Modix Big-60 Assembly Manual Part 2 Version 1.0, October 2017
Menu 1. Motors & End Stop Wiring... 3 2. Controller Wiring Check... 6 3. Extruder Wiring... 7 4. Electronic Box Cover... 9 5. Filament Sensor... 9 6. Spool Stand Assembly (for printers without enclosure)... 12 7. Silicon Heater Assembly... 15 8. Bed Assembly:... 17 9. PEI Sheet Assembly... 20 10. Support Brackets Assembly... 21 11. Decorative Panels Assembly... 22 12. Second Extruder (Optional)... 23 13. Secondary Hot-end... 25 14. Secondary Hot End Extruder... 26 15. Tight All Screws... 29 16. Enclosure Assembly (Optional)... 31 17. Top lid (top cover)... 35 18. Assemble the top pivoting lid... 38
1. Motors & End Stop Wiring Required Items X, Y & Z Motor Wires X & Y End Stops 4X M2.5 Screws Locate the correct nylon bag Locate the correct nylon bag 4 X M2.5 Nuts Assembly Steps Start with the Z motor wire. Locate the Z motor wire and insert the labeled side into the electronic box through the oval slot on the bottom of the electronic box. First connect the Z motor wire at the left side of the machine (the side with the single motor). Then connect the two other motors at the opposite side of the machine. Insert the wires into the 4040 T slot. Cover teh T - Slot with a plastic cover.
X Motor Wires Assembly: Connect the X motor wire connector to the X motor. Insert the other side through the oval slot on the bottom of the electronic box. Y Motor Assembly: Connect the Y motor wire to the bottom of the Y motor. Secure the Y motor wire with zip ties to the holes in the bracket. Y End Stop Assembly: Connect the Y end stop into the Y pulley bracket with 2 X M2.5 screws and nuts. Add a drop of locktight glue on the screws before tightening. Note - the end-stop lever base (where the metal lever connects the plastic ) should be on the side of the Y axis belt (as shown in the picture). Open the drag chain links. Insert the Y motor and Y end stop wires through the entire drag chain, all the way towards the electronic box. X End Stop Assembly: Install the X end stop wire with 2 X M2.5 screws and nuts. Add a drop of lock-tight glue, tighten the screws.
Arrange the X stop wire and insert it inside the 4040 T slot, cover the T slot with the T slot plastic cover. Secure the wires with zip ties to the x motor mounting bracket. Inside the electronic box you will find the MKS GEN 1.4 controller board from Makerbase: There are 6 connectors for end stops: From right to left: X Min & Max (RED) Y Min & Max (Blue) Z Min & Max (Green) In Modix Big we use X Min, Y Max and Z Min. Z Min is the auto leveling sensor. Note - Connect the top pins only (there are 3). Note - Polarity is not important for X & Y but it is important for Z min, reversed won't work. Connect the motor wires according the the drawing on the right. X, Y & Z are for the motor cables EXT0 and ETX1 are the main and secondary extruders.
2. Controller Wiring Check Attention! hot-end cooling fans are sensitive to polarity. If connected in the wrong way they will burn. Therefore, make sure that the polarity is correct and follow the diagrams on the right. The red wire from the fan should be connected to the brown-green wire on the command cables. This is true in for both hotends as we have one fan for each hotend. On the controller board, the plus is on top and therefore the brown-green wire should be on top of the white-green wire. The thermistor connectors are located on the left side of the controller. There are three connectors for thermistors: - The main hotend (T0) is the one connected on the bottom. - The secondary hotend (T1) is the one connected on the top.
The 8 pin flat cable connector for the touch screen is located on the top of the controller. Polarity is important. If the wire is reversed, the touch screen will not work (it won t burn if flipped). The BL touch servo connector is connected on the right side of the servo connector. The green wire is on the top. Cable A 3. Extruder Wiring Hot-end Heater Polarity is not important. Cable B On the extruder - you can identify the motor 6 pin white connector. On the controller side - The extruder motor cable is connected on the bottom of the board as the picture on the right.
Hot-end Thermistor Follow the wires with the right label. This is a different modular connector than the other connectors. Main Hot-end 0 Cooling Fan Follow the label "Blower Fan 1" BL Touch 3 Pins Connector BL Touch 2 Pins Connector Cable C This cable is for the secondary hotend only. The labels of cable C are white while the labels of cable B are blue. Cover the wires with the wiring cover bracket.
4. Electronic Box Cover Connect the electronic box cover cooling fan to the white terminal connector. Warning! Wrong polarity will burn your fan. Make sure to connect the red wire of the cooling fan to the blue wire (Labeled as Fan + ) Close the electronic box with M4-25mm screws. 5. Filament Sensor Required items: Filament Sensor Metal Mount 3D Printed Part FIlament Tube Mounting Press Fit Acrylic Part. Make sure it maches the 3d printed part.
Limit Switch with Roller (soldered to a long wire) 1 Meter PTFE Tube 4 X M3 30mm Screws M2.5 16mm Screws M2.5 Nuts Assembly Steps: Screw in the press fit metal mounting into the plastic part. Keep it as straight as possible. Install the limit switch and use the M2.5 screws and nuts to attach it to the plastic part. Use the M3-30mm screws to mount the plastic part onto the Metal mounting bracket. Assemble the metal bracket. We do not assemble it to the printer yet. This will be explained later.
Cut a small square of foam (from the motor packing or from another source) and use it as a filament dust filter. Place it in the filament access point where the filament is inserted. Attention - the use of this filament dust filter will keep your nozzle clean and dramatically reduce the chances of clogging. Install the PTFE tube by pressing the push fit and inserting the PTFE tube all the way in. Check your work by inserting a filament from the filter side. You might need to straighten the filament with your fingers and practice a little before you get used to insert it easily. On the extruder side of the PTFE tube: Chamfer (shave just a bit) the other side of the PTFE to allow easy inserting into the titan extruder. Attention - it is better to start with a very small cut and deepen it later. If you over shave it, it won t sit tight inside the titan extruder.
6. Spool Stand Assembly (for printers without enclosure) Required Items: 2 X 4040 Profiles 400mm long 3 X 4040 Profiles Corner Bracket Filament Sensor Module (from previous step) Spool Mount Round Plastic & 3 Plastic Nuts Metal Mount Bracket 10 X T Nuts for 4040 Profiles 2 X M5 12mm Screws 6 X 14mm OD M5 washers
Assembly Steps: Position the spool mount (quite freely - you can choose the middle of the machine rear side, left side or right side of the machine, based on your convenient access to filament changing. Start with assembling the 400mm 4040 profile in middle of the machine rear side. Use two 4040 corner brackets and M5 screws, use 14mm OD washers to mount the screws. Connect another 4040 profile on top of the vertical profile and support it with another 4040 corner bracket. Assemble the round plastic filament mount to the metal mounting bracket. Use the plastic nuts from both sides of the metal bracket, tighten well. Install the filament sensor for the main hot-end and rotate the bracket until you get an angle with a minimal bend with the filament spool. 1. Cover the wires with T slot plastic cover 2. Cover the 4040 profile with the provided plastic cover.
The filament sensor wire should be mounted at the back of the touch screen. The picture on the right shows the location of the pins on the right top corner of the 6 pins at the back of the touch screen. The filament sensor will work only while using the touch screen to execute your print job. The filament sensor will not work if print job is initiated from the PC/Mac.
7. Silicon Heater Assembly Required Items: Silicon Heater & Temperature Controller Aluminum Bed 660 X 660 mm 2X 860 mm 2020 Profiles 4 X M5 12mm Cone Screws 4 X 2020 Profile M5 T-nut Assembly Steps: Start with checking the silicon heater before applying it to the aluminum bed. 1. Note the small white sticker on the bottom of the heater. Verify the voltage (110V or 230V). If voltage is correct, connect the heater to the main power with the power cord provided in box 6 (a small box inside box 1). Once it s connected, the temperature controller should show the room temperature immediately. 2. Turn on the two switches to make sure the heater is working: - Place the heater flat on the aluminum plate. - Warning! It is forbidden to power on the heater without placing it on the aluminum bed. - Turn the heater on using the two switches. There is an automatic two minutes delay till the switch lights turn on - (we will later learn how to change it). The light indicates that the heaters are working. - Check the heater: Put your hand on the heater to feel its warmth. Now its working! Turn the heater off when it starts to get hot. For now, do not heat it to more than 40-50ºc. FYI The reason for having two switches is that there are two heater spirals inside the silicon (one of the 200X200 mm size in the center and the other is around it). This way you can turn the inner heater only for a small prints and save energy.
If the heater is working fine, remove the aluminum bed protective film. Connect the 2020 profiles from the bottom of the plate. The cone screw should be flashed with the top of the plate. Make sure the silicon heater has enough space between the 2020 profiles (it is designed to match exactly the space between them). If not, you try to rotate the heater 90 degrees to find a better matching size. If it still doesn t fit, make sure that the 2020 profiles are aligned with the bed. Carefully peel off a small corner of the protective film attached to the silicon heater. Start applying the heater to the bed and use the 2020 profiles as a guideline. It is recommended to start with one side first (the closest 2020 profile). Make sure it is aligned first and then move to the other side. Keep 20 mm from both sides of the plate. Warning - Do not bend the silicon heater or use metal tools as you might damage them. Be careful not to break the internal heater spiral. Warning - the glue is very strong, and after applying the silicon it will not remove easily. Be patience and work slowly while making sure there are no bubbles and that the heater is aligned with the bed! Unscrew the cone screws and remove the 2020 profiles. Mark the side you have assembled the profiles and keep the screws in a safe place.
8. Bed Assembly: Required Items: The Print Bed Plate with heater installed 2X 860 mm 2020 Profiles 2X 620 mm 2020 Profiles 4 X 2020 Corners 26 X 2020 T-Nuts 34 X M5 8mm Screws M5 12mm Cone Screws Assembly Steps: For easy assembly, position both Z mid plates in the same height at the middle of the Z ball screws length. You can rotate the screw manually till you get the right height. It is easier to rotate the screw when you hold the 40 teeth gear at the bottom. Start with the 620 profiles and attach the above the Z mid brackets with 2020 T-nuts and M5 12 mm screws.
Add the 2020 corner brackets to the 620 profiles and then add the longer 860 profiles Align the two long 860 profiles with the Z mid brackets in all 4 corners Tighten it well from the bottom of the two Z mid brackets (right and left) It is recommended to get some help with this step as the print bed is heavy, please carefully follow the next steps! 1. Make sure you are positioning the bed plate in the right direction for assembly. It should be the same direction as it was in between the 2020 profiles while assembled the silicon heater. 2. Before placing it on the floor make sure that the temperature controller wires are safe. 3. Place one side on the floor and lift it carefully until it is lays on the front 2020 profile.
Change your hands position one by one until your hands are above the front 2020 profile. Reach out to the middle of the plate and rotate it in the air and then push it towards and over the rear 2020 profiles. Now you can pull it back and place it carefully on the rear and front 2020 profiles. Make sure that the silicon heater is not squeezed between the plate and the 2020 profiles. Finally, secure the plate with 4 x M5 cone 12mm screw and 4 2020 M5 T-nuts. The plate should be placed closer to the right side of the printer and 10 mm away from the right 2020 profile.
9. PEI Sheet Assembly The PEI sheet is optional. It helps in attaching the first layer of the 3d printed model to the bed and avoid wrapping. You can use other products and methods based on your desired printing profile. Attention! This thin film is very sensitive to scratches. Be careful with using it with first prints. To easily complete this step, we provided a sheet that has the same width as the bed. First of all clean the bed from dust and other particles that may be trapped under the PEI sheet. Wash your hands with soap and dry them well. Carefully peel the PEI. Apply the sheet to the bed start on one of the corners, ensure the sheet is aligned with the edge of the bed. Attention - Removing the PEI sheet after you already applied it is not recommended. We have provided a wider sheet than needed (660mm), therefore, there is room for an error to a certain extent. It is better to have a slight angle than peeling off and re-applying! To apply the rest of the sheet it is recommend to ask for assistance. With help, use both hands to stick the sheet - slowly yet firmly, from the center to the sides. Take care of any tiny air pockets - it will be harder to get rid of them later on. If you notice any wrapping or uneven tension in the sheet that is being placed, start with applying this region first and slowly this irregularity will vanish. After completing this task, use Alcohol Isopropyl (not supplied) to clean the PEI surface from hand moisture. It is also recommended to clean the PEI sheet the same way before new prints.
10. Support Brackets Assembly Required Items: 4 X Top Support Brackets 11 X Side and Back Support Brackets 8 X Side Support 3 X Back Support 2 X Front Top Brackets 1X Front Bottom Right Bracket 1 X Temperature Controller Mount Bracket 46 X 4040 T-Nuts 46 X M5 12mm Screws 46 X M5 Black Nylon Washers Assembly Steps: Open the temperature controller and unscrew the supplied nylon screws from the box. Make sure to use these screws for connecting the temperature controller to the metal mounting bracket. These nylon screws keep the required double insulation safety standard. Connect this bracket to the lower front left side of the printer with 4 M5 12 mm screws, nylon washers and T-nuts to the 4040 profiles Connect the rest of the support brackets according to their names as described at the "required items" section
11. Decorative Panels Assembly Required items: Top Cover Logo Background Bottom Plate 8 X T Nuts for 4040 Profiles 8 X M5 12mm Screws Assembly steps Add a tiny drop of super glue (not provided) to the edge of the small red acrylic panel and attach it to the background of the top cover. Install the top and bottom cover in front of the machine as shown in the diagram on the right.
12. Secondary Hot End mount (Optional) Second Hot-end Mounting Hot-end Mounting Bracket Second Hot-end Blower Fan Mount Blower Fan 3D Printer Part 6 X M5-8 mm Screws 2 X 25mm M4 Screws
Assembly Steps Position the hot-end mounting bracket (red, in illustration) on top of the main extruder mounting bracket (yellow, in the illustration). Secure it with 4 M4 8mm screws. Add a drop of lock-tight glue. Secure the blower fan mounting bracket with two M4 8mm screws, at a tiny drop of lock-tight glue. Make sure the PEM of the blower fan mount are facing outwards. The order of assembly is: - The flat surface of the 3d printer part is mounted to the metal bracket - The blower fan vent (rotating part) face outwards. - Secure it all with two M4 25mm screws.
13. Secondary Hot-end Required Items: Secondary Hot-end parts: Heat Sink, Heat Block, Heat Break, Nozzle, Thermistor, Heater cartridge Hot-end PTFE Clip and Locker 3D Printer Part (flat 3 mm thick) 2 x M4 8mm Screws Assembly steps: Assembly Steps differences Follow instructions to assemble the hot-end first. The only difference is the way we attach filament guide with a small black push fit clip and blue locker. Install the hotend on the hotend mount bracket and secure the hotend by sliding the 3d printed part between the hotend top and the mounting bracket. Secure the part with 2 x M4 8mm screws. It is recommended to adjust the secondary hotend higher than the main hotend at that stage.
14. Secondary Hot End Extruder Required Items: Remote Extruder Mounting Bracket E3D Titan Extruder E3D Titan Extruder Bowden adaptor 1 Meter PTFE Tube ID 2mm OD 4mm 3d printed Secondary Hot-end Filament Sensor Acrylic Secondary Hot-end Filament Sensor Nema 17 Motor 40mm Filament Sensor Switch, with roller.
Assembly Steps: The assembly of the secondary Titan extruder is similar to the main extruder with these differences: Use the bowden adapter at the bottom of the extruder. The same location you were previously installed the hotend. The motor wire connector is towards the center of the bracket. The extruder filament access is towards the filament sensor filament exit. There is no PTFE tube between them. Connect the filament sensor modular connector to the main extruder filament sensor wire. Ignore this step if you are using the printer enclosure: Assemble the second round plastic spool mount to the metal mounting bracket. The second is the upper one in the photo on the right. After you position the extruder (check options next page) insert the PTFE tubes through the extruder filament guide into second extruder.
Positioning the Second extruder & the main extruder filament sensor. There is more than one way to assemble the two spool mountings. 1. Side by side on the filament stand, you can rotate the metal brackets until you find the suitable position with a minimal bend. 2. One from each side of the stand. 3. On one of the sides of the printer (or back). While the filament tube is supported by a vertical 4040 profile. 4. In case you are installing the enclosure, you should install the two spool mounts on the left side of the printer. (the white background is for the photo only)
15. Tight All Screws This is an important step that is required before proceeding to the next Item M8 Screws that holds the 4040 profiles Z Motors Check list Total of 16 screws on 8 corners Tighten the pulleys set screws Make sure the 200mm belts are stretched, tighten the motor mounting screws Check the set screws on the 40 teeth gears Check the motor wire connector Z Bottom, Mid and Top All M5 screws that are mounted to the 4040 profiles. M4 screws that hold the bearing and ball screws All set screws that holds the 12mm rods (bottom and top) X Axis Check the X motor screws and tighten the 200 belt Check the motor wire connector Check the screws on the X guide rails and tighten them firmly. They will hit the block if they unscrew. Tighten the 8 screws (4 on each side) that hold the Y axis brackets to the X rails blocks. Tighten the X idler and X pulley brackets on both sides of the printer (front and back) Tighten the 4 belt clamp that holds the X belt (2 on each side) X Shaft Y axis Tighten the X end stop limit switch Tighten all of the screws and set screws along the X shaft. Tighten screws on Y Pulley including motor, limit switch and drag chain mounting
Check the belt clamps and belt tension Check the 10 screws in the guide rail Check the Y motor wire connector Bed Extruder Check all the screws that hold the bed to the Z mid brackets, the 2020 corners and the 4 cone screws that hold the bed to the 2020 profiles. Tighten all of the screws in the metal brackets In the hotend, make sure that the heat block is not spinning under the heat sink. Important! Make sure that the hot-end fan duck is flashed with the bottom of the heat sink. Tighten the Bl touch mounting and the device Check all of the extruder wiring connectors and the motor wire connector Filament spool mount & sensor Check all of the screws on the 4040 profile corners and the spool mounting bracket
16. Enclosure Assembly (Optional) Required Items: Machine Side Panels (clear acrylic) 2 X Side Panel 1 X Bottom Panel 1 X Back Panel 1 X Back Cable Cover 49 x M5 4040 Profile T-Nuts 49 x M5-12mm Screws 49 x M5 Black Nylon Washers.
Assembly Steps: For assembling the side panels, please insert the screws inside the nylon washers to protect the acrylic panels before you tight it. You may need to move a little the support brackets to make a room for the panels. Attention - Do not over tight the acrylic panels as they may easily break! Add the bottom and the back panels carefully The small brackets goes at the back of the printer below the electronic box and holds the cables.
17. Doors Assembly Required Item 2 X Doors 5mm thick (left and right) 3 black long panels for the door support. 4 Large Modular Hinges. Notice the two mirrored sets. The hinge on the left is for the left door, the one on the right is for the right door. 1 X Handles 4X Round Magnets Attention! The magnets are very fragile. Handle with care. Do not drop on the floor. 4 x M4 10mm screws & M4 nuts 16 x M5 Cone 20mm 4 x M5 12mm 8 x M5 nut 12 x M5 4040 T nut Assembly Steps Remove the film protection from the acrylic parts, notice that the black parts have a matt side, this side will face outwards. It might be required to adjust the height of the touch screen for easy assembly.
Use the small black part and add a left side hinge on top of it with two cone screws and T nuts Connect the other half of the hinge to the doors with cone screws and M4 nuts. Be careful when closing the doors for the first time as you might break them if the screen is not aigned correctly. Use M4 screws to attach the magnets from the back of the door, Keep in mind that the magnets on either the right or the left doors should be flipped. otherwise you will never be able to close the doors due to similar magnets polarity. Even in case you are breaking the magnets you can still use them by flipping one of the halves.
18. Top lid (top cover) Required Items: 2 X Side Panels 1 X Back Plate 1 X Top Back Panel 1 X Top Front Panel (note the holes in the center) 1 X Front Panel 22 X 2020 Corner Bracket 46 X 4040 T-Nuts 46 X M5 12mm Screws 46 X M5 Black Nylon Washers
2 X Small Hinges 1 X Handles 2 X Small L Type Bracket. 4 Top Lid Mounting Brackets (2 mirror sets) Left right 2020 Profiles 20X20 Length 145 mm 2 pc 20X20 Length 165 mm 4 pc 20X20 Length 380 mm 2 pc 20X20 Length 525 mm 3 pc 20X20 Length 830 mm 2 pc 20X20 Length 845 mm 2 pc Assembly Steps: Assemble the mounting brackets on top of the supporting brackets. Assemble the 4 x 165 mm 2020 profile to the brackets. Add 2 X 2020 corners from both sides
Assemble the 845 mm on top of the 165 profiles on both sides of the machine The 845 profile is a bit short to enable a plastic cover to the front of the profile Connect the back 2020 profile and mid 2020 profile both are 830mm long. Support the middle profile with two 2020 corners from both sides ( total 4 pc). Assemble the acrylic panels for the top back cover, the back and the two side panels. On top acrylic panel add the two small plastic hinges, tighten them with two cone M5 screws.
19. Assemble the top pivoting lid This is the final look of the pivoting top lid. Start with assembling the frame (the three horizontal 2020 profiles are 525 mm long) Strengthen the corner with 3 x 2020 corner brackets. Install the two small support brackets and the handle from the front. Use M4 25mm screws for the handles. Carefully place the pivoting lid on the printer and tighten the small hinges with additional two cone screws for each one. Insert two small plastic clips one on top of the other into a M5 8mm screw and assemble it below the mid 2020 profile that holds the top lid. This will be used to hold the PTFE tubes.