Modix Big-60 Assembly Instructions Part 1

Transcription

1 Modix Big-60 Assembly Instructions Part 1 Version 1.0, October 2017

2 Menu 1. X Idler Pulley Assembly Connecting X Axis Brackets to Z Profiles Assemble X Rails on X Top Profiles Assemble X Top Profiles to Z Profiles Assembling the Z Axis Top Brackets Assembling the Z Axis Top to Z Profiles Assembling the Z Axis Bottom Brackets Assembling the Z Axis Mid Brackets Assembling the Z Axis Sets Assembly X Bottom 4040 Profiles Installing the X Shaft Assembling the Y Axis Motors Assembly Installing Y Axis Timing Belts Installing X Axis Timing Belt Install the Timing Belt at the frontal X axis Hot-End Assembly Extruder Assembly Install the BL Touch Sensor Touch Screen Assembly Electronic Box Assembly... 44

3 1. X Idler Pulley Assembly Required Items X Idler Back (back of the printer) U bracket, note the square cut. X Idler Front (front of the printer) U Bracket 2 X M5 Screws, 50mm Length 2 X M5 Nylock Nuts 6 X M5 Nylon Round Spacers Assembly Steps Note - We will start by finding all the required parts above. It will get easier as we go you will remain with less and less unused parts. We Recommend sorting all the screw bags on a table by type and size, for easily locating them. 1. Insert the M5 50 mm screw from the short flange side. 2. Add one spacer, the idler and then two spacers. 3. Make sure that you have two spacers on the tall flange side and only one on the other side. These are the parts needed for each side. Although we have PEM (built in nut in the metal bracket) please secure the M5 screws with the nylock nuts as these screws vibrate a lot during printing.

4 2. Connecting X Axis Brackets to Z Profiles Required Items: 4 X M8 Button-head Screws 4 X Metal Clip for 4040 Profiles X Pulley - back and front X Idler back and front (assembled in the previous step) 4 X 4040 Profiles of Z Axis, 935mm (longest profiles) 8 X T Nuts for 4040 Profiles 4 X M5 16mm Screws 4 X M5 12mm Screws Assembly Steps: Sort all the 4040 Profiles and locate the longest. List of profiles from the longest to the shortest: 4 x 935 mm - Z Axis 2 x 870 mm - X Axis Top profiles 2 X 790 mm - X Axis bottom profiles 4 X 770 mm - Y Axis Two 4040 of 40cm length are not shown

5 Identify the bottom of the 4040 Z Profiles - there is a drill along the profile, 65mm from one of the profile ends. This is the bottom of Z profile. We will install the brackets at the opposite side - the top of Z profile. Install the metal clip and the M8 screws on the top of the Z profiles. Do not tighten it yet. We will soon slide it into another 4040 profile. Add two T nuts on each Z profile, the tapped drill side of the nut should be facing up towards the metal clip. We will use different screws for the idler and pulley brackets. X pulley - M5 12mm X Idler - M5 16 mm. * The idlers screws are longer since later we use them as belt tensioning device. Place these brackets 3 mm distance from the top of the 4040 profile. Do not over tighten it, we will later find the right position and tighten it. Finally you should have 4 Z 4040 profiles with the U brackets installed on top. Verify that this is the top side by checking again the holes located in the bottom of the Z profile, 65mm from the edge.

6 3. Assemble X Rails on X Top Profiles Required Items: 2X 4040 Profile, length 870 mm 2X MGN Rails 700m long Be careful not to let the rail block fall from the rail. It is advised secure it with a tape. 20 M3 Spring Shims (10 per each side) 20 M3 16mm Screws (10 per each side) 2 X Flat Metal Brackets, 789.5mm long 2 X Thin Metal Brackets, 695 mm length, it is preinstalled built-in nuts (PEM) Assembly Steps: Insert one screw into a spring shim and add a drop of lock tight glue on the tip of the screw. Install one side loosely, slide it into the profile (any side of the profile is ok) and then add screw the opposite side and slide it back. Position the base bracket 4 cm distance from the edge of the profile. Do not over tighten it yet. Install the rest of the screws (with spring shim and glue), 10 screws in total on each rail with a distance of two holes between the screws. Finally you should have two rails installed. Secure the rail block to the profile with a tape.

7 4. Assemble X Top Profiles to Z Profiles Required items 2 X Profiles (installed in previous step) 4 Z Profiles (installed in previous step). 4 X 4040 T Nut 4 X M5 12mm Assembly Steps: Identify the pair Z profiles for the back and front of the printer. The two brackets for the back side each has a unique feature that allow easy identification (check pictures). X Pulley back X Idler Back Slide the X profile over the Z profiles. Make sure that you slide the right pair of Z profiles. Make sure the long bracket flanges (white arrow) are on the same side of the profile. X Pulley Front X Idler Front

8 Tighten the M8 Screws (do not over tight) Add the 4040 T nut and the 12mm M5 screw on all the long flanges. Pay attention to the right side of the T nut (white arrow) Final result: two U shapes assembled profiles. 5. Assembling the Z Axis Top Brackets Required Items 2 X Z Top Sheet Metal Brackets, left and right. For easy assembly, place these brackets facing up according to the pictures on the right. right Left X Axis Motor Mounting Bracket 2 X 4040 Profiles, size 770 mm length. Attention - make sure that this is the right size! Choosing wrong profiles instead will lead to a trapozdial enclosure. 4 X M8 Button-head Screws 4 X Metal Clip for 4040 profiles 4 X SHF12 (12mm rod mount) 7 X T Nuts for 4040 Profile

9 8 X M5 Nuts 6 X M5 12mm Screws 9 X M5 16mm Screws Assembly Steps: Z Top Right Bracket Assembly (we are not using the 4040 profiles yet). Assemble two SHF12 rod mounts with M5 16mm screws. On the other side, please use regular M5 nuts. Do not fully tighten. Add 3 M5 12mm screws, and 4040 T-Nut, check pictures on the right for the assembly location. Same as above for the Z Top left bracket. Make sure the M5 nuts flat sides are aligned along the bracket long axis. This will allow you to easily slide the assembled bracket inside the 4040 profile. Slide the red metal bracket over the 4040 profiles. * if sliding is inconvenient, release the T Nut a bit and try again or align the M5 nut. Alternatively, you can insert the T Nut directly to the 4040 profiles, adjust its location and tighten the screws later on. Correct Incorrect Add the metal clips and M8 screws from both sides of the two 4040 profiles. Keep loose.

10 Align the flat edge of the red bracket with the end of the profile and tighten all M5 screws. Assemble the X motor bracket on the Z top left bracket. Secure the bracket with M5 16mm screw T Nut. Make sure the bracket flange is flushed with the profile and Z top bracket. 6. Assembling the Z Axis Top to Z Profiles Required Items Assembled Z Top Brackets (installed in previous step) Assembled Z Profiles (installed in previous step) 6 X M5 12mm Screws 7 X T Nuts for 4040 Profile

11 Assembly steps We will start by showing you the final required result of this step: This is an upside down "table" with the four Z profiles facing upwards. Attention - Before starting, make sure you have a clean floor and a cloth or soft foam to place on the floor for avoiding scratches on the top of the machine later on. Locate the assembled U shape profiles with the X axis limit switch mounting holes (check picture). This U is the back side of the printer. Slide the assembled Z top bracket with the X motor mounted bracket. Keep the metal clip loose for easy sliding. After sliding, tighten the M8 nut with the Allen key.

12 Complete connecting the rest of the profiles. Notice the different shape of the red brackets on the left & right sides. The dual slots (mounting holes) on the Z top brackets face inwards. At the bottom of the drawing at the right you will find an arrow pointing on the location of the corner appear at the drawing from previous step (also next step below) Finally, secure the X motor mount bracket with two M5 12mm length screws + 2 x T- Nuts.

13 7. Assembling the Z Axis Bottom Brackets Required Items 2 X 4040 Profile, size 770 mm length. Attention - make sure that this is the right size! Choosing the short X profiles instead will lead to a trapozdial enclosure. Z Axis Bottom Left Bracket Z Axis Bottom Right Bracket 3 X KFL08 Pillow bearing flange 4 X SHF12 (12mm rod mount) 15 X M5 12mm Screws 8 X M5 16mm Screws 9 X T Nuts for 4040 Profile 14 X M5 Nuts 4 X M8 Button-head Screws 4 X Metal Clip for 4040 Profiles

14 Assembly Instructions 1. Align the two metal brackets according to the diagram on the right. Notice that the rounded corners should be on the same right side. This is the front side of the machine. 2. Assemble the KFL08 with M5-12mm screws + M5 nuts. 3. Assemble the SHF12 with M5-16 mm screws and M5 nuts. On the right you can see the places you will need to assemble the M5-12mm screws and the 4040 T-Nuts. There are 8 more holes for screws in the flanges that we will assemble later on. Before assembling to the 4040 profiles, make sure the M5 Nut flat sides are aligned along the bracket long axis. This will allow you to easily slide the assembled bracket inside the 4040 profile. 1. Slide the red metal bracket over the 4040 profiles. Correct Incorrect Alternatively, you can insert the T-Nut directly into the 4040 profile, adjust its location and tighten the screws later on. Add the metal clips and M8 screws from both sides of the two profiles, 4 clips in total. Keep them loose.

15 8. Assembling the Z Axis Mid Brackets Required Items 2 X Z Axis Mid Brackets 4 X LMKL12UU Linear Bearing 3X GT2 40 Teeth Gears 3X SFU1204 Ball Screw length 830mm 28x M4-16mm Screws Assembly Steps: Align the brackets according to the diagram on the right where the round openings are facing outwards. The side of the brackets with the PEM (built in nuts) should face down. Assemble the 4 LMKL12UU linear bearing with 4X M4-16mm screws for each bearing. Add a drop of lock tight glue on the screws. Assemble the 40 teeth gears on the end of all the three ball-nut screws. The side with the set screw should be inserted first. Check picture. At this stage, do not tighten more than the point of securing it from falling out. X 3

16 Assemble the ball-nut screw from the same side of the LMKL12UU Linear Bearing. Repeat for all the three ball screws. 9. Assembling the Z Axis Sets Required Items 4X 12MM Smooth Rods length 840mm (located in the flat big box of the print bed). 3X GT2 Belt Closed Loop 200 Pre-Assembled Structure Pre-Assembled two Z Mid axis and two Z bottom sets Assembly Steps Slide one 200mm closed loop timing belts on top of the ball nut screws from the 40 teeth gear side (bottom). Repeat this step for the three ball-nut screws.

17 Locate the pair of Z Mid and Z bottom brackets for the left and right of the printer. The Z bottom bracket with dual motor mounts goes with the rounded end Z Mid bracket. The Z bottom bracket with the single Motor mount goes with the symmetrical Z mid plate. 1. Make sure the 200mm timing belt is positioned on the 40 teeth gear. 2. Carefully open the set screw of the pillow bearing and slide the ball-nut screw into the pillow bearing all the way in. Add lock tight glue on the set screw and tighten well (this will be installed upside down). Loose the 40 teeth gear's set screw. Slide the gear all the way down towards the pillow bearing until it touches it. Tighten the set screw. Slide the four 12mm smooth rods into the rod mounts SHF12. Add lock tight glue on the mounting set screw and tighten it well. Slide the installed Z mid +Z Bottom sets on the machine, one from each side according to the diagram on the right. The single motor Z bottom bracket goes on the side of the X motor mount bracket. Once you have both Z axis sets installed, you can tighten the M8 screws on the sides of the Z bottom 4040 profiles.

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19 10. Assembly X Bottom 4040 Profiles Required Items Assembled Structure 2 x 790 mm length- X Axis Bottom Profiles 8 X M5 12mm Screws 8 X T-Nuts for 4040 Profile 4 X M8 Button-head Screws 4 X Metal Clip for 4040 Profiles Add the metal clips and M8 screws from both sides of the two profiles, 4 clips in total. Keep loose. Insert 4 T-nuts on each of the profiles and move them to a position that will allow you to screw the M5-12mm into the red brackets. Slide the 4040 profiles on the Z 4040 profiles and insert the M5-12mm screws Tighten the M8 screws on all corners (8 corners X 2 screws) and flip the machine to upright position.

20 11. Installing the X Shaft Required Items The X Shaft is an 8mm smooth rod 845mm length installed with bearings pulleys and a gear. It is located in the big flat print bed box. 1 x GT2 Belt Closed Loop 200 X Shaft Support Bracket 4 X M5-12mm Cone Screw 2 x M5-12mm Screws 2 x M4-10mm Screws 4 x M5 Nuts Assembly Steps Insert the timing belt on the X Shaft. Do not let it fall as you will have to disassemble the shaft to reinstall it. It is advised to secure it with some tape during the assembly so it will not fall. Install the X shaft support on the X motor bracket with two M4-10mm screws. Tighten firmly.

21 Insert the X shaft into its mounting brackets. The 40 teeth gear is positioned in the back of the printer (same side as X motor bracket). The position of the pulleys and gear are supposed to be accurate. If not, you can release a set screw and move the gear or a bearing to its correct position. Open all set screws carefully and add lock tight glue. Front Back Secure the shaft from both sides with the M5- cone 12mm screws and M5 nuts. Before tightening, make sure that the 200mm belt is still in its place. Use M5-12mm screws to secure the rest of the pillow bearings to their mountings, 3 in total. The final position of the 40 teeth gear is the point where it touches the pillow bearing behind it (at the back of the printer). The position of the pulley in the front of the machine is the point where it touches the pillow bearing in front of the printer. Keep this screw set loose for later steps of belt tensioning.

22 The position of the pulley at the back side of the machine is the point where it touches the rear pillow bearing (the back of the printer). 12. Assembling the Y Axis Required Items Y Idler Bracket Y Pulley Bracket Rail Guide (the last one available) 2020 Profile length 760mm 10 x 2020-M3 T-Nut 6 X 2020-M5 T-Nut 10 x Spring Shim 10 x M3-10mm Screws 6 X M5-8mm Screws 8 X M3 6mm Screws Assembly Steps

23 1. Insert 10pc 2020 M3 T-Nuts into the 2020 profile. Adjust their position to match every third hole of the rail. 2. Insert a spring shim on a M3-10mm screw, add a drop of lock tight glue and secure the guide rail onto the 2020 profile. Do not tighten it yet. Attention - do not let the rail block fall from the rails. It is recommanded to use tape to secure it to the 2020 profile. Installing the X pulley bracket. The picture on the right is showing the result. Please follow instructions below. First, insert two T-Nuts on the 2020 profile and another one at the side of the guide rail. Position the Y pulley bracket and tighten it. The guide rail should touch the red metal bracket. You may need to reposition the rail in order to let the bracket installed correctly. The 2020 profile should be flushed with the end of the flange of the Y pulley bracket. Assemble the Y idler bracket. Follow the picture for the correct orientation. Do not tighten this bracket yet, we will soon have to adjust its position based on the distance between the two X rails.

24 Secure the Y pulley bracket to the X rail block in the back of the machine. Attention - do not let the rail block fall during this step. If you can, call for assistance and let someone hold the Y axis for you while you install it. As a reminder the back of the machine the side of the X mounting bracket. Attach the Y idler bracket to the rail on the other side. It may need to adjust the position of the Y idler bracket. Before moving to next step, tighten all screws. Last step, slide the Y axis over the machine and make sure that it can slide smoothly. If not, you will have to loosen some of the screws that hold the X rail and find the position where it is parallel and allows a smooth ride on the X rails Rails are oiled and ready for use. However, it is advised to lightly lubricate the rails with Lithiumbased grease spray (examples on the right - not provided). Alternatively you may use grease.

25 13. Motors Assembly Required Items 3X 40mm Nema 17 Motor 2 X 60mm Nema 17 Motors 5 X 16 Teeth Pulley 20 X M3 Shims 20 X M3 8mm Screws Assembly Steps: Add a drop of lock-tight glue on the pulley's set screws. Install one pulley and keep it 3mm from the edge of the shaft (higher). Tighten the set screw against the flat side of the shaft. Install the motors at the bottom Z bracket motor mounts. Keep the motor wire connector facing towards the back of the printer. Add 4x M3-8mm screws and shims.

26 Make sure the timing belt is horizontally flat with both the gear and the pulley. If the belt is not horizontally flat, adjust the height of either the gear or pulley. Attention - failing to adjust the level of the belts will lead to high pressure on the top of the pulley which will break it (the top of the pulley is manufactured with pressure only). This is the reason you provided with a spare pulley. Install the X motor Assemble the pulley on the flat side of the large X axis motor, add a lock tight glue and tight it. Install the X motor while the motor wire connector is facing upwards. Before you tighten the m3 screws and shims, make sure the belt is vertically aligned. If not, make sure that the 40 teeth gear is touching the pillow bearing. Install the Y motor Tighten the timing belt by pulling the motor down and use 4 x M3 8mm & 4 x M3 shims to secure the motor the mounting bracket.

27 14. Installing Y Axis Timing Belts Required Items 2X Belt Tensioning Clamp GT2 Timing Belt, length 165 CM (Kit includes a 5 meter timing belt. You will need to cut to size) Extruder Mount Bracket Y Axis Belt Mount Bracket Filament Guide Mount Bracket 3 X M3-12 mm Screw 1 X M3-10 mm Screw 1 X M5 16mm Screw 1 X M5 50mm screw 2 X M5 washers 1 X M5 Nylock nut 1 X Idler Pulley

28 Assembly Steps: Assemble the 3 brackets: 1. Start with the "Extruder Mount Bracket". The PEM are facing the guide rail. 2. Add the "Y Axis Belt Mount Bracket" 3. Finally add the "Filament Guide Mount". Secure the three brackets with 3 M3-12mm and 1 M3-10mm screws (add a drop of locktight glue). Additional views Install idler bearing on the Y idler bracket: 1. Insert the M5-50 mm screw from the rail guide side. 2. Insert the idler bearing with a washer from each side. 3. Secure the idler position with Nylock. Keep idler bearing loose for easy rotation. 1. Cut 165cm of the timing belt 2. Insert one of the metal clips with the set screw on the side of the belt teethes 3. Bend the edge of the belt with your fingers Insert the belt with teeth facing up into the left belt mount bracket holes, bottom up. The metal bracket in the photo is from previous batch. Slide the belt back into the clip and keep a minimal slack (1mm). Important: Release the set screw and add a drop of lock-tight glue Attention - the belts clips set screws are exposed to high level of vibrations. Make sure you tighten them well with lock tight.

29 1. Wrap the belt around the idler bearing and the Y motor pulley and hand tighten the belt. Tighten the belt as much as you can before next step. 2. Insert the other side of the belt end into the belt and keep at least 20 mm belt slack for future tension. 3. Add a drop of lock-tight glue on another belt clip set screw. 1. Loosen the Y motor 4 mounting screws. 2. Tighten the M5-16 mm screw until you get a desired tension. Do not over tighten (it will overload the motor bearings). Check yourself: you should be able to easily squeeze the top and bottom side of belts, one towards the other. Tighten the 4 motor mounting screws. 15. Installing X Axis Timing Belt Required Items 2x GT2 Timing Belt, length 165 CM 4 x Belt Tensioning Clamp

30 Assembly Steps Preparing the X idler brackets: Before installing the belts,,make sure that the idler pulley brackets (both on the back and front of printer) tall flanges are assembled with M5 screw & a T-nut. Do not tighten it yet. Loosen as much as possible the M5-16mm screws that hold both idler brackets (back and front of printer) to the Z 4040 profiles. Slide the brackets inwards as much as possible. Installing Belts 1. Start from the belt located at the back of the machine. 2. The belt mounting slots are located on the bottom of the Y Axis mounting brackets (Y pulley & Y Idler). 1. Add a drop of lock-tight glue on the belt clamp set screw and insert it while the set screw is on the side of the belt teeth. 2. Cover the edge of the belt with tape for easily inserting it into the tightly located slots. 3. Start with inserting the belt from the idler side while belt teeth face down. 4. Tighten the belt clamp set screw and keep a minimal slack of 1mm belt.

31 Wrap the belt around the pulley and hand tighten as much as you can. Install another belt clamp and tighten the set screw. Give it a good tension before closing the clamp as we have a very few millimeters for extra tension later on. Make sure that the belt is parallel to the rail guide. This inspection step is to verify that you have followed the previous instructions correctly. Pay attention to the position of the idler and pulley. 1. Tighten the screws in the idler bracket )below and above the belt) until you reach the desired tension. 2. If the screws are fully tighten and yet the belt is not tight enough, you will have to repeat the last step. Remove the belt clamp, loosen the M5-16mm screws as much as possible, reinstall the belt and hand tighten as much as possible. 3. Tighten the M5 screw in the inner tall flange. Cut the rest of the belt and leave 20mm (more than shown in the photo) from the side of the X Pulley.

32 16. Install the Timing Belt at the frontal X axis Attention - before installing the frontal belt: Read carefully the following instructions to avoid uneven tension while Installing the frontal belt: Loosen this frontal pulley before assembling the frontal belt: 1. Before installing the frontal belt release the set screw of the frontal pulley until the pulley is fully loose and can easily rotate on the X shaft (don't lose the set screw!). 2. Install the frontal belt and reach the desired belt tension. 3. Tighten the frontal X pulley set screw. Tighten the set screw of the pulley. Make sure the belt is parallel to the X guide rail. The pulley should be as close to the frontal pillow bearing as possible.

33 17. Hot-End Assembly * Assembling the Hot-End is an important skill for 3D printer users. Replacing the nozzle or cleaning out clogged Hot-Ends is a common maintenance task. Required Items 0.4 mm Volcano Nozzle Volcano Heat Block FYI, it is possible to use a standard V6 Heat Block (not supplied) instead of the Volcano Heat Block. The standard heat block will allow you to use smaller nozzles (0.35, 0.3, 0.25 & 0.15 mm) and will generate more accurate printing in small objects as it holds a lower amount of molten plastic during the print. E3D V6 Heat Break E3D V6 Heat Sink E3D Volcano Silicone Insulator Thermistor Cartridge Heater Cartridge Thermal Paste Fan Fan Duct Universal Fixing Kit (small bag with screws) 50 mm long PTFE Tube

34 Assembly Steps Open the small screws bag carefully. Release its content into a plate or into a safe container. Keep an eye on the screws; do not lose any of them! Install the two longer black screws from the bag. Insert them from the side that does not have the tapping. Insert the heater cartridge from the shorter edge of the heater block until it is flushed with the bottom of the heat block. Tighten the screws. Insert the thermistor cartridge from the other side of the heater block until it is flushed with the other side of the heater block. Add lock-tight glue and tighten the set screw that holds the thermistor. Tighten the grub screw until it just touches up against the cartridge. Secure the screw by screwing an additional half turn. Do not over-tighten it! Attention - It is important not to over-tighten the screw against the relatively soft copper cartridge, doing so can cause a range of problems: 1. Deformation of the cartridge (making it hard to remove in the future) 2. Cracking of the internal potting ceramic (causing poorer thermal response or, in extreme circumstances, short circuit). 1. Fully screw nozzle into the heater block. 2. Unscrew the nozzle a 1/4 to a 1/2 turn. Install the heat break from the other side of the nozzle. Use the shorter thread all the way in. Use spanner or clamp to hold the heater block and use another spanner to tighten the nozzle. Do not over tighten (It will be tightened when the heater block is hot). Be careful not to damage the wires!

35 Attention - The Heat Break is very fragile due to its narrow neck. This is why the Modix kit includes a spare Heat Break. The Heat Break will easlily bend if your hotend hits the bed unintentionally. While tightening the Heat Break, do not apply any force on it. FYI, E3D has released a titanium heat break and it is supposed to be more robust but not yet tested by us. Furthermore, do not be attempted to buy a clone to this part, this part is what makes the E3D hotend so succesful with printing any filament out there. It is highly polished (electro polishing) and manufatured with high precision. Add thermal paste on the threads of the heat break. Screw it into the heat sink 1. Install the fan, sticker facing the fan duct (the side with the sticker defines the air direction) 2. Use the 4 self tapping screws to tighten the fan into the fan duct. 3. Keep the fan wires towards the extended side of the duct (right top corner) Insert the PTFE tube into the upper side of the hotend. Both sides of the tube are chamfered for easy filament access. Therefore, it doesn t matter from which side you insert the tube. Keep the assembled hot-end in a safe location and prevent it from falling on the floor etc.

36 18. Extruder Assembly Required Items Extruder Mounting Bracket Blower Fan Mounting Bracket 1 X Nema 17 Motor 40mm E3D Titan Extruder Box 3D-Printed Blower Fan Duct 2 X M4 25mm Screws 6 X M4 8mm Screws Assembly Steps Prepare the small screw and insert the small Allen Add a tiny drop of lock-tight glue on the set screw and insert it into the small metal gear Hold the motor with the wire connector to the right side

37 Place the mounting bracket on top of the motor. For your convenience, place the motor close to the edge of the table for easy assembly. Insert the small screw into the main extruder black housing plastic part; mount it onto the lower right mounting hole. Make sure the wire connectors are still on the right side. 1. Insert the metal gear while the set screw side is facing the Nema 17 motor (down) 3. Turn the plastic housing slightly to the right (use the small screw as a hinge). 2. Insert the large plastic gear into the bearing socket and turn the housing plastic until the gears teeth match. 1. Make sure the gears top-faces are flushed. 2. Tighten the metal gear s set screw. Place the idler lever plastic part and insert it onto the gear shaft. The lever is made of a selflubricating plastic so don t worry of friction when the motor rotates. Do not sand the gear shaft!

38 Install the nut onto the thumb nut and screw it all the way down. Insert the spring on top of the screw and place it carefully in the plastic housing. Notice the small socket created for the flange of the thumb nut. Do not tighten the screw FYI, we use this thumb nut to adjust the tension on the filament. Flexible filaments require minimal tension. Attention - This spring easily gets lost during assembly or maintance. Make sure to set the thumb screw to the minimal tension before opening the extruder, wrap the extruder with your hand when extruder top cover is open. After opening the extruder, place the screw and the spring in a safe container. Install the hot-end adapter on the PTFE tube that already is installed inside your hot-end. Notice that there are two black adaptors, the one with the smaller hole is designed for 3 mm filament, if required. The PTFE length is cut to size already for you. If the adapter is not going all the way down release it and try to push it down again. If you still notice a bit of PTFE, cut one side with a paper cutter knife, and insert from the other side of the cut (both sides are chamfered so you can flip it and still enjoy the chamfer that helps inserting the filament). if you cut it too much you have a spare PTFE tube inside the extruder box. Insert the hot-end with the adapter on top of it (flat face of the adaptor flange turning upwards). It should firmly sit in place. Keep the long side of the heat block vertically when you insert the hot-end (turning it will unscrew the heat sink). Flat side of flange heat block position

39 Place the transparent plastic cover on top of the black housing. Omit the three longest screws from the supplied pack. They are not required. Add a drop of locktight glue to the screws - Important - The shortest screw is required for the right bottom corner, as it is not mounted into the motor. Attention - Do not over tighten the top right screw. It might prevent the black plastic gear from rotating freely. A drop of lock-tight glue should hold it in place. Install the fan duct while the fan wires are positioned on the top. Attention make sure that the fan duck is flushed with the bottom of the heat sink (covering the bottom fin). This will prevent heat from crawling up and widen the filament resulting in clogged hot-end. Place the silicone cover on top of the heat block. Before the first heating you will take it off for completing the tighting under heat. Tighten the blower fan mounting bracket with two M4-8mm Screws. Add a drop of lock-tight glue first. In case you have no plan to use the cooling fan part, you can skip this step.

40 Assemble the 3d printed fan duct, use the two m4 25mm screws and tighten it into the mounting bracket. Adjust the fan dunt metal mounting bracket up or down in a way that allows clear cooling path towards the nozzle. This adjustment will allow you to raise the blower fan in case you will use the shorter standard heater block (not supplied) 19. Install the BL Touch Sensor Required Items Bl Touch Mounting bracket. 2 X M4 8mm Screws Bl touch, the nylon bag is supplied with the required M2.5 screws and nuts. It is also supplied with a 1 mm acrylic spacer. This is provided in case the metal bracket is bended to less than 90 degrees (between flanges) 1 mm thick acrylic spacer (optional)

41 Assembly Steps Locate the small auto leveling mounting bracket. Add a drop of lock-tight glue on the screws. Assemble the device with the logo as in the photo on the right. The BL Touch is installed behind the main extruder mount (yellow in diagram) and next the stepper motor. Keep it as low as possible (if you use the single slot version) or use the top mounting holes if you use the part with the three holes. Verify that the nozzle is ~2 mm higher than the BL touch with the pin fully out (pull with fingers), and 2 mm lower than the pin when it is closed. If not: try to adjust the Bl touch mounting bracket or use the supplied 1 mm thick acrylic spacer. Small height differences are later calibrated in the slicer software. 1. If you are installing a secondary print head, jump to this section or you can start printing with a single print head and add the secondary later on. 2. Use 4 x M4-8mm screw to tighten the Extruder mount bracket to the Y axis rail block. Add a drop of lock tight glue on the screws. 3. Slide the bracket towards the bottom of the mounting slots. These slots are designed to allow calibration of a second robot printer in a dual robot configuration (Tango mode).

42 20. Touch Screen Assembly Required Items Front Touch Screen Mounting Bracket Touch Screen Housing Bracket. 5mm Brass Female-Male Spacer 10mm Female-Female Spacer 8 X M3 6mm Screws 2 X 4040 T-Nut 2 X M5-12mm Screws 8pin Ribbon Flat Cable 0.5Meter of 4040 Profile Slot Plastic Cover (located in the big flat-bed box). Assembly Steps Install the 5mm brass spacer between the metal bracket and the touch screen PCB, male side towards the PCB. Install the 10mm brass spacer from the side of the PCB. Remove the buzz modular sticker

43 Remove the screen protecting film Install M3 6mm screws from the front side of the metal bracket. Assemble the housing with 4 M3 screws. Connect the 8pin flat cable to the bottom of the LCD. Attach the touch screen to the front left Z profile. If you are installing the enclosure, the touch screen upper side should be 24cm from the top of the machine. Final adjustment will be done when we will assemble the left door. Secure the 8pin ribbon cable to the upper left 4040 profile (Z Top left) with the T Slot plastic cover.

44 21. Electronic Box Assembly Required Items Electronic Box Drag Chain Cable, 37 chain links Drag Chain Cable, 29 chain links Drag Chain Mounting Bracket 2 x M5-12mm Screws 2 x 4040 Profile T-Nut 12 X M4-10mm Screws 3 X M4 Nuts Assembly Steps Open and spread out both drag chains. An easy way is to insert a flat screw driver and rotate it until the small plastic cover clicks out. Insert three command cables - first to the longer chain. Close the links. Afterwards insert the shorter chain. The correct order is Box - long chain - short chain. While placing the cables, try to keep them lined and prevent them from overlapping as much as possible.

45 On the longer chain only! Use a screw driver to remove the last chain (the mounting part that is far from the electronic box). Flip it over, and reassemble it to the chain. This assembly stage should result in a box, and two chains lined (as shown). The longer chain is the one closer to the box. The last part of the longer chain is flipped. Use the already the preinstalled in the box four M5-12 screws and T-Nuts to assemble the electronic box to the back side of the machine (side and top 4040 profiles). Note the location of the screws before removing them. Install the drag chain mounting bracket at the rear left Z 4040 profile (close to the electronic box) and at the mid-height of the Z 4040 profile. Use two M5 12mm & 4040 T-Nuts to attach the bracket into the Z profile.use the 3 M4-10mm screws to attach it to the plastic chain mounting bracket. NOTE - Do not over tighten it to the 4040 profile - as you might need to readjust its height to control the length of cables on the extruder side. Attach the other side of the chain to the Y pulley bracket. This is the part we have flipped in previous step.

46 Before assembling the short chain, we recommend removing the mounting bracket and assembling it with three M4 screws and M4 nuts. Add a drop of lock-tight glue. Once assembled, reconnect the chain. Assemble the remote side of the chain to the extruder mounting bracket. You can remove the last clip to give the cables some flexibility.. You don t need to put it back. The cables should look like in the photo on the right. If your cables don t end this way, adjust the location of Z mounting bracket. For example, lowering it down will shorten the cables at the extruder side.