Open Hardware
Assembly Instructions

Gather the required documents.

• You will need a Quality Checklist and a Test/Acceptance Record.
• Take the next available serial number for the machine. There should also be a matching number for the power supply.

Inspect the mechanical assembly - complete the Quality Checklist as you proceed.

• Check to ensure that all screws and zip ties are tight and in the correct position.
• Make sure the X and Y motor pulley set screws are tight and that one of them directly engages the flat on the motor shaft.
• Ensure that the belts are tight and do not rub on the idler end or belt mounts throughout the range of motion.
• Belts should be trimmed far enough to prevent interference.
• Check that the X axis smooth rods are aligned flush with the X motor mount and the Z smooth rods are flush with the top of the unit.
• The Y axis smooth rods should be flush with both Y ends.
• Ensure the drive rod zip ties are very tight (vertical pull test).
• Make sure the Y frame is directly contacting the XZ frame.

Inspect the electronics.

• Check the wiring for correct positions.
• Verify that no wire insulation is inside the screw terminals and check for screw tightness.
• Make sure that all plug connectors are fully seated and in the proper locations.
• Ensure the lower strain relief is installed and screws are tight.
• Check that both nuts on the 3mm ground lugs are tight.
• Install the cooling fan using 4x 3mm x 12mm screws and washers. Power the unit on and check for fan rotation and interference.

Install the heat bed as indicated. Connect the heat bed wires.

Install the serial number on the machine and power supply. Also apply the 24v sticker above the power connection as indicated.

Make sure Pronterface is connected to the printer then click the 'MOTORS OFF' button.

With the nozzle slightly above the heat bed, manually move the print head along the X axis eyeing the distance between the nozzle and the bed as you go.

Adjust one drive rod by rotating it while holding the other stationary until the X axis is parallel to the bed.

Rough level the bed by checking the distance from front to back as well as side to side. Adjust the bed corner screws accordingly.

Add a HOT placard to the printer and install the calibration SD card.

Ensure that Pronterface is connected to the printer and the nozzle and bed temperatures are set.

Click 'LOAD FILE' in Pronter and navigate to 'bed_calibration.gcode'

Click the home button on the bottom left of the axis controller. Check the distance between the nozzle and the heat bed when the Z axis is in the home position. Adjust the Z limit screw until the nozzle is just slightly (approximately .5mm) above the heat bed.

Click 'PRINT' in Pronterface.

Examine the resulting print. The extrusion should be uniform from side to side and front to back and approximately 1mm wide.

Adjust the heat bed screws in small increments to achieve the desired result. Back the bed corner screws out to raise a corner of the bed, turn them in to lower a corner.

If the print is uniform across the bed, the bed is leveled. Otherwise, gently remove the print with a clam knife, adjust the bed corners and repeat the process until the print is uniform.

After successfully completing the bearing burn-in and printing a quality octopus, the printer is ready to ship.

• X and Y belt tensions may loosen during bearing burn in and octopus printing. Re-check the belt tensions.
• REMOVE THE CALIBRATION SD CARD and the HOT placard.
• Ensure that both the Quality Checklist and Test/Acceptance Record are completed.
• Enter the printer information in the Master Build Log.
• Gather the Test/Acceptance Record, Quality Checklist, power supply, power cord, USB cord and printer. Move all components to the shipping area.