Rapman v3.0.0 Build Manual

Build Manual
RapMan V3.0.0
DocumentNo:D100236
Ver 1.2
Build Manual: RapMan V3.0.0
Contents
Section Title
Page
Contents
BuildManualInstruction
BuildingwithAcrylic
PartsintheKit
PanelLayout5mm
Extruder&3mmPanel
8mmPanel&Beds
i
ii
iii
iv
v
vi
vii
Section Title
Page
Section318Continued
151
TopBed
161
X&YBelts
171
Electronics
181
FilamentReel
3AxisCartesianRobot
Section1
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
Section2
201
202
203
204
205
CornerBottomBlockRx2
CornerBottomBlockLx1
MotorBlockx1
CornerTopBlockRx2
CornerTopBlockLx1
YMotorBlockx1
BedCornerx4
BedBasex1
DiagonalTieBase8mmx2
DiagonalTieSide8mmx4
DiagonalTieSide12mmx4
FilamentReelx1
PCB&Screenx1
WireSteppersx3
WireMicroSwitchesx3
ZIdlerPostsx4
BedTopx1
ElectronicsHousingx1
XMotor&IdlerPlate
XRod&BeltClamps
Section3to18
301
BaseFramex1
401
Verticals
501
ZIdlers
601
TopFrame
701
SettingTopFrame
801
SettingVerticals
901
DiagonalTies
101
XMotor&Rails
111
YMotorBracket&BearingBracket
121
YMotor&Drive
131
XCarriage
141
BedBase
151
TopBed
161
X&YBelts
DocumentNo:D100236
Ver 1.2
Using the Instructions & 3D PDFs
PleasereadandwatchtheseinstructionsbeforestartingtobuildyourRapManV3.0.0Kitinordertogetthemost
outofyourcompletedRapMan.
Theseinstructionsaredesignedtobeusedonacomputerastheyarefullyinteractive,printedcopieswillnotallow
interactionwiththe3Dmodelsorviewingtheanimations/videos.
Themanualisbrokendownintosectionsallthepartsinonesectioncanbebuiltsimultaneouslyi.e.allthe1xxitems
canbebuiltatthesametime.TheSection2xxbuildswillrequirepartsfromthesection1xxbuildsandsection3xx
fromsection2xxandsoon.
SettingupthePDFenvironment:
ThisdocumentisbestviewedinAdobeAcrobatReader9.
Set the document to view Two Up go to View Page Display Two Up this will allow you to see the
instructionpageontheleftandtheanimationontheright.
3DMenuBar
Rotate
Lights
BackgroundColour
ModelTree
Home
PartsList
Animation
SelectedPart
ToolsRequired
DangerHazards
SpecialCareNotes
UsingtheinteractivePDF:
Build
Instructions
Interactive3DPDFsallowtheusertoseealltheinformationnormallyonlyavailabletotheoriginaldesigner
the models can be rotate and zoomed, individual parts can be turned on and off to allow the user to see
hiddenpartsorabetterviewofdifficulttounderstanditems,thisistrueforboththestatic3Dmodeland
the3Danimation.
Allthe3Dmodelscanbeinteractedwith,toenableinteractionclickonthemodelandthe3Dmenubarwill
openallowingthemodeltoberotated,panned,zoomed,sectionedetc.
The background colour, model display and lighting can also be changed the view can always be reset by
pressingthehomebutton.
Iftheanimationdoesntstartasthepageismadevisible,clickonthemodel,selectingthedropdownonthe
play/pausebuttonwilldisplayatimelinecontrolallowingyoutopositionthebuildatanypointrequiredthe
modelcanthenberotatedetctogetabetterview
Selectingthemodeltreedisplaywillallowyoutoclickonanyiteminthemodelortreeandthepartwillbe
highlightedinboththemodelandthemodeltree,thisallowsveyeasyidentificationofallparts.
DocumentNo:D100236
Ver 1.2
Building with Acrylic
The Bits From Bytes RapMan kit consists of a steel frame held together by sandwiched and clamped
acrylic parts to give a fully function 3D printer. When building the kit consideration of the limits of acrylic
need to be taken into account. The 5mm Panel is Hi-Impact acrylic which makes it tougher, but if the parts
are over tightened they will still break.
To help prevent this happening included in the kit are 7 practice parts,
Part 10112 is for testing the corner blocks slide a 8 500mm rod (20001) into the 8 hole then install a M5
Nut & Grub Screw, tighten until the rod is held firm, typically finger tight followed by of a turn, practice on
all six holes. Maximum torque setting 0.5 Nm
Part 10113 is for testing the clamping of the steel rods. Clamp 2off parts around an 8 500mm rod
tightening until the rod is held firm, typically finger tight followed by of a turn, practice on all six holes.
Maximum torque setting 0.75 Nm
.
All parts have a blue protective film to protect them during transport, remove this film before building the
RapMan as it is not possible to fully remove it after building.
Acrylic can be cleaned using IPA and a lint free rag.
If parts are broken they can be repaired using Cyanoacrylate glue (super glue) if possible clamp the joint
during gluing.
Under no circumstances use a hammer when assembling the parts as the shock loading will break the
parts.
DocumentNo:D100236
Ver 1.2
In The Box
DocumentNo:D100236
Ver 1.2

5mm Acrylic Parts Panel
Ver 1.2

5mm Extruder & 3mm Parts Panel
Ver 1.2
8mm Acrylic Parts & Print Platen
DocumentNo:D100236
Ver 1.2
Steel Pack Contents
DocumentNo:D100236
Ver 1.2
Bolt Bag Contents
One of the setting jigs has a small bolt measure cut into the side this will help identify some of the bolt
lengths
DocumentNo:D100236
Ver 1.2

Build #: 1-01
Name: Bttm Corner Block R x 2
Level: Easy Previous

Part#
10008
10009
10010
M3x25CP
M3Nut
M3Washer
Qty
2
2
2
16
16
32
Builds Required: None
Tools:
Spanner5.5mm
AllenKey2.5mm
:None

:Checkorientationofallparts
duringthebuild.
PreAssembletheBottomCornerblocksreadyforassemblyoftheCartesianbots
frame.
StartwithpartNo10008thismakesfittingthenutseasier
Takespecialcareovertheorientationofeachpartastheyareveryeasilyfitted
thewrongwayroundandthiswillonlybecomeapparentlaterinthebuild
Fingertighteneachnutbytwoorthreeturns
DocumentNo:D100236
Ver 1.2

Build #: 1-01 Animation
Name: Bttm Corner Block R x 2
DocumentNo:D100236
Ver 1.2

Name: Bttm Corner Block L x 1
Build #: 1-02

Part#
10008
10009
10011
M3x25CP
M3Nut
M3Washer
Qty
1
1
1
8
8
16
Tools:
Spanner5.5mm
AllenKey2.5mm
:None

duringthebuild.
PreAssembletheBottomCornerblocksreadyforassemblyoftheCartesianbots
frame.
DocumentNo:D100236
Ver 1.2

Name: Bttm Corner Block L x 1
DocumentNo:D100236
Ver 1.2

Name: Z Motor Block x 1
Build #: 1-03

Part#
10009
10008
10012
10014
10015
10016
10079
625Bearing
FL57Stepper
M3x25CP
M3Nut
M3Washer
M3x20CP
M3x6Grub
M5x16CP
M5x30CP
M5Nut
M5Washer
M5x30
Washer
Qty
1
1
1
1
1
1
1
1
1
8
12
34
3
1
4
1
5
7
2
Tools:
Spanner8mm
Spanner5.5mm
AllenKey4mm
AllenKey2.5mm
:None

duringthebuild.
DocumentNo:D100236
PreAssemble the Bottom Z Motor Corner block ready for assembly of the Cartesian
botsframe.
File a flat on the motor shaft before fitting, this helps to prevent the pulley
slippingduringuse
Notetheorientationofthemotorwiresasthismakesfittingtheconduiteasier
Fullytightenthe4motormountingbolts
LooselyassemblytheZbelttensioningbearing
Ver 1.2

Name: Z Motor Block x 1
DocumentNo:D100236
Ver 1.2

Build #: 1-04
Name: Top Corner Block R x 2

Part#
10001
10002
10003
M3x25CP
M3Nut
M3Washer
Qty
2
2
2
16
16
32
Tools:
Spanner5.5mm
AllenKey2.5mm
:None

duringthebuild.
PreAssembletheTopCornerblocksreadyforassemblyoftheCartesianbotsframe.
DocumentNo:D100236
Ver 1.2

Name: Corner Top Block R x 2
DocumentNo:D100236
Ver 1.2

Name: Top Corner Block L x 1
Build #: 1-05

Part#
10001
10002
10007
M3x25CP
M3Nut
M3Washer
Qty
1
1
1
8
8
16
Tools:
Spanner5.5mm
AllenKey2.5mm
:None

duringthebuild.
PreAssembletheTopCornerblocksreadyforassemblyoftheCartesianbotsframe.
DocumentNo:D100236
Ver 1.2

Name: Corner Top Block L x 1
DocumentNo:D100236
Ver 1.2

Name: Y Motor Block x 1
Build #: 1-06

Part#
10004
10005
10006
M3x25CP
M3Nut
M3Washer
Qty
1
1
1
8
8
16
Tools:
Spanner5.5mm
AllenKey2.5mm
:None

duringthebuild.
PreAssembletheTopYMotorCornerblockreadyforassemblyoftheCartesianbots
frame.
DocumentNo:D100236
Ver 1.2

Name: Y Motor Block x 1
DocumentNo:D100236
Ver 1.2

Name: Bed Corner x 4
Build #: 1-07
Level: Easy - Moderate

Part#
10017
10018
10019
SlideBearing
M3x15
Spacer
M3Washer
M3x12CP
Previous Builds Required: None
Qty
4
4
4
8
12
24
24
Tools:
Spanner5.5mm
AllenKey2.5mm
Round/HalfRoundNeedleFile
:None

:Checkthatthebedcorner
slidesfreelyonthesteelrods
PreAssembletheBedCornerreadyforassemblyoftheZIdlerPosts.
All laser cut parts have a slight taper meaning the slide bearing will fit more
easily from one side than the other, check this before assembly so the parts
10018&10019arethecorrectwayuptoalloweasierassemblyofthebearings
Usingoneoftheshortsteelrodscheckthattheslidebearingslidefreelyonthe
rodifnotremovetheslidebearingusingasmallscrewdriverthengentlyfilethe
holejustenoughtoallowthebearingtoslidefreely,thisnormallyonlyrequires
thetapermentionedabovetobefiledi.e.theholeissmallerononesidebya
fractionofamillimetreandthisisallthatneedsfilling.
DocumentNo:D100236
Ver 1.2

Name: Bed Corner x 4
DocumentNo:D100236
Ver 1.2

Name: Bed Base x 1
Build #: 1-08

Part#
10020
M8x60Hex
SetScrew
M8Nut
M8Washer
Qty
1
3
6
6
Tools:
Spanner13mm2off
:None

:None
PreAssembletheBedBasereadyforassemblyoftheCartesianbotsframe.
Ensuretheengravingisthecorrectwayupwithrespecttothebolts
DocumentNo:D100236
Ver 1.2

Name: Bed Base x 1
DocumentNo:D100236
Ver 1.2

Name: Diagonal Tie Base x 2
Build #: 1-09

Part#
10040
20011
M8Nut
M8Washer
M3x25CP
M3Nut
M3Washer
Qty
8
2
8
8
4
4
8
Tools:
None
:None

:None
PreAssembletheBaseDiagonalTiereadyforassemblyoftheCartesianbotsframe.
DocumentNo:D100236
Ver 1.2

Name: Diagonal Tie Base x 2
DocumentNo:D100236
Ver 1.2

Name: Diagonal Side 8mm x 4
Build #: 1-10

Part#
10040
20009
M8Nut
M8Washer
M3x25CP
M3Nut
M3Washer
Qty
16
4
16
16
8
8
16
Tools:
None
:None

:None
DocumentNo:D100236
Ver 1.2

Name: Diagonal Tie 8mm x 4
DocumentNo:D100236
Ver 1.2

Name: Diagonal Side 12mm x 4
Build #: 1-11

Part#
10040
10066
20009
M8Nut
M8Washer
M3x25CP
M3Nut
M3Washer
Qty
8
8
4
16
16
8
8
16
Tools:
None
:None

:None
DocumentNo:D100236
Ver 1.2

Name: Diagonal Tie 12mm x 4
DocumentNo:D100236
Ver 1.2

Name: Filament Reel x 1
Build #: 1-12

Part#
10103
10104
10106
M8x140
CoachBolt
M8x120Hex
SetScrew
M8Nut
M8Nut
M8Washer
M8x30
Washer
Qty
1
2
3
1
3
3
4
3
3
Tools:
Spanner13mm2off
:None

:None
PreAssembletheFilamentReelreadyforassemblyoftheCartesianbotsframe.
DocumentNo:D100236
Ver 1.2

Name: Filament Reel x 1
DocumentNo:D100236
Ver 1.2

Name: PCB Screen x 1
Build #: 1-13
Level: Difficult
Part#
10090
10101
Electronics
Screen
ElasticBand
3x150
M2x12
CheeseHead
M2Nut
M2Washer
Qty
4
1
1
1
1
4
4
8
Tools:
Spanner4mm
Electronicsscrewdriver(Flat)
Lengthof24SWGwireforlocatingpins
Scissors
Multimeter
Glue

:None
AttachOLEDdisplaytothePCB.

Cut25mmlengthofthe3mmwideelasticband
Looselyassemblethescreenclamp(10101&10090)tothePCBwithM2screws&nuts
:
Be very careful when fitting
Slidetheelasticbandundertheclamp(thiscanbegluedtotheclamp)
thelocatingpinsnottodamagethe
Slidethescreenconnectorundertheclampwiththescreenfacedown
flexible
PCB of the screen, do not
Carefully insert the 2 24SWG wire locating pins this will ensure the screen terminals
forcethemintoplace.
havethecorrectlocationonthePCB
Tighten the screws starting with the middle 2 screws until the elastic band becomes
Take care when taking voltage
slightlytranslucent
reading
not too short nearby pins
Nowpoweruptheboardtocheckthescreenfunctions
withthetestprobe.
Set the Stepper motor currents; adjust the trimmer pots on the PCB while taking a
DocumentNo:D100236
voltagereadingonthecorrespondingtestpoint
TPE=1.1V,TPZ=1.3V,TPX&TPY=1.0V
Ver 1.2

Name: Wire Stepper Motor x 3
Build #: 1-14
Level: Moderate
Part#
FL57Stepper
Motor
RedWire530mm
BlackWire530mm
GreenWire
530mm
BlueWire530mm
RedWire680mm
BlackWire680mm
GreenWire
680mm
BlueWire680mm
Heatshrink
1.6mmx20mm
Heatshrink
2.4mmx15mm
Qty
3
2
2
2
2
1
1
1
1
12
6
Tools:
Wirecutters
WireStrippers
SolderingIron
Helpinghandclamp
Hotairforheatshrink
:HOTSOLDERINGIRON
:Alwaystinthewiresto
ensureagoodmechanical&
electricaljoint
ConvertStepperMotorfromUnipolartoBipolarSeriesandextendwires.
CutallwirestolengthX=530mmred,black,green&blue,Y=680mmred,black,green
&blue,Z=530mmred,black,green&blue
Jointheblue&red/whitemotorwirestogetherandheatshrinkoverthejoin2.4mm
Jointhegreen&black/whitemotorwirestogetherandheatshrinkoverthejoin2.4mm
ThishasconvertedthemotorfromUnipolartobipolarseries
Extendedtheredandblackmotorwireswiththeredandblackwiresandcoverthejoin
withheatshrink1.6mm
Extendtheblue/whitewirewiththebluewireandcoverthejoinwithheatshrink1.6mm
Extend the green/white wire with the green wire and cover the join with heat shrink
1.6mm
DocumentNo:D100236
Ver 1.2

Name: Wire Micro Switches x 3
Build #: 1-15
Level: Moderate
Part#
V15Micro
Switch
PurpleWire
830mm
GreyWire
830mm
GreyWire
980mm
Qty
3
2
2
2
Tools:
Wirecutters
WireStrippers
SolderingIron
Helpinghandclamp
:HOTSOLDERINGIRON

:Alwaystinthewires&
connectionstoensureagood
mechanical&electricaljoint
WireMicroSwitchesforallaxis.
BendtheMicroSwitchconnectortabasperthedrawingabove
CutallwirestolengthX=Purple,830mm2off,Y=Grey,980mm2off,Z=Grey,
830mm2off
Strip approx 5mm on the cable ends, tin the wire and tin the micro switch
connection
Solderthewiretothemicroswitch
Forneatnesstwistthewiretogetherastheycomeawayfromthemicroswitch.
Twist40mmfortheX&Ymicroswitchesand350mmfortheZmicroswitch
Asthewirecomefromaswitchtheyhavenopolarity
DocumentNo:D100236
Ver 1.2
Intentionally Blank
DocumentNo:D100236
Ver 1.2

Name: Z Idler Posts x 4
Build #: 2-01

Part#
10013
20002
608Bearing
C2Spring
M8x40
Washer
M8Nut
M8Washer
Previous Builds Required: 1-07
Qty
4
4
4
4
8
16
16
Tools:
Spanner13mm2off
:None

:None
PreAssembletheZIdlerPostsreadyforassemblyoftheCartesianbotsframe.
TrytocentretheM8x40washeronthethreadedrod
Whenfittingthesecondnutintothebedcornersetitsuchthatofitextends
abovetheplastic
Make sure the bed corner rotates freely on the threaded bar if not adjust the
nuttoreducethespringforce
Windthebedcornerapproxwaydownthethreadedrod
DocumentNo:D100236
Ver 1.2

Name: Z Idler Posts x 4
DocumentNo:D100236
Ver 1.2

Name: Bed Top x 1
Build #: 2-02

Part#
10021
10038
10039
M3x30CP
M3Nut
M3Washer
M5x16CP
M5x25CP
M5Nut
M5Washer
Previous Builds Required: 1-15 Z micro switch
Qty
1
2
1
2
2
4
2
4
6
10
Tools:
Spanner8mm
Spanner5.5mm
AllenKey4mm
AllenKey2.5mm
:None
PreAssembleBedTopreadyforassemblyoftheCartesianbotsframe.

Solderwirestothemicroswitch,asperwiringinstructions115Zmicroswitch
:
Make sure the M3 x 30 bolts
are fitted
as per the drawings or
theywill
hit thecornerblockwhen
themachinehomes.
Take care tightening the Z limit

switch mounts as they are not Hi
ImpactAcrylic.
DocumentNo:D100236
Ver 1.2

Name: Bed Top
Previous Builds Required: 1-15 Z micro switch
DocumentNo:D100236
Ver 1.2

Name: Electronics Housing x 1
Build #: 2-03
Level: Moderate
Part#
10093
10094
10095
10097
10099
10100
Fan80mm
M3x25CP
M3x20CP
M3x16CP
M3Nut
M3Washer
Qty
10
7
1
1
1
1
1
4
4
2
10
14
Tools:
Spanner5.5mm
AllenKey2.5mm
Wirecutters
WireStrippers
Electronicsscrewdriver(Flat)
:None
AssembletheElectronicsHousing

Cutthefanpowerleadto70mmlongandstriptheendsofthewirebackapprox
5mm&twisttheendstokeepthemtidy
:Ensurefanwireareconnected
Attachthefantotheconduitmount(10098)makingsurethecableisintheTop
withthecorrectorientation
Rightcorner
Connect the fan to the connect marked FAN with the red wire going to the
connectormarkedRED
Setup the electronics lower plate (10095) with bolts and spacers (10093) then
lowerthePCBintoplace
Attachcompleteassemblytotheconduitmount(10098)andthefan
DocumentNo:D100236
Ver 1.2

Level: Moderate
Name: Electronics Housing x 1
DocumentNo:D100236
Ver 1.2

Name: X Motor & Idler Plate
Build #: 2-04
Level: Moderate
Part#
10024
10028
623Bearing
FL57Stepper
MXL18T
Pulley
M5x16CP
M5Nut
M5Washer
M3x16CP
M3Nut
M3x12
Washer
M3Washer
Previous Builds Required: 1-14 X motor
Qty
1
1
3
1
1
4
4
4
3
3
3
21
Tools:
Spanner8mm
Spanner5.5mm
AllenKey4mm
AllenKey2.5mm
AllenKey1/16
:None

:None
Steppermotor&XidlerbearingsforXFrame
Fit the stepper motor to the X Motor Plate (10024) check orientation of the
motorplate
TheXmotorwiresneedtocomeoutontheYmotorside
Fitthesuchthatthealuminiumhubisuppermostandlevelwiththetopofthe
motorshaft
FittheIdlerbearingtakingnoteofthenumberofwasherforeach,3belowthe
bearing&3abovebeforethelargewasher
Repeat the idler bearings on the Idler bracket again taking care over the
orientation
DocumentNo:D100236
Ver 1.2

Level: Easy
Name: X Motor & Idler Plate
Previous Builds Required: 1-14 X motor
DocumentNo:D100236
Ver 1.2

Name: X Rod & Belt Clamps
Build #: 2-05

Part#
10026
10027
10030
10036
10037
M3x25CP
M3x20CP
M3Nut
M3Washer
Builds Required: 1-15 X micro switch
Qty
1
8
2
1
1
2
8
10
20
Tools:
Spanner5.5mm
AllenKey2.5mm
:None

:None
XRodClamps&YBeltClamps
Fitbeltsclampsleavingtheboltsloose
FittheXmicroswitch
DocumentNo:D100236
Ver 1.2

Name: X Rod & Belt Clamps
Builds Required: 1-15 X micro switch
DocumentNo:D100236
Ver 1.2

Name: Base Build
Build #: 3-01

Part#
20001
Builds Required: 1-01, 1-02, 1-03
Qty
4
Tools:
Spanner5.5mm
AllenKey2.5mm
SettingJig2off
:None

:Ensurecorrectsettingofthe
barsasifthisiswrongitisalotof
worktoalterlater
AssembleBaseoftheCartesianbotsframe.
Fitthefirst8rodsettingtheendtoprotrude20mm(thewidthofthesetting
jig)tightentheclampboltsmax0.75Nm
Installtheother38rodsensuringthecorrectendsprotrude20mmandtighten
theclampbolts
Usingthesettingjigssettherodstothecorrectlengthusingtheholesmarked
8andHorizontal
DocumentNo:D100236
Ver 1.2

Name: Base Frame
Builds Required: 1-01,1-02, 1-03
DocumentNo:D100236
Ver 1.2

Name: Verticals
Build #: 4-01

Part#
20001
20006
M5x6Grub
M5Nut
Builds Required: 3-01
Qty
1
3
8
8
Tools:
AllenKey2.5mm
SmallPliers
FootSettingJig4off
:None
AssembletheCartesianBotsVerticalBars.

Putthe4footsettingjigsontothebaseframe301slowerbars
Slidethe3rods20006intothe3corners
:Thesepartsareeasilybrokenif
Sliderod20001intotheZmotorcorner
thegrubscrewsareovertightened
Screwthe8grubscrewsintotheirnutsmakingsuretheydontprotrudeoutthe
besureyouhavepracticedwiththe
otherside
trialpieces
Fitthenut&grubscrewintothehousingineachcornerplateusetheballendof
theAllenkeytohelpslidethemintoplace
Dothetop4firstthenthebottom4
Tightenonlyenoughtopreventtherodsslippinganytighterrisksbreakingthe
parts
DocumentNo:D100236
Ver 1.2

Name: Verticals
DocumentNo:D100236
Ver 1.2

Name: Z Idlers
Build #: 5-01

Part#
ZBeltXL
Builds Required: 2-01, 4-01
Qty
1
Tools:
None
:None
:None
AssembleZIdlersontotheCartesianBotsframe.
LooselylaytheZbeltintoposition
FittheZIdlerssuchthatthebeltgoesarounditandthebearingdropsintothe
housinginthecornerbracket
Repeatfortheother3corners
Adjustthebedcornerssuchthattheyareapproximatelylevel
DocumentNo:D100236
Ver 1.2

Name: Z Idlers
DocumentNo:D100236
Ver 1.2

Name: Top Frame
Build #: 6-01
Level: Moderate
Part#
20001
20004
KH1228Linear
Bearing
608Bearing
M8Nut
M8Washer
Previous Builds Required: 1-04, 1-05, 1-06 & 5-01
Qty
2
2
4
4
8
4
Tools:
Spanner13mm
:None
:None
AssembletheTopFrameoftheCartesianBots.
Loosely fit the 2 M8 nuts and the M8 washer to the top of each idler post
windingthemdownatleast70mm
Putthe608bearingontopoftheM8washerontheidlerposts
Slide each corner block into place ensuring correct orientation & ensure the Y
motor corner is above the X motor corner. The corner sometimes need a little
gentlerotationtogetthemtomoveintoposition
Slideintoplacethetoprailsandthelinearbearings,the12mmrodsareinthe
topposition.
Leaveallthebars&boltslooseatthisstage
DocumentNo:D100236
Ver 1.2

Name: Top Frame
DocumentNo:D100236
Ver 1.2

Name: Setting Top Frame
Build #: 7-01
Level: Moderate
Part#
Qty
Tools:
Spanner5.5mm
Allenkey2.5mm
SettingJigx2
:None
:Ensurecorrectsettingofthe
barsasifthisiswrongitisalotof
worktoalterlater
SettingtheTopFrameoftheCartesianBots.
Fitthefirst8rodsettingtheendtoprotrude20mm(thewidthofthesetting
jig) tighten the clamp bolts max 0.75Nm. This end is diagonally opposite the
20mmendonthebaseframe
Install the other 3 rods ensuring the correct ends protrude 20mm and tighten
theclampbolts
8 and Horizontal for the 8 Bars and the holes marked 12 and
Horizontalforthe12bar
DocumentNo:D100236
Ver 1.2

Name: Top Frame
DocumentNo:D100236
Ver 1.2

Name: Setting Verticals
Build #: 8-01
Level: Moderate
Part#
M3x20
M3Nut
M3Washer
M5x6Grub
M5Nut
Previous Builds Required: 1-15 Y micro switch, 7-01
Qty
2
2
4
8
8
Tools:
Spanner5.5mm
Allenkey2.5mm
SettingJig
:None
SettingtheTopFrameVerticalsoftheCartesianBots.
Screwthe8grubscrewsintotheirnuts
:Thesepartsareeasilybrokenif
8andVerticalforthe8Bars.Thiswillseteachcorner
thegrubscrewsareovertightened
Fitthenut&grubscrewintothehousingineachcornerplateusetheballendof
besureyouhavepracticedwiththe
theAllenkeytohelpslidethemintoplace
trialpieces
Dothetop4firstthenthebottom4
Tightenonlyenoughtopreventtherodsslippinganytighterrisksbreakage
FittheYmicroswitch
DocumentNo:D100236
Ver 1.2

Level: Moderate
Name: Setting Verticals
Previous Builds Required: 1-15 Y micro switch, 7-01
DocumentNo:D100236
Ver 1.2

Name: Diagonal Ties & Feet
Build #: 9-01
Level: Difficult
Part#
8RodCover
M8NutCover
Qty
4
20
Tools:
Spanner13mm
Spanner5.5mm
Allenkey2.5mm
SettingJig
ShortSteelBarsx2
:None
:Thesepartsareeasilybroken
ifovertightenedbesureyouhave
practicedwiththetrialpieces.
Making
sure all diagonals are the
samecriticalforcorrectoperation
DocumentNo:D100236
FittingtheDiagonalTiesontheCartesianBot.
Take the 2 setting bars and join them together by lining up the 4 8mm holes
marked A and slide in the 2 short steel bars to hold them in place the holes
markedBaseDiagonalsetthelengthofthebasediagonals
Fitthefirstbasediagonalandsettolengthwiththejig
Repeat for the other base diagonal, recheck the first diagonal and readjust if
necessary
Fit the side diagonals doing one face at a time using the setting jig to get the
distancescorrectagainrecheckeachdiagonalasyoufitthenext
Notethereare4diagonalsforthe12mmrodsand4forthe8mmrods
Afterfittingalldiagonalsrecheckall10diagonalsandadjustifnecessary
Pushfitthe4feet
Ver 1.2

Level: Difficult
Name: Diagonal Ties )HHW
DocumentNo:D100236
Ver 1.2

Name: X Motor & Rails
Build #: 10-01
Level: Difficult
Part#
10025
10029
10041
20004
Fan80mm
KH1228
Bearing
M5x55CP
M5x35CP
M5x30CP
M5Nut
M5Washer
M3x30
M3Nut
M3Washer
Previous Builds Required: 2-04, 2-05 & 9-01
Qty
1
2
1
2
1
3
2
14
10
26
52
2
2
4
Tools:
Spanner8mm
Spanner5.5mm
Allenkey4mm
AllenKey2.5mm
:None
:
Only tighten the linear
bolts until they grip the
bearing
bearing
if they are over tightened
theywillpreventthecarriagefrom
movingandincreasebearingwear
DocumentNo:D100236
FittingX Motor & X RailsontheCartesianBot.
FittheXmotorplate(204)tooneofthelinearbearings
Ifusingthefaninthisposition,installitsclampboltsandmountontheXlinear
bearingclamp(10025)
Fitthesecondlinearbearingclamp(10041)ensurethelinearbearingsareeven
spacedwithregardtotheboltsitalsohelpsiftherowofvisiblebearings isset
intheuppositioni.e.at12OClock
RepeatfortheIdlerPlate(204)
Fittherods(20004)notforgettingtoslideonthelinearbearings
Whentighteningtherodclampplates(205)makesuretherailsareparalleland
squaretotheYrails,thiscanbemadeeasierbysettingthewholeassemblyto
oneend
Ver 1.2

Level: Difficult
Name: X Motor & Rails
Previous Builds Required: 2-04, 2-05 & 9-01
DocumentNo:D100236
Ver 1.2

Name: Y Motor Bracket, Bearing
Build #: 11-01
Level: Moderate
Part#
10022
10023
10031
10032
10033
10089
20003
20005
20007
623Bearing
M5x25CP
M5x6Grub
M5Nut
M5Washer
M3x30CP
M3x25CP
M3Nut
M3x12
Washer
M3Washer
Qty
1
1
2
1
1
2
1
2
1
2
4
8
12
4
2
10
12
2
34
Tools:
Spanner8mm
Spanner5.5mm
Allenkey4mm
AllenKey2.5mm
:None
:None
FittingtheYMotorBracket&YIdlerBearingPlatestotheCartesianBot.
Fitthe4steelrodssameastheverticalrods,Notethedifferentlengthspositions
LooselyfittheYmotorbracketmakingsurethetabistouchingthecornerblock
FittheYbearingplate(10032)makingsurethetabistouchingthecornerblock
RepeatfortheYIdlerbearingplatestakenoteoftheorderofwasheronthe623
bearings(sameastheXplates)
DocumentNo:D100236
Ver 1.2

Level: Moderate
Name:Y Motor Bracket, Bearings
DocumentNo:D100236
Ver 1.2

Name: Y Motor & Drive
Build #: 12-01
Level: Moderate
Part#
20008
MXL18T
Pulley
Coupling
R4ABearing
Previous Builds Required: 1-14 Y motor, 11-01
Qty
1
2
1
1
Tools:
Spanner8mm
Allenkey4mm
AllenKey1/16
AllenKey3/32
:None
:None
DocumentNo:D100236
FittingtheYMotor&DriveRodtotheCartesianBot.
Fit the MXL 18T pulley the Y motor shaft with the aluminium hub is facing the
motorandthepulleyhanging5.75mmofftheendoftheshaft
FittheYsteppermotortothemounting
Fit the bearing MXL 18T Pulley to the drive shaft on the end with the longer
rebate,pushthebearingandpulleytightuptotheshoulderoftherebate
Tightenthepulley
Fitthecouplingtotheotherendofthedriveshaft
Slide the shaft through the bearing housing and fit the coupling on to the
motorshaft
Set the shaft such that the bearing is flush with the outside of the bearing
housing
Ver 1.2

Level: Moderate
Name:Y Motor & Drive
Previous Builds Required: 1-14 Y motor, 11-01
DocumentNo:D100236
Ver 1.2

Name: X Carriage
Build #: 13-01
Level: Moderate
Part#
10034
10035
M5x40CP
M5x35CP
M5x20Hex
M5Nut
M5Washer
Qty
2
1
2
12
3
17
25
Tools:
Spanner8mmx2
Allenkey4mm
:None
:
Only tighten the linear
bolts until they grip the
bearing
bearing
if they are over tightened
theywillpreventthecarriagefrom
movingandincreasebearingwear
FittingtheXCarriagetotheCartesianBot.
Fit M5 x 20 Hex Head bolts to the X carriage top plate, pay attention to the
orientation
LaythetopplateontothelinearbearingsfittheM5x35boltswithoutawasher
underthehead
IfusingtheXcarriagemountedfanpleasefitatthisstage
Fitthelowerplateensurethelinearbearingsareevenspacedwithregardtothe
boltsitalsohelpsiftherowofvisiblebearingsissetintheuppositioni.e.at12
OClock
LoosefittheXspacer(10035)
DocumentNo:D100236
Ver 1.2

Level: Moderate
Name: X Carriage
DocumentNo:D100236
Ver 1.2

Name: Bed Base
Build #: 14-01
Level: Moderate
Part#
10020
C2Spring
M8x60Hex
M8Nut
M8Washer
M5x20CP
M5Nut
M5Washer
Qty
1
3
3
6
9
12
12
24
Tools:
Spanner13mmx2
Spanner8mm
Allenkey4mm
:None
:Adjustthebedcornerstobe
levelpriortofittingthebed
FittingtheBedBasetotheCartesianBot.
Slidethebedbaseinthroughthetopbars
Ensurethebed/bedcornersarelevelandboltthecorners
Fitthespringsandspringtopwashers
DocumentNo:D100236
Ver 1.2

Level: Moderate
Name:Bed Base
DocumentNo:D100236
Ver 1.2

Name: Top Bed
Build #: 15-01
Level: Moderate
Part#
M8Nut
M8Washer
Qty
3
3
Tools:
Rule
:None
:
Adjust
the bed to be exactly
leveltotheXaxisbars
FittingtheAdjustableBedtotheCartesianBot.
Slide the adjustable bed in through the top bars and lower onto the 3 bolts &
springs
Fit the washers & nuts tightening enough to give a little compression to the
springs
LeveltheadjustablebedtotheXaxisbarsbyensuringthemeasurementfrom
theXaxisbartothebedisthesameinall4corners
After setting all four corners recheck the dimensions as each adjustment can
affecttheprevioussettings,repeatuntilthebedisperfectlylevel
DocumentNo:D100236
Ver 1.2

Level: Easy
Name:Top Bed
DocumentNo:D100236
Ver 1.2

Name: X & Y Belts
Build #: 16-01
Level: Moderate
Part#
10027
MXLBelt
Qty
4
1
Tools:
5.5mmSpanner
2.5mmAllenKey
:None
:None
FittingtheX&Ybelts.
DocumentNo:D100236
CuttheMXLbeltinto3lengths2x750mm&1x910mm
Fitthe2Ybelts(750mm)first,clamptheendofeachbeltinthebeltclamps
Fitaroundthetimingpulleysandidlerbearingsandintotheotherbeltclamp
Pullthebeltstightbeforetighteningthebeltclamps
LoosenthegrubscrewinthenonmotorYpulley
Movethecarriagefullytothefrontofthemachinesuchthatbothsidestouch
thecornerblocksthiswillsetthecarriageparallel&tightenthegrubscrew
FittheXbelt(910mm)wrappingoneendaroundtheM5boltontheXcarriage
andclampbackonitself
Feed the belt around the pulleys and repeat clamping on other side of the X
carriage
Ver 1.2

Level: Difficult
Name: X & Y Belts
DocumentNo:D100236
Ver 1.2

Name: Mounting the PCB
Build #: 17-01
Level: Easy
Part#
10096
M3x12CP
M3Nut
M3Washer

Qty
1
2
2
4
Tools:
5.5mmSpanner
2.5mmAllenKey
:None
:None
FittingthePCB.
Slide the clamp plate to the top of its slots and lower the assembly onto the
frontlowerrail
Slidetheclampplatedownunderthelowerrail
Gentlytightentheclampbolts
Aftercompletingsection1901connectingthePCBfittheelectronicstopplate
(10096)andboltdown
Use a little grease to hold the nut & washer in place while fitting the M3 x 12
bolt
DocumentNo:D100236
Ver 1.2

Level: ModeratePrevious
Name: Electronics
Builds Required: 1-13, 16-01
DocumentNo:D100236
Ver 1.2

Name: Filament Reel
Build #: 18-01
Level: Easy
Part#
10105
10049
10048
M3x25CP
M3Nut
M3Washer
M8WingNut
Previous Builds Required: 1-12 & 17-01

Qty
1
1
1
5
5
10
1
Tools:
5.5mmSpanner
2.5mmAllenKey
:None
:None
InstallingtheFilamentReel.
ThefilamentreelmountsontheXmotorsideofthemachine
Boltthereelmount(10105)tothediagonaltiesusingtheclampplates
Thetopend(with3bolts)sitsontheinsideoftheouterdiagonaltie
Thelowerend(with2bolts)sitsontheoutsideoftheinnerdiagonaltie
Youmightneedtoslightlymorethetiestogetagoodfitwithoutoverbending
thediagonalties
Usingthewingnutboltthereelintoplace
Adjustthe2ndreelbearingdisc(10104)suchthatwhenthereelismounteditis
stillfreetorotate
DocumentNo:D100236
Ver 1.2

Name: Connecting the PCB
Build #: 19-01
Level: Moderate
Part#
PVC
conduit
Qty
1630mm
Tools:
Smallflatelectricalscrewdriver
Pullwire
Insulationtape
3Drillbit
6Drillbit
Wirestrippers
Wirecutters
:None
:
Ensure the PCB is not
powered
when connecting the
wires
DocumentNo:D100236
ConnectingthePCB.
CutthePVCconduittolengthX=700mm,Y=870mm
Bothlengthsofconduitrequireholesdrillingforwireaccesspartwayalongtheir
length
Drilla3mmhole300mmfromthemotorendoftheXconduitthisisfortheZ
axismicroswitchwires
Drilla6mmhole400mmfromtheYmotorendoftheYconduitthisisfortheZ
motorwires
Feedthewiresthroughtheconduit(apullwirewillhelp)
Cliptheconduitintoitsmountingclipsasperthepictures
Wiretotheboardasperphotosandschematics(seeschematicssection)
Ver 1.2
Appendix
1. Conduitcuttingdetail
2. WiringSchematicCartesianBot
DocumentNo:D100236
Ver 1.2
400
Y Conduit
6
870
300
X Conduit
3
700
Designed by
Checked by
Approved by - date
Ian Adkins
09/04/2009
X & Y Conduit
6
Date
Edition
Sheet
Ver 1.21
/ 1
Ver 1.2

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Name: Bttm Corner Block R x 2

Level: Easy Previous

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Name: Bttm Corner Block R x 2

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Level: Easy Previous

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Builds Required: None

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Builds Required: None

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Level: Easy Previous

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Level: Easy Previous

Name: Y Motor Block x 1

Builds Required: None