SeeMeCNC rostock max v2.0, Assembly Manual

Page 1: ...Assembly Guide for the Rostock MAX v2 0 3D printer Version 4 47 September 28th 2016 Fourth Edition Copyright 2016 by Gene Buckle Licensed as Creative Commons Attribution ShareAlike 3 0 Questions or corrections should be emailed to geneb deltasoft com 1 ...

Page 2: ...achine Automatic machine can start unexpectedly Pay close attention and keep clear while power is connected to the machine The machine power supply is connected to AC voltage and can be hazardous Disconnect power before servicing this machine The hot end of the machine can reach very high temperatures of 700F and can cause serious burns The heated print surfaces heated bed can also reach temperatu...

Page 3: ...stalling the Vertical Support Retaining Nuts 48 6 4 Installing the Vertical Supports and Power Supply Mount 49 6 5 Installing the Power Supply 51 6 6 Connecting the Power Supply and Fitting the Side Panel 52 6 7 Assembling the Tower Supports 55 6 8 Installing the Tower Supports 59 6 9 Installing the Base Top Plate 60 7 Installing the Towers Tower Wiring 62 7 1 Running Wire in the Towers 62 7 2 Set...

Page 4: ...m 106 13 Installing the Hot End 108 14 Finishing the Top End 109 14 1 Installing the Spool Holder 109 14 2 Installing the Top Plate and Spool Support Arm 111 15 Installing the Onyx Heated Bed 114 16 Assembling Installing the LCD Panel Mount 116 16 1 Assembling the Front Panel 116 16 2 Installing the LCD Trim Panels 118 17 Installing Connecting the RAMBo Controller 120 17 1 Preparing the RAMBo Moun...

Page 5: ...he box containing the RAMBo and its wiring should also contain a printed black white sheet that looks like this http www reprap org wiki File Rambo conn all jpg Please refer to this sheet when you reach Chapter 18 This is a valuable guide to wiring the RAMBo up to your Rostock MAX v2 Note that the connector polarity is clearly marked on the board for the MOSFET Outputs The Five Stages of Masking T...

Page 6: ...en hex wrench A ball end T handle version is a good choice for this and the other sizes of Allen wrenches used 5 32 Allen hex wrench 7 64 Allen hex wrench Needle nose pliers Slip joint pliers Forceps these will come in handy when routing the belts and reaching for small hard to reach parts They can be purchased from Amazon for as little as 3 50 for a set of two Wire strippers Wire cutters flush cu...

Page 7: ...tps www sparkfun com products 9161 Blue thread locking compound Loctite or Permatex Threadlocker Blue A small file 12 framing square A small razor knife like an X Acto knife This will be handy for cleaning the flashing off the injection molded parts Additional Materials Toothpicks Isopropyl Alcohol 1 Roll of ABS filament Needed to print the fan shrouds at the end of the build PermaTex Ultra Copper...

Page 8: ...find it here http www skygeek com wht string html While expensive you ll never really need to buy a wire tie again and it ll likely last you the rest of your life I d also recommend a little plastic box with part compartments in it They re really cheap at craft stores and are perfect for building a kit like this you can store all the various fasteners and have them ready to go as you need them Her...

Page 9: ...pply 12VDC 30A Model LIHUA 360W 26733 1 Rostock MAX v2 Electronics and Hardware Pack Rev3 If you re planning on painting your Rostock MAX v2 especially the part edges you would be well served to carefully trace the outline of each part with a razor knife in order to cut the supporting masking tape This way you can retain the protective mask on the parts in order to make painting the edges easier O...

Page 10: ...eep them grouped together by sheet number after you paint them you ll spend more time looking for the parts I call out for a particular step Take special care when removing the laser cut parts from the sheets Sometimes the laser doesn t quite cut all the way through If you find a part like this you ll want to gently score the back side of the sheet along the faint cut line and then press the part ...

Page 11: ...d the Rostock MAX v2 Many are in individual baggies some are in heat sealed bag packs As you go through the following Bill of Materials please count and check off each item This is important as you don t want to be short a vital part during the build It s better to find out before hand than being forced to stop the assembly process due to a missing part If you are missing any parts please contact ...

Page 12: ...ble I ll include the SeeMeCNC part number enclosed in square brackets Quantities are surrounded by parentheses Rostock MAX v2 Hardware Pack 1 Rev3 84381 Rubber foot pack Contains the following components ___ 6 10 32 5 8 Nylon Pan Head Screws 29998 ___ 6 10 32 Nylon Finish Nuts 30170 ___ 6 Injection molded feet black 17505 ___ 6 Soft rubber shoes 44010 ___ 9 10 32 3 4 Knurled Black Nylon Thumb Scre...

Page 13: ...acrylic panels and the three end stop triggering screws installed in the Cheapskate U Joint mounts 30135 ___ 25 20 1 2 Stainless Steel Button Head Cap Screws Used for tower mounting 30419 ___ 25 20 nut plates Used for T Slot mounting 32005 ___ 4 4 40 T Nuts Used for RAMBo mounting 30222 ___ 4 4 40 3 4 Phillips Flat Head Machine screws Used for mounting the RAMBo Controller 30236 2 Visual Bill of M...

Page 14: ... 3 8 Phillips Pan Head Sheet Metal screws Used for LCD sides and tower alignment stops 30250 ___ 12 M3x 5 10mm Pan Head Machine screws Used for mounting the stepper motors 30318 ___ 18 6 Stainless Steel Flat washers Used on the 608 bearings that go in the top bottom T Slot rails 30450 ___ 9 R4 Small Ball Bearings Used in the belt idlers 35008 ___ 1 10 32 5 8 Socket Head Cap Screw Used as a tap for...

Page 15: ...Used to hold the Borosilicate glass build plate to the Onyx heated bed 58761 ___ 5 Plastic Bearing Rollers Used for RAMBo mounting 71505 Qty shown in the photo is higher than qty shipped ___ 1 15 Tooth Gear Used for manually operating extruder motor 71566 This part is replaced by the part shown below and may not be included in your kit ___ 1 Stepper Motor 5mm Shaft Handwheel Used for manually oper...

Page 16: ...Rostock MAX v2 Assembly Guide 4thEd ___ 9 Pulley Bearing Cover for R4 Bearings 39756 ___ 18 R4 Bearing Standoffs 39757 2 Visual Bill of Materials 16 ...

Page 17: ... ___ 1 LCD Smart Controller with SD card LCD to RAMBo Adapter Kit and 1 Soft Touch 5mm knob 26720 ___ 4 NEMA 17 Stepper Motors 4800gcm holding torque Used for three motion axes and extruder drive 26501 ___ 1 25x25x10mm 12VDC fan Used to cool the PEEK section on the hot end 26309 This fan is installed after you print the PEEK fan shroud as covered in the User Guide ___ 1 40x40x10mm 12VDC fan RAMBo ...

Page 18: ... diameter Expandable Mesh Wire Loom black Used to cover wiring bowden tube from the top to the hot end platform Includes 3 of 5 16 heat shrink tubing 26727 26729 ___ 3 76 GT2 Timing Belts 39910 ___ 1 EZStruder Cold End Kit Includes stepper motor mounting hardware 70780 ___ 1 Hot End Kit Includes hot end heating resistors thermistor PTFE sleeve for thermistor PTC fittings and PTFE bowden tube 68394...

Page 19: ...2VDC fan Used for part cooling 26171 This fan is installed after you print the layer cooling fan shroud as covered in the User Guide ___ 8 feet 18ga Red wire 8 feet 18ga Black wire 26724 26723 ___ 15 feet 26ga White wire 26730 2 Visual Bill of Materials 19 ...

Page 20: ..._ 1 18awg 8 Green 84314 IEC Connector to PSU ___ 1 18awg 8 White 84315 IEC Connector to PSU ___ 1 18awg 8 Black 84316 IEC Connector to PSU ___ 1 18awg 3 Black 84317 Rocker switch to PSU ___ 1 AC Connector Screw Mount IEC Plug Style 26180 ___ 1 AC Power Cord with IEC termination 26737 ___ 2 6 32 x 1 Pan Head Screws 30033 for IEC connector ___ 4 6 32 x 1 75 Pan Head Screws 30034 for 60mm fan ___ 6 6...

Page 21: ...tch Black Round 26175 ___ 4 M4 x 16mm Pan Head Screw Used for power supply mounting 30102 ___ 4 M4 Flat Washer 30103 ___ 1 60mm x 60mm x 25mm fan 26310 ___ 5 Spade Terminal Red Insulated for 18 22awg 26174 ___ 5 Ring Terminal Red Insulated for 8 Stud and 18awg 26179 2 Visual Bill of Materials 21 ...

Page 22: ...Rostock MAX v2 Assembly Guide 4thEd ___ 2 Ring Terminal Yellow for 8 stud and 12awg 26178 2 Visual Bill of Materials 22 ...

Page 23: ...ylic parts pack Includes LCD face LCD sides left right base and top covers Miscellaneous Parts ___ 1 300mm x 3mm Borosilicate Glass Build Plate Used with Onyx Heated Bed Yes there s a big glass disc inside that foam sleeve ___ 3 T Slot rail 32 long 68310 2 Visual Bill of Materials 23 ...

Page 24: ...mbly Guide 4thEd Carriage Parts Pack 70849 ___ 15 4 Pan Head Phillips x 1 2 Sheet metal screws 30249 ___ 3 Outer Carriage Half 70851 ___ 3 Inner Carriage Half 70852 ___ 6 4 Flat Washers 30449 2 Visual Bill of Materials 24 ...

Page 25: ...2 R4ZZ 1 4 ID x 5 8 OD x 0 196W Ball Bearings 35008 ___ 24 R4 Bearing Sleeves Color may vary 87941 ___ 3 Inner Spring Arms for Injection Molded Carriage 70854 ___ 3 Outer Spring Arms for Injection Molded Carriage 70853 ___ 3 4 40 x 3 8 Flat Head Machine Screws 30237 2 Visual Bill of Materials 25 ...

Page 26: ..._ 6 Ball Joints for IM Carriage Platform 70855 ___ 3 Hot end Platform Spacer Machined Aluminum 68334 ___ 6 Tension Spring for IM Ball Joint Arms 70860 ___ 3 6 32 x 1 75 Phillips Pan Head Screw Stainless 30034 ___ 3 6 32 Nylon Lock Nut Stainless 30164 ___ 6 4 x 3 8 Pan Head Phillips Screw Stainless 30250 2 Visual Bill of Materials 26 ...

Page 27: ...2 Assembly Guide 4thEd ___ 6 4 Flat Washer Stainless 30449 ___ 1 Ball Joint Platform 70857 ___ 1 Hot End Adapter for the Ball Joint Platform 70862 This component is included on Sheet 4 2 Visual Bill of Materials 27 ...

Page 28: ... to remain upright during the period that the RTV is curing The simplest way to do this is to use the large white box the Acrylic parts are shipped in Take the parts out of the box and using a pair of scissors cut a hole in the top by shoving the scissor blade straight in Put the Acrylic parts back in the box and set it aside we ll use it soon Before we start on this I d like tighten the nozzle th...

Page 29: ...ing each heating resistor with RTV as shown in Fig 3 3 You ll want to try to keep the resistor leads free of RTV but don t skimp on the RTV application You can always clean off excess RTV after it s cured This stuff is goopy and sticks to everything Avoid having to use the cat so keep a paper towel or ten handy 3 Preparing the Hot End and Power Supply 29 Fig 3 1 2 RTV heating resistor Fig 3 1 3 Co...

Page 30: ...ife of the resistors because air exposure will allow the resistor to over heat in a single area Don t be surprised if your application of RTV is not nearly as neat as shown above These hot end assembly photos were shot by Andy Oprisko a SeeMeCNC employee He s literally built hundreds of hot ends and is very very good at it Set the hot end aside with the nozzle pointing up We re going to prep the t...

Page 31: ...the thermistor and PTFE tubing as shown on the right Take special care to not damage the thermistor head It s made of glass and is very delicate Take the nozzle off the Permatex Ultra Copper RTV tube and dip the end of the thermistor into the RTV as shown below The thermistor should now be installed in the thermistor port on the flatted side of the hot end as shown Set it aside in a safe place to ...

Page 32: ...Rostock MAX v2 Assembly Guide 4thEd 3 Preparing the Hot End and Power Supply 32 Fig 3 1 9 Thermistor installed Fig 3 1 10 Hot end plugged into the cardboard box for curing ...

Page 33: ...ontroller the Onyx heated bed and the hot end The power supply won t be installed until a later step but there s some prep work that you can do now The very first thing you need to do is verify that the power supply is configured for the voltage source in your country In the USA Canada it s 115v In Europe and other countries it s likely 230v If you don t know ask 3 Preparing the Hot End and Power ...

Page 34: ... connector oriented as I show on the right The red black wires must go in the positions shown If they re not the RAMBo or the power supply could become quite annoyed with you and stomp off in a cloud of noxious smoke If you can see more than 1 16 of bare wire after the wire is fully seated into the terminal block remove it and trim a tiny amount off and re install the wire Repeat until the wire le...

Page 35: ...ime to finish the RAMBo connector wiring by attaching two 12 10 AWG ring terminals to the 12ga wires coming out of the compression terminal block When crimping a connector like this you ll want to make sure that the tip of the wire is visible at the end of the crimp barrel as shown below Each connector only needs a single crimp there s no reason to hammer it with the crimping tool As you can see i...

Page 36: ... last task for this section is to attach two 22 16awg ring terminals to the 60mm fan as shown in Fig 3 3 3 Set aside the 60mm fan and the one 3 18ga wire you put the female spade connectors on We ll get to those in a later step 3 4 Attaching The Wiring To The Power Supply The first thing I want you to do is remove the screws from the terminals marked V V N and L 3 Preparing the Hot End and Power S...

Page 37: ...r connector you just finished wiring up and attach the black 12ga wire to the terminal section marked V and the red 12ga wire to the terminal section marked V This completes the work you need to do on the power supply Set it aside and we ll get it installed in the base very soon Checkpoint Video 1 3 Preparing the Hot End and Power Supply 37 Fig 3 4 2 A C wires installed Fig 3 4 3 Completed power s...

Page 38: ... Thermistor The first thing we re going to do is cover the thermistor hole that s in the center of the Onyx Cut yourself about 3 4 of Kapton tape and fold the end over to give yourself a pull tab Then cover the center hole with it as shown You re covering the center hole in order to prevent any RTV from escaping the hole In the parts pack for the Onyx you ll find a small baggie containing a thermi...

Page 39: ...the hot end Insert the RTV coated thermistor into the hole in the center of the Onyx as shown in Fig 4 1 4 Next you ll cover the thermistor with a few strips of Kapton tape in order to keep it in place Now go ahead and solder the two thermistor leads to the two closest pads and then trim the leads 4 Preparing the Onyx Heated Bed 39 Fig 4 1 3 Thermistor ready Fig 4 1 4 Thermistor in place Fig 4 1 5...

Page 40: ... up The flat side of the Led is the cathode or negative side You want to insert the diode in the hole with the cathode lined up with the rectangular solder pad as shown below You ll notice that the part outline also has a flatted area that matches the one on the LED Bend the leads over so they are laying flat against the two solder pads as shown in Fig 4 2 4 and then solder them into place If you ...

Page 41: ... and Power Wiring The last two things you need to do is attach the thermistor signal wires and the 18ga power wires that feed the Onyx itself Let s start off with the thermistor signal wires Strip off about 3 16 of insulation off of the leads and solder into place using the two pads near the thermistor as shown in the figures below 4 Preparing the Onyx Heated Bed 41 Fig 4 3 2 Signal leads in place...

Page 42: ...sier Next trim about 1 2 of insulation off one end of the two 18ga power wires and about 1 4 off the other end On the 1 2 end I want you to flatten the wire out in something of a fan shape Tin the wire end Solder the red wire to the pad marked as shown below Solder the black wire to the pad Finally you ll need to cover all the exposed solder pads with Kapton tape This will help ensure that no acci...

Page 43: ...nd then slide it on to the stepper shaft as shown Make sure that a grub screw is aligned with the flatted portion of the shaft You also want to make sure that the end of the stepper shaft is flush with the outside face of the drive gear again as shown below Get your thread locker out and dribble a tiny bit on the threads Tighten the grub screws with the included Allen wrench Complete the gear inst...

Page 44: ...Rostock MAX v2 Assembly Guide 4thEd 6 Assembling the Base For the following task you ll need the following parts 6 Assembling the Base 44 Foot Pack ...

Page 45: ...ate The top surface has axis labels at each corner as shown The nylon screws need to be inserted into the foot base as shown below Install two feet at each location as indicated by the green rectangles Don t install the soft rubber shoe parts yet They ll make it difficult to move the machine during the build 6 Assembling the Base 45 Fig 6 1 1 The X axis label Fig 6 1 2 Screw orientation Fig 6 1 3 ...

Page 46: ...l the screw all the way just drive it enough so that the bottom face of the screw is flush with the opposite face of the vertical support as shown below Now I need you to locate the 10 32 5 8 Socket Head Cap Screw We re going to use this to cut threads into the vertical support plates These threaded holes will be used later with nylon thumbscrews to hold cover plates in place You ll need a 5 32 Al...

Page 47: ... top on each vertical support plate in the location shown in the figure below and then carefully drive the 10 32 socket head cap screw through the holes closest to the top Drive the screw though completely and then remove it Repeat this for the other two vertical support plates 6 Assembling the Base 47 Fig 6 2 4 Redneck Tapping Tool Fig 6 2 5 Orientation marking Fig 6 2 6 Tap driven through comple...

Page 48: ...cut pocket The laser cut pockets are designed to be a very snug fit However sometimes the pockets may feel a bit too tight If this is the case try inserting the nut in from the other face It may be easier due to the slight bevel the cut has in it due to the laser focus You may also run into a situation where the nut pocket doesn t hold the nut tightly enough to keep it from falling out In that cas...

Page 49: ...er The Rostock MAX v1 and many v2s used the ATX power supply and now SeeMeCNC has gone to a much more compact and reliable power supply The power supply mount has been left in as a structural component The power supply support is held in place with the vertical supports that are installed to either side of it You ll install all three parts at the same time the fit tolerance is loose enough that th...

Page 50: ...o RAMBo support panel legs to the front of the base The support legs just rest in place they re held firmly when the support plate is installed over the top of them Use two 6 32 1 Stainless Steel pan head screws to attach the front vertical support over the two RAMBo legs as shown below Like the two back supports leave this a bit loose in order to assist with fitting the top Checkpoint Video 4 6 A...

Page 51: ... friction fit no fasteners are used It ll be locked into place once the top of the base is fitted The power supply rests upon four laser cut melamine spacers In order to install all four at the same time you ll need to get creative I used some clear tape in order to hold each spacer The spacers are centered over the threaded holes in the power supply The screw can easily punch through the tape so ...

Page 52: ... and the M4 washers Make sure that you ve got the terminal end of the power supply facing the opening in the vertical support The screws may appear to be too short but they will reach 6 6 Connecting the Power Supply and Fitting the Side Panel 6 Assembling the Base 52 Fig 6 5 3 Power supply mounted ...

Page 53: ...ll it This ensures that up is the on position The spade terminals should be closest to the IEC power connector Install the jumper wire exactly as shown in Fig 6 6 4 This switches the Load or hot wire to the power supply Now install the 60mm fan on the back face of the power supply cover The fan has a mark that indicates the airflow direction Make sure you ve got it pointed out as shown in below 6 ...

Page 54: ... to the right connector Connect the black wire from the power supply to the center connector on the power switch Using two black nylon thumbscrews attach the power supply cover to the vertical support This would be a good time to test the power supply Plug in the AC cord and turn on the power switch The large cooling fan should start running If it doesn t turn the power switch off unplug the power...

Page 55: ...Rostock MAX v2 Assembly Guide 4thEd 6 7 Assembling the Tower Supports For this task you ll need the following components 6 Assembling the Base 55 3 Steppers with Drive Gears ...

Page 56: ...stop When it comes time to set the towers in place you ll slide the tower down until the bottom strikes the head of the screw This will guarantee that you ve got all three towers at the same height Sometimes the screw pockets are a tiny bit over sized When this happens you can use a short bit of tape to hold the 6 32 nut in place You can see I ve had to do this on one spot in Fig 6 7 3 The tape wi...

Page 57: ...t holds the idler bearing assemblies that you put together In order to install them you ll need to add a 6 32 washer to two of the 6 32 1 3 4 Stainless Steel pan head screws and insert them into the back of each stepper motor mounting plate as shown below Install one idler bearing spacer on the two idler bearing support screws 6 Assembling the Base 57 Fig 6 7 4 First motor in place Fig 6 7 5 Motor...

Page 58: ...much Finger tight is fine You want a bit of wobble in the assembly to assist in getting the top of the base installed Repeat this assembly process for the other two motors When you re done you should have one motor assembly for each axis as shown on the left The green labels indicate where each motor assembly is installed Checkpoint Video 6 6 Assembling the Base 58 Fig 6 7 9 Idler bearings install...

Page 59: ...tor support installs the same way as the other two The wires for the Z axis stepper motor should be routed through the lower hole in the power supply bracket as shown below The connector is a tight squeeze but it WILL fit Now you need to install four of the 20 cap head screws and four T Slot nut plates into each tower support assembly Only thread the T Slot nut plates enough to feel the end of the...

Page 60: ...rew and a white spacer from the Onyx parts pack and use those to draw the t nuts into the hole Lay the top plate down with the lettering facing the table surface and insert a t nut into each of the locations marked in green in Fig 6 9 3 When you re done put a small bit of clear tape over each t nut This will help ensure that they won t fall out before the Onyx has been installed If your base top p...

Page 61: ...e and if you find yourself getting frustrated with it walk away for a bit The last thing you want to do is get annoyed and help it along with a little percussive maintenance Once you ve gotten the top fully seated fully tighten all of the 6 32 1 screws Tighten the three vertical supports from the top and then tighten down the three tower supports Flip the base upside down and repeat on the bottom ...

Page 62: ... to be used to provide power for the PEEK and layer fans on the effector platform Before you can run those wires in the tower you ll need to cut the red black wires in half so you have two red black pair of equal length In the Rostock MAX v2 you ll be routing the hot end extruder stepper fan wires and end stop wires through the center of the three towers If you re upgrading a Rostock MAX v1 and us...

Page 63: ...doing this until it s split the whole gray outer jacket When you re done you can discard the outer jacket and the thin aluminum wrap However don t discard the bare wire that was woven around the four conductors You re going to use that shortly as a pull line to get the thinner wires down the towers The 18ga wire is the largest in diameter followed by the 22ga wire and the 26ga wire is the thinnest...

Page 64: ...n one end Do the same thing to find a red 26ga wire Take the knot out of the black wire and knot the black red together Tie the knot in BOTH ends This pair will be for the PEEK fan Leave the other wire pair without a knot That pair will be for your layer fan Stick a note on the tower extrusion with Z Axis written on it Now cut the white 26ga wire in half just as you did with the red black 26ga wir...

Page 65: ...ion Identify three black white pairs Write the axis name on the spade connectors and on the opposite end using a printed label or a bit of tape Tie a loose knot in the spade connector end to make them more easily separated Tower Wiring Summary X axis 18ga for the hot end 26ga for the thermistor Y axis end stop wires from Rambo Kit Z axis 22ga 4 wires for extruder motor 26ga 4 wires 2 pairs for PEE...

Page 66: ...ect to the end stop switches at the top We re going to start with the Z axis In order to set the Z axis tower you ll need to turn the T Slot nut plates such that they re oriented vertically as shown below Next you re going to thread the wires coming out of the Z axis tower through the square opening in the top of the base that s right over the T Slot nut plates 7 Installing the Towers Tower Wiring...

Page 67: ...ntil it comes into contact with the depth stop green arrow in Fig 7 2 2 that you installed in the tower assembly After the tower is set use a 5 32 Allen hex wrench to slightly tighten the 20 cap screws finger tight You ll tighten them up after the top as been mounted While the Z and X tower wires exit to the right the Y tower wiring exits to the left as you can see in Fig 7 2 4 Fig 7 2 3 reflects ...

Page 68: ...w These screws perform the same function as the ones previously installed in the lower tower mounts This helps guarantee that the top section will be at the correct height on all three towers Next grab your handy dandy Redneck Tapping Tool and tap the hole in each of the Upper Tower Support Spacers It s easier to do this now instead of after they re installed 8 Assembling Installing and Wiring the...

Page 69: ...and set them into the tower socket as shown in Fig 8 2 1 Once you ve gotten them staged as shown carefully rotate the right side mount s edge nearest the center of the top plate base out This will result in the part being in the position shown below Now you can rotate the part into it s final position Now move the left mount into position the same way that you did for the right side Install the Y ...

Page 70: ... apart at the very ends to get the first tab of the spreader block set It WILL fit but be careful you don t want to break the tower mounts Repeat the process for all three upper tower supports 8 Assembling Installing and Wiring the Top Section 70 Fig 8 2 5 First tab inserted Fig 8 2 6 Second tab set in place Fig 8 2 7 Spreader fully seated Fig 8 2 8 Tower mounts installed ...

Page 71: ...p switch over the two screws Make sure you ve got the switch properly oriented The back of the switch should be closest to you as shown Finally install one 2 56 finish nut on to each mounting screw Use a little bit of thread locker here Take special care to not over tighten the screws or you ll crack the switch body which could cause it to malfunction When you re finished the underside of the top ...

Page 72: ...our 20 button head screws and four T Slot nut plates into each upper tower support as shown in Fig 7 17 Thread the nut plates only a couple of turns they need to be as loose as the lower ones were in order to properly fit the towers 8 Assembling Installing and Wiring the Top Section 72 Fig 8 4 1 Screws nut plates installed Fig 8 4 2 Offset view ...

Page 73: ... to the bearing as shown and slip the whole thing into the upper tower mount as shown Using your thumb and forefinger hold the idler assembly in place as you insert a 1 75 Pan head screw in from the side Attach a 6 32 nylon lock nut on the screw finger tight and then install the other two idlers the same way 8 Assembling Installing and Wiring the Top Section 73 Fig 8 5 1 Assembled bearing sleeves ...

Page 74: ...ires through the tower openings in the top plate you ll want to rest the plate on top of the towers We ll start the installation with the X axis tower wires Carefully route the wires through the opening under the idler bearing as shown in Fig 8 6 1 Now route the Y axis tower wires up underneath the idler the same way you did the X axis Finally route the Z axis wiring as you did the other two axes ...

Page 75: ...e to allow the other axes to slide onto the towers easily Once you ve got the t slot nuts in the other axes started come back to the Z axis and settle the upper pair of t slot nuts into the channels Set the other two axes down the same way After you ve got all three mounts set tap them down gently so that the depth stop screw in each tower mount makes solid contact with the top face of the tower b...

Page 76: ... tower a little bit to lessen the bend radius the wire needs to feed Now carefully seat each spade lug connector on to the end stop switch as shown below It doesn t matter where the white black wires go just as long as one is on the innermost spade lug and the other the outermost Repeat this process for the X and Y towers Once all three towers are done carefully pull the wires at the bottom of the...

Page 77: ... rubbing on the wires coming out of the towers they ll need to be tied out of the way Take a wire tie and bind the hot end wires to the side of the tower mount using a wire tie Lift the idler up to the top of its range of motion to give yourself a bit more room to work When you tie down the end stop wires coming out of the Y tower you should carefully take the slack out of the wires before you pul...

Page 78: ...The first thing to remember about this process is to make sure that the tower is in contact with the depth stop screw BEFORE you begin to tighten down each tower bottom top If you don t the top of the machine won t be level and that will make calibrating the printer very very difficult Grab your trusty 12 framing square and a clamp and use the clamp to hold the framing square to the center of the ...

Page 79: ...those four using the same order as you did the bottom Make sure the top of the tower is in contact with the stop screw Repeat the square tighten tasks for the Z and Y towers Checkpoint Video 11 8 Assembling Installing and Wiring the Top Section 79 Fig 8 9 2 Lower tightening order Old style wire shown Fig 8 9 3 Upper tightening order ...

Page 80: ...have a sharp lip on the outer face You might want to use some of the scrap Melamine to help you press the sleeves on to the bearings without leaving a ring on your palm Start by laying a sleeve half on the table face up Set an R4ZZ bearing into it and firmly press it into place Now set another sleeve half on the table and press the R4ZZ bearing and sleeve into the new sleeve half to complete the c...

Page 81: ...t into the edge and then slowly rotate the bearing while holding your razor knife in place This will shave away the edge without damaging the sleeve When you re done trimming the edges off the bearing sleeves repeat the assembly trimming process for the remaining 11 bearings 9 Assembling Installing the Carriages Belts 81 Fig 9 1 4 Edge to remove Fig 9 1 5 Removing the edge Fig 8 6 Edge removed Fig...

Page 82: ... screw into the top of the inner carriage half as shown below Make sure you drive the screw to the depth indicated by the green line Do this task for all three inner carriage halves 9 3 Installing the Drive Belts and Carriages For this task you ll need the following components 9 Assembling Installing the Carriages Belts 82 Fig 9 2 1 Correct screw depth ...

Page 83: ...ace in towards the tower Next I want you to feed the belt down and under the upper idler and around the top of the GT2 drive gear as shown in Fig 9 2 Pass the belt around the gear and under the lower idler as shown below 9 Assembling Installing the Carriages Belts 83 Fig 9 3 1 Starting to route the belt Fig 9 3 2 Passing under the idler and over the gear Fig 9 3 3 Around the gear and under the idl...

Page 84: ...own from the top and let it hang Do this for the other two belts and we ll move on to getting the carriages assembled and installed 9 4 Assembling the Carriage Spring Arms The new injection molded carriage includes a plastic spring arm that provides a constant side force to the tower that requires no adjustment Each spring arm assembly consists of an inner spring arm an outer spring arm and two sl...

Page 85: ... shown Next press the inner spring arm on to the two mating posts that are on the outer spring arm As I said before the fit is very tight You can get each side started by aligning the holes in the inner spring arm over the posts in the outer spring arm and then tap them into place with the handle of your P2 screwdriver You want the pins fully seated Assemble the remaining spring arms as you did th...

Page 86: ...nds in place while you mount the carriage on the tower Slide the belt ends through the opening in the inner carriage half and clip the belt ends together with the binder clip as shown You want to make sure that the belt teeth are facing the tower Now you can attach the partially assembled carriage to the tower The easiest way is to start with the spring arm side and press down in order to compress...

Page 87: ...h the top of the clip slightly in order to get it to fit into the center opening in the inner carriage half but it will fit When you re ready to install the bottom belt clamp remove the binder clip from the belt end and pull the belt up and away from the carriage this will help remove any slack in the belt When you ve got the slack out install the bottom belt clamp in the same manner as the top cl...

Page 88: ...agonally through the tower under the idler bearing as shown below This technique depends on you having pulled the belt reasonably tight when you installed the last belt clamp into the carriage you re working on If that wasn t the case you should pop a clip out and tighten the belt a bit more and re install the clamp When the screwdriver is under the pulley you should see a small gap under the scre...

Page 89: ...mplete this task you ll need the EZStruder hardware kit This kit consists of the following components 1 ___ Filament Tensioner 2 ___ Filament Guide Block 3 ___ Metric Stepper Motor Mounting Screws 4 ___ Std Mounting Hardware Unused 5 ___ Hobbed Gear Allen Wrench You ll also need the remaining NEMA17 stepper motor 10 Assembling and Installing the EZStruder 89 Fig 10 1 1 EZStruder Hardware Pack ...

Page 90: ...crew from the hobbed gear and set it aside Press your thumb against the red lever on the filament tensioner and slide the hobbed gear on to the shaft with the hobbed portion closest to the face of the stepper motor You want to align the hobbed portion of the gear with the steel bearing on the filament tensioner as shown in Fig 10 1 5 The idea is to get the center line of that little bearing lined ...

Page 91: ...r motor The filament guide block is installed on to the stepper motor using the two metric screws included in the hardware pack Using Fig 10 1 8 as a guide insert the shorter screw in the hole to the right and the longer screw in the hole to the left Set the filament guide block on to the stepper motor and tighten the attachment screws 10 Assembling and Installing the EZStruder 91 Fig 10 1 6 Grub ...

Page 92: ...embly Guide 4thEd 10 2 Installing Mounting the EZStruder For this task you ll need the assembled EZStruder as well as the following components 10 Assembling and Installing the EZStruder 92 Push Fit Connector Stepper Knob ...

Page 93: ...m in a bit more to strip out the threads you just cut It will make installing the nylon lock nuts easier The 1 75 screw goes in on the left the 2 screw goes in on the right see Fig 10 2 1 Now you can install the mounting spacers on the two screws To install the EZStruder on to the support bracket orient the EZStruder and support bracket as shown in Fig 10 13 10 Assembling and Installing the EZStru...

Page 94: ...s first First up install the stepper motor knob on to the output shaft of the stepper motor This knob will allow you to manually feed filament if you need to Next you ll need to install the brass push fit connector to the bottom of the filament guide as shown below Use your fingers to tighten Finally you ll need to install two 6 32 nylon lock nuts into the nut capture pockets in the top of the EZS...

Page 95: ... be easier to do this if you lay the machine down horizontally Insert two 6 32 1 pan head screws into the locations shown They should fit into the nuts in the EZStruder bracket perfectly Tighten them down and we ll move on to wiring up the stepper motor I ve labeled the X axis to help orient you Wanna know why there s only one screw Ask JJ 10 Assembling and Installing the EZStruder 95 Fig 10 2 10 ...

Page 96: ...wer fed wires by about 3 inches When you trim the wires down to length hang on to the connector you ll be left with We ll use that later to solder to the other end of the wires at the bottom of the tower Strip about 1 2 of insulation off both the stepper motor wires and the feed wires coming from the Z tower If you ve never spliced wire before I d recommend using a simple splice called a Western U...

Page 97: ...s is important in order to get the pin assignments correct when you solder the connector you just cut off back on to the bottom end of the wiring If you re color blind please get some assistance with this step Getting the wires backwards will make you crazy Checkpoint Video 13 10 Assembling and Installing the EZStruder 97 Table 10 3 1 Wiring Color Chart Pin Stepper Color Extension Color 1 Green Gr...

Page 98: ...pe the hot end and fan wires together and slide the mesh loom section you just cut over them Make sure that when you slide the loom over the wiring that it reaches up to the center hole in the top plus a little bit more Now I want you to cut a 1 piece of heat shrink tubing Slide it over the bare wire end of the mesh loom Adjust it such that half is covering the mesh and half is covering the wire S...

Page 99: ...ull the mesh towards the end of the wire and add another 1 piece of heat shrink to the end Pull the mesh tightens it up and it lengthens as this happens Once you ve done that take a few minutes to tape down the hot end and fan wiring as shown Note that the photos here show the B hot end wires For the A hot end wires you ll have two each red black 26ga wires one pair of white 26ga wires and one eac...

Page 100: ...d WILL BE DESTROYED when the hot end temperature exceeds 247 degrees Celsius The reason this happens is due to the firmware on the controller trying to get the hot end to it s target temperature based on a thermistor input that is no longer close enough to the heater block to return a reliable reading When you ve got the heater block wrapped go ahead and throw a loop around the upper hot section t...

Page 101: ...ark the wires just behind the center point of the crimp as shown below Trim the leads off at that mark Finally attach the crimp on connector to the freshly trimmed leads as shown Repeat the process for the leads on the other side of the heater block 11 Installing the Hot End and Bowden Tube 101 Fig 11 3 1 Step 1 Fig 11 3 2 Step 2 Fig 11 3 3 Step 3 Fig 11 3 5 Marking the trim point Fig 11 3 4 Leads...

Page 102: ...the older hot end wiring that used 4 18ga wires For the new hot end wiring you ll use the 18ga red black wires as stated but you ll use the white 26ga wires for the thermistor As soon as you finish soldering the white wire to the thermistor lead cover the joint with Kapton tape Solder the other thermistor lead to the green wire and also cover it with Kapton After you ve done that I want you to use...

Page 103: ...hot end Start by removing the large nut and the press fit connector from the hot end Slide the mounting plate on to the hot end as shown on the left Next slide the spacer on to the hot end and then thread the large nut back on to the hot end Carefully tighen the nut with an 11 16 wrench You don t have to treat like a lug nut a little tightening goes a long way Using a small wire tie fix all four w...

Page 104: ...d on the table This will open up the mesh enough so that you can insert the Bowden tube Insert the tube 1 from the upper edge of the heat shrink tubing as shown below Thread the Bowden tube up the loom to a point a few inches short of the press fit connector on the extruder Open up the loom at that point and allow the Bowden tube to exit Now you can insert the Bowden tube into the press fit connec...

Page 105: ...oing so will ruin the fit of the parts Assembling the effector platform consists of installing three Ball Joint Arms on to the Ball Joint Platform Start by pressing a Ball Joint Arm on to a pair of mounting posts as shown in Fig 12 1 1 Fix the Ball Joint Arm into place with two 4 x 3 8 machine screws and two 4 flat washers 12 Installing the Effector Platform and Delta Arms 105 Fig 12 1 1 Ball Join...

Page 106: ... way by looping it over the Y tower Make sure you ve got each carriage moved to the bottom of the machine It ll be easier to get the arms installed with them in that location Take two Ball Cup Delta Arms and press them on to the Ball Joint Arms as shown The cup on the arm will make a soft click sound as it seats fully on the ball arm 12 Installing the Effector Platform and Delta Arms 106 Fig 12 1 ...

Page 107: ...Install a spring at the carriage end of the arm pair The advantage here is that when you re attaching the other ends to the effector platform the spring you just installed will help the arms grip the ball arms until you can get the other spring installed After you have the carriage end done install the effector end as shown Now install the other two arm sets in the same manner as you did this pair...

Page 108: ... shown Next set the hot end on the screw and thread a 6 32 nylon lock nut on the screw It doesn t need to be tightened yet we just want it there to keep the screw from falling out the bottom Repeat that process for the other two screws standoffs Tighten it down with a 5 16 wrench when you re done Checkpoint Video 17 13 Installing the Hot End 108 Fig 13 1 1 First screw ready Fig 13 1 2 First of thr...

Page 109: ...is going to be installing two 6 32 nylon lock nuts into the spool holder brace as shown in Fig 14 1 1 Now install the brace into the inner spool holder support Make sure you ve got the support oriented as I show in the photo Use a 6 32 1 pan head screw to fix it in place 14 Finishing the Top End 109 Fig 14 1 1 Spool holder brace done Fig 14 1 2 Brace installed ...

Page 110: ... into the nut capture pockets The spool holder support is attached to the printer s top plate using the three holes highlighted below Set the spool holder support on top of the machine and fix in place using three 1 6 32 pan head screws 14 Finishing the Top End 110 Fig 14 1 4 Assembled spool holder support Fig 14 1 3 Nuts installed Fig 14 1 5 Three mounting holes and JJ s Bus Fig 14 1 6 Spool hold...

Page 111: ... in until the tip of the screw is flush with the outside face of the part just like you did on the vertical supports in the base Now you can insert each one of the vertical supports on each side of the top The tolerance for the tabs is VERY tight If you re unable to get the tabs to seat properly you can use a squeeze clamp to help fit the vertical support into place Take care not to blow out the s...

Page 112: ...he three mounting holes at the corners of the top Congrats There s one last step to take before the mechanical build of your Rostock MAX v2 3D printer is completed That s right you need to install the spool holder IN the mount Now pay close attention this is brutally complex First put your arms together No not YOUR arms those arms Jeez Now oh so carefully slide the arms no your arms won t fit into...

Page 113: ...Rostock MAX v2 Assembly Guide 4thEd TA DA Okay so I lied You re not done yet You re almost done Checkpoint Video 18 Checkpoint Video 19 14 Finishing the Top End 113 Fig 14 2 6 Yer done ...

Page 114: ...s to the bottom when you re transporting your Rostock MAX v2 That will help ensure that the nozzle doesn t strike the heated bed during transport When you ve got the arms moved grab the assembled Onyx and the bed support Route the two 18ga power wires and the thermistor leads through the center of the bed support then thread them through the hole in the top of the machine base as shown 15 Installi...

Page 115: ... finish the installation Now you can install the remaining 5 remaining screws spacers What I do is work in a counter clockwise direction around the Onyx I set a screw and then slide a spacer under it with the tip of a small screwdriver until the screw falls through the spacer You can then tighten the screw a little bit before moving on to the next screw After you ve got all the screws started tigh...

Page 116: ...ockets on the two LCD mounting brackets Keep in mind that the panel mounts come as left and a right part The left side has a notch cut out to accommodate the SD card reader socket in the LCD panel itself This notch is highlighted in green in Fig 16 1 1 04May16 Note that your LCD panel may have a red or blue circuit board instead of a white one The color change simply indicates the unit came from a...

Page 117: ...ont panel as shown Fix in place with a 6 32 pan head screw Now install the right side and fix it in place with another 6 32 pan head screw Now you can attach the LCD control panel to the mounts Orient the LCD panel as shown so that the SD card socket matches the notch for it Attach the LCD panel to the mount using four 2 56 5 8 screws 16 Assembling Installing the LCD Panel Mount 117 Fig 16 1 2 Ins...

Page 118: ...he same manner as the left Set the acrylic face plate over the LCD it should clear easily and install two 2 56 5 8 screws at the locations shown below Do not tighten the screws all the way leave them a few turns loose Next install two more of the 2 56 5 8 screws at the top front of the faceplate and tighten Tighten the lower screws at this time Install the knob last 16 Assembling Installing the LC...

Page 119: ... LCD controller in a safe place we ll get back to it soon enough You should congratulate yourself at this point the mechanical assembly of your Rostock MAX v2 kit is complete Wander off and enjoy ADULT_INTOXICANT kick back and relax for a while Next on the agenda is the electronics Checkpoint Video 21 16 Assembling Installing the LCD Panel Mount 119 Fig 16 2 4 Marked interface cable positions ...

Page 120: ...o mounting plate Let s get the 40mm fan attached Lay the mounting plate on your work surface so that the opening for the fan is on the left edge Set the 40mm fan over the opening with the blades facing you Fix the fan in place with two wire ties First attach the lower left corner as shown Try not to capture the power wires when you close the wire tie 17 Installing Connecting the RAMBo Controller 1...

Page 121: ...AMBo Controller For this task you ll need the following components The first thing you ll need to do is get the 40mm fan wires soldered to the RAMBo controller Start by cutting off the connector at the end of the fan leads and strip off about 1 8 of insulation 17 Installing Connecting the RAMBo Controller 121 Fig 17 1 3 Fan installed Fig 17 1 4 Completed RAMBo mount Fig 17 2 1 Fan leads stripped ...

Page 122: ...place and flip the RAMBo controller upside down so you can reach the solder pads on the back side of the board Solder the leads in place Mounting the RAMBo is very straightforward Simply set the RAMBo on top of the mount and slide a plastic roller between the RAMBo and the mounting plate as shown in Fig 17 2 4 Insert a 4 40 3 4 flat head screw in the hole and tighten a few turns When you ve got al...

Page 123: ...into the pin 1 position on the connector as shown Make sure that the locking tab is oriented in line with the locking tab retaining hole You ll hear a soft click sound when the tab engages the hole At that point the connector is fully seated Insert the black wire from the X axis end stop into the second position right below the first Repeat this task for the Y and Z axis end stops You ll want to b...

Page 124: ...rmistor leads you got from the RAMBo box and cut them so you ve got about 3 of wire after the 2 pin connector Solder the shortened thermistor leads to the 18ga white green wires Use the same splicing technique you used when working on the EZStruder stepper motor Note that if you have the white 26ga A wires you ll solder those to the thermistor connector instead of the 18ga white green When you re ...

Page 125: ...You ll want to loop up and tie the extra thermistor lead as shown 17 6 Wire Prep Extruder Motor Connector For this task you ll need the wiring and connector that you cut off the extruder stepper motor back in Section 10 Solder the tail to the extruder motor wires that are coming out of the Z axis tower and cover the soldered joints with Kapton Make sure you follow the wiring diagram shown in Table...

Page 126: ...al block DO NOT UNDER ANY CIRCUMSTANCES TIN THE LEADS GOING INTO THE TERMINAL BLOCKS DOING SO CAN CREATE AN INTERMITTENT OR HIGH RESISTANCE CONNECTION THAT COULD BECOME A FIRE HAZARD The next pair of wires to be installed are the layer fan wires These are the black red 26ga wires that do not have the knot tied in them The layer fan wires should be inserted into the terminal block position marked F...

Page 127: ...inal block at the position marked Heat2 Bed as shown below in Fig 17 7 4 Warning Improperly installed heated bed wiring can do catastrophic damage to the RAMBo board Please make sure that the heated bed wires are fully seated and tightened down in the compression terminal So what s all the hubub bub It s been discovered that folks are not properly installing the wiring into the compression termina...

Page 128: ...o its small size Now you can install the thermistor connectors Remember how I had you label the thermistor leads with T0 and T2 Well there was a method to that particular madness The thermistor positions on the RAMBo are marked T0 through T3 By labeling them ahead of time it eliminates any confusion about which is which and you won t have to refer to the manual to see who does what I ve marked the...

Page 129: ...connectors That means they ve got a little locking tab that positively engages a little ledge on the inside of the socket that s on the RAMBo The motors provided do not use this locking feature so you need to make sure you insert the connector with the proper pin 1 orientation In Fig 17 8 6 I indicate the pin 1 position with a green arrow If you look closely at the image you ll see a small arrow p...

Page 130: ... has two curved tabs that fit into slots located on the top plate of the base When installed correctly the tabs will fit into those notches and the base of the RAMBo mount will rest on the two support legs that you installed when you were building the base 17 Installing Connecting the RAMBo Controller 130 Fig 17 9 1 RAMBo installed Fig 17 9 2 Right slot Fig 17 9 3 Left slot ...

Page 131: ...panel came in you ll find two gray flat ribbon cables and a small circuit board marked RAMBo to SmartController adapter These cables connect the LCD to the RAMBo controller via the LCD interface board Label the adapter board s two 10 pin connectors as A and B as shown below Next label the two cables with A on both ends of one and B on both ends of the other Install the ribbon cables on the LCD int...

Page 132: ...g has been omitted for clarity Make sure that the interface adapter board is properly seated on the RAMBo board it is possible to set the board down offset one row to the left or right and the LCD will not function Checkpoint Video 22 17 Installing Connecting the RAMBo Controller 132 Fig 17 10 4 LCD interface adapter installed Fig 17 10 5 Install complete Fig 17 10 3B Red or Blue Display PCB cabli...

Page 133: ...mbscrews to fix the cover in place Now install the A and B cables on to the back of the LCD controller in the locations you labeled when you first assembled it You ll notice two small tabs on the bottom edge of the LCD controller assembly Those tabs fit a pair of slots in the center vertical support Coil up the controller cables in the space at the bottom of the LCD controller and fit it to the fr...

Page 134: ...front of the machine and install it into the RAMBo as shown After you ve got the USB cable installed I want you to inspect all the wiring and belt paths to ensure that there s no interference between the wiring and the belts make sure the belt paths are clear and no wiring is rubbing against a belt 18 Final Assembly Tasks 134 Fig 18 1 4 LCD panel installed Fig 18 2 1 USB cable installed ...

Page 135: ...rt with the Z axis Insert the acrylic panel as shown it will rest against the side of the 6 32 flat head screw you installed when building the base Carefully bend the panel over the back of the Z axis tower and slide it into the open space on the right it should come to rest on the 6 32 flat head screw on that side The other retaining screw is indicated by the green arrow in Fig 18 3 2 You ll want...

Page 136: ... L marking facing inward so it can t be seen once installed The top acrylic covers are all the same size so you don t have to worry about which one goes where Install all three in the same manner as you did the lower acrylic cover panels 18 Final Assembly Tasks 136 Fig 18 3 3 Z Axis cover installed Fig 18 3 4 Upper acrylic covers installed ...

Page 137: ...sing a permanent marker make a 1 4 wide mark on the edge of the glass The mark will give you a guide when replacing the Borosilicate glass build plate if you remove it for any reason Even though the glass thickness is very consistent tiny variations in the surface of the glass can introduce calibration issues if the glass isn t replaced in the exact spot it was when you first calibrated your print...

Page 138: ...own I bet the guy that invented those things is constantly amazed at their unintended uses 18 5 Smoke Test One last thing there s always something else isn t there you should do is a final check of all your wiring in the Rostock MAX v2 Make sure no bare wire is touching any other bare wire etc Finally plug the sucker in and hit the power switch If everything works as expected you should hear the R...

Page 139: ...You ve not only built a pretty technical kit but you ve joined the ranks of many brilliant and distinguished people on the bleeding edge of 3D printing technology Kick back for a bit and relax Have a beer or other drink of choice Scotch and enjoy the moment Congratulations on a job well done Hey Put down that beer We ve got software to install AND ANOTHER MANUAL TO DOWNLOAD Checkpoint Video 23 Ros...