switch and thermostat wires can be inserted either way but must be inserted into the correct pins as shown. - The X, Y, and E motor wires should be inserted with the closed end of the connector facing the top of the PCB as viewed in the picture above. Step 2: Power supply wiring

14 13 COPPERHEAD 3D PRINTER ASSEMBLY GUIDE - Do not touch the power supply when plugged in or powered on. Always handle the power supply when the power is OFF. - The power supply can be connected to the bottom plate and then to the shelf. - Connect the wiring from the power supply as shown. - Never pull on the wires to disconnect the connections. Grip the disconnect and gently wiggle while pulling apart. It may help to use small needle nose pliers.

15 14 COPPERHEAD 3D PRINTER ASSEMBLY GUIDE - Never allow wires to hang freely from components. The wires can be damaged due to weight pulling against the connections. This is extremely important for the motor connectors. Step 3: Main carriage wiring Step 4: Connect all wire connectors Step 5: Install back panel using ¾ wood screws. - Secure the wiring to the back panel using ½ wood screws and 3/8 wire clips. Step 6: Install front panel Congratulations. You can move on the hardware and software set up guide.