OHAI: Open Hardware Assembly Instructions

1 Components, Hardware, and Tools

Material list will be done later

2 Tension Z-Belts

a) On the X-End Idler, loosen the upper Z-Belt Clamp using a 1.5mm Hex driver.
Grip the end of the belt above the X-End Idler and twist to apply tension to the Z-Belt.
Tighten the two M2x6 SHCS on the upper Z-Belt Clamp to secure the Z-Belt.

b) Use the 508C Sonic Tension Meter to ensure the belt is tensioned sufficiently.
Acceptable tension for the Z-Belts is 35-45N For proper measurement results, obtain measurements with the Z-axis near mid travel, ensuring the section of belt being measured is not contacting printed parts; this will provide incorrect tension readings.
Setting number 3 on your 508C Meter is set-up with proper parameters for the Z-axis, if unsure contact your line lead, supervisor, or MER Technician.

c) Slide the Belt Tensioning Collar [PP-GP0307] down over the end of the belt to capture the slack. Push it as close to the X-End Idler printed part as possible.
Trim the excess belt straight with the teeth of the belt, leaving ~5mm above the belt tensioning collar.

d) Repeat this process on the X-End Motor side;
Grip the bottom of the X-End Motor printed part and lift until the upper Z-Belt Clamp is visible through the cut-out in the left frame plate.
Loosen the two M2x6 SHCS securing the upper Z-Belt Clamp until the belt is able to move.
Grip the end of the belt on top of the X-End Motor printed part and twist to apply tension to the Z-Belt.
Tighten the two M2x6 SHCS on the upper Z-Belt Clamp to secure the Z-Belt.

e) Slide the Belt Tensioning Collar [PP-GP0307] down over the end of the belt to capture the slack. Push it as close to the X-End Motor printed part as possible.
Trim the excess belt straight with the teeth of the belt, leaving ~5mm above the belt tensioning collar.

f) Use the 508C Sonic Tension Meter to ensure the belt is tensioned sufficiently. Acceptable tension for the Z-Belts is 35-45N. It is best to set the belt towards the top of the range, because they will settle to a lower tension after burn-in. For proper measurement results, obtain measurements with the Z-axis near mid travel, ensuring the section of belt being measured is not contacting printed parts; this will provide incorrect tension readings.
Setting number 3 on your 508C Meter is set-up with proper parameters for the Z-axis, if unsure contact your line lead, supervisor, or MER Technician.

Both Z-Belts should be as close to each other in tension as possible.
Torque Z-Belt Clamp fasteners to 2in*lbs

a) Use pliers to grip on to the belt and twist to apply tension

a) Secure the 2x M2x6 SHCS on the upper z-belt clamp

d) Use pliers to grip on to the belt and twist to apply tension

e )Secure the 2x M2x6 SHCS on the upper z-belt clamp

3 Connecting Z-Motors

a) Completely remove the Z-Right motor housing screw below the connector using a P2 Phillips screwdriver

b) Insert the right motor's housing screw through the ring terminal of the Z-Right Motor cable, reinstall the housing screw into the Z right motor capturing the ring terminal.
Ensure the screw becomes recessed and tight.
Connect the JST connector to the Z-Right Motor

c) Completely remove the Z-Left motor housing screw below the connector using a P2 Phillips screwdriver

d) Insert the left motor's housing screw through the ring terminal of the Z-Left Motor cable, reinstall the housing screw into the Z-Left motor, capturing the ring terminal.
Ensure the screw becomes recessed and tight.
Connect the JST connector to the Z-Left Motor

b) Connect the ground to the right z motor

d) Connect the ground to the left z motor

4 Install X-Axis Carriage Assembly

a) Flip the assembly back upright with the back of the machine facing you.

b) Use a 8mm part reaming tool to ream the smooth rod holes of the X-End Idler.

c) Push both Left & Right X-Ends down against the Z-Lowers so that they are level with each other.

d) Slide the two smooth rods through the X End idler assembly and the X carriage assembly as pictured

e) Insert the ends of the Smooth Rods into the X-End Motor assembly
It is important not to push too far as too much distance between the X-Ends will cause the Z-Axis to bind at the top. Make sure the X-Ends remain relaxed with no outward tension from the Smooth Rods. The ends of the smooth rods should protrude an even distance from the right side of the X-End Idler printed part.

f) Tighten the set screws already installed in the rear of the X-End Idler; torque to 3in*lbs

g) Using a 2mm Hex Driver, remove the four M3x8 BHCS securing the X-Bearing Holder to the X-Carriage, slide the X-Bearing Holder to your left on the smooth rod.
Using an eyedropper, apply a small amount of Loctite® 425™ to the now exposed M3 inserts on the back of the X-Carriage.
Re-install all four of the M3x8 BHCS with washers [HD-BT0137] & [HD-WA0038]
Torque all of these fasteners to 3in*lbs

h) Measure the drag of the x-carriage making sure the the peak drag does not measure above 15N and record the result in the x-carriage drag spec sheet.

i) Remove the zip tie from the end of the cable chain.
Remove the cable chain mount from the cable chain and attach to the X-Carriage as pictured using two M3x6 FHCS [HD-BT0128]
Re-attach the cable chain to the mount as pictured.