There were some important updates during the preparation of this guide. There might some steps which you will encounter the older photos of the machine. Due to time it takes to shoot the photos we simply decided to keep the older versions as it is for now.
We switched the stepper motor driver with a more advanced version.
3D Printed components required
Prepare the following 3d printed parts below.
1x 48V PSU Bottom Bracket
1x Stepper Driver Bracket
1x 12V PSU Bottom Bracket
1x 48V PSU Back Bracket
1x 12V PSU Top Bracket
1x 48V PSU Top Bracket
Electronic components required
Prepare the following parts below.
1x 48V PSU
1x 12V PSU
1x Stepper Driver
1x AC Contactor
1x DC Relay
Step 1: Installing the T-nuts using cold insertion method
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Tip: For the rest of the installation we suggest to keep all the T-nuts in a freezer to make the installation easier to the 2020 aluminum extrusions since cold metal shrinks, thus makes it easier to slide between t-slot spacing of the extrusions. We call this method cold insertion method
Using the M4-40mm screw as a tool, screw one piece of cold M4 T-nut to it.
Insert the top side of the t-nut to the top side of the extrusion t slot space.
Apply a considerable amount of force to the other side of the screw to use it as a lever insert the t-nut to the extrusion t slot.
Using this method insert the 6 pieces of M4 T-nuts to the following t slots marked on photo.
Using this method insert the 4 pieces of M4 T-nuts to the following t slots marked on photo.
Insert 1 piece of M4 T-nut to the following t-slot marked on photo.
Insert 1 piece of M4 T-nut to the following t-slot marked on photo.
Step 2: 48VDC 350W PSU - Voltage selection
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IT IS IMPORTANT THAT 48VDC 350W PSU IS SET TO CORRECT VOLTAGE INPUT MODE THAT MATCHES WITH YOUR COUNTRY'S DEFAULT POWER OUTLET VOLTAGE. FAILURE TO DO SO WILL DAMAGE THE PSU AND OTHER COMPONENTS AS WELL.
Check the 48VDC PSU AC input voltage mode by looking for yellow label and rectangular opening.
Voltage selection is marked on the red slide button. By default it is set for 110-120VAC input operation.
If you need to change the input voltage to 220-230V operation insert a flat screwdriver and move the red switch to other direction.
Now it should set for 230VAC input mode.
You do not need to do this step for 12VDC 75W PSU since it has automatic voltage selection built-in by default.
Step 3: 48VDC 350W PSU installation - Preperation
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Grab the 48V PSU Bracket and place it in the correct position as shown on a flat surface.
Place 6 pieces of M3-4mm heat inserts through the holes and use a heat insertion method of your choice to secure the heat inserts into the holes marked in photo.
Place the 48V PSU and align the 48V PSU bottom bracket as shown in photo.
Insert 2 pieces of M4-8mm socket head screws through the holes through the holes and tighten them fully.
Rotate the 48V PSU and place the 48V PSU top bracket as shown in photo. Insert 1 piece of M4-8mm socket head screw through the hole and tighten it fully. THERE IS A NEW MIRRORED VERSION OF PSU TOP BRACKET INCLUDED WITH THE KITS THAT SHOULD BE INSTALLED IN 180 DEGREE POSITION WHERE THE SCREW HOLE FOR ALUMINUM EXTRUSION SHOULD BE LOOKING DOWNWARDS INSTEAD OF UPWARDS.
Grab the 48V PSU back bracket (larger one) as shown in photo.
Position the 48V PSU back bracket as shown in photo to the back side of the 48V PSU where there is a M4 screw hole located near the terminal blocks. Insert 1 piece of M4-6mm socket head screws through the thicker side of the 48V PSU back bracket and tighten it fully in correct alignment as as shown in photo.
Step 4: 48VDC 350W PSU installation - Securing to the frame
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Using this photo as a guide the correct installation and screw positions of the 48V PSU assembly is shown with blue arrows.
Place the 48V PSU assembly as shown in photo.
Align the 1 piece of M4 T-nut to the screw hole located on 48V PSU top bracket with the help of allen key.
Insert 1 piece of M4-8mm socket head screw to the marked hole and tighten it fully.
Align the 1 piece of M4 T-nut to the screw hole located on 48V PSU back bracket with the help of allen key.
Insert 1 piece of M4-8mm socket head screw to the marked hole and tighten it fully.
Step 5: 48VDC 350W PSU installation - Securing to the frame
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Turn the machine upside down. Align the 3 pieces of M4 T-nuts to the screw holes marked in photo located on 48V PSU bottom bracket with the help of allen key.
Insert 3 pieces of M4-8mm socket head screws to the marked holes. DO NOT TIGHTEN THEM FULLY YET!
On the opposite side of the 48V PSU bottom bracket align the 2 pieces of M4 T-nuts to the screw holes marked in photo with the help of allen key.
Insert 2 pieces of M4-8mm socket head screws to the marked holes. DO NOT TIGHTEN THEM FULLY YET!
Step 6: AC contactor and DC relay installation
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Place the AC Contactor as shown in photo and align the screw holes with 48V PSU bottom bracket. TAKE EXTRA ATTENTION OF THE CORRECT ORIENTATION OF THE AC CONTACTOR BY LOOKING FOR THE CONTACTOR INPUT AND OUTPUT TERMINALS. INPUT TERMINALS SHOULD BE ALIGNED ON LEFT SIDE WHERE THE 48V PSU FAN IS LOCATED AND OUTPUT TERMINALS SHOULD BE ALIGNED ON RIGHT SIDE WHERE THE 48V PSU TERMINALS ARE LOCATED.
Insert 4 pieces of M3-10mm socket head screws to the marked holes and tighten them fully.
Place the DC Relay as shown in photo and align the screw holes with 48V PSU bottom bracket. TAKE EXTRA ATTENTION OF THE CORRECT ORIENTATION OF THE DC RELAY BY LOOKING FOR THE INPUT AND OUTPUT TERMINALS.
Insert 2 pieces of M3-6mm socket head screws to the marked holes and tighten them fully.
Step 7: Stepper driver installation - Preperation
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Grab the stepper driver bracket (longer one) and place it on a flat surface.
Place 2 pieces of M4-5mm heat inserts through the holes and use a heat insertion method of your choice to secure the heat inserts into the holes marked in photo.
Insert 1 piece of M4-8mm flat head screws to the marked hole. DO NOT TIGHTEN IT FULLY YET!
Slide the stepper driver screw hole through the stepper driver bracket screw hole with M4-8mm flat head screw. Loosen the screw if needed to slide it properly. TAKE EXTRA ATTENTION TO THE CORRECT ORIENTATION OF THE STEPPER DRIVER BY LOOKING FOR THE TERMINAL CONNECTOR POSITION AND BRACKET ORIENTATION.
Insert 1 piece of M4-8mm flat head screw to the marked hole and tighten it fully.
Tighten the other M4-8mm flat head screw to the marked hole to secure the bracket in place.
Step 8: Stepper driver installation - Securing to the frame
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Using this photo as a guide the correct installation and screw positions of the stepper driver assembly is shown with blue arrows.
While holding the stepper driver assembly with one hand align the M4 T-nut to the screw hole located on stepper driver bracket with the help of allen key.
Insert 1 piece of M4-8mm socket head screw to the marked hole. DO NOT TIGHTEN IT FULLY YET!
Repeat the whole step for the other screw hole as well.
Step 9: 12V PSU installation - Preperation
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Place the 12V PSU and align the 12V PSU bottom bracket as shown in photo.
Insert 2 piece of M3-6mm socket head screw to the marked hole and tighten them fully.
Grab the 12V PSU top bracket (smaller one) as shown in photo. Place 1 piece of M3-4mm heat insert through the hole and use a heat insertion method of your choice to secure the heat insert into the hole marked in photo.
Place the bracket as shown in the photo under the screw hole located on the 12V PSU, next to terminal connector area.
Insert 1 piece of M3-6mm flat head screw to the marked hole and tighten it fully.
Step 10: 12V PSU installation - Securing to the frame
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Using this photo as a guide the correct installation and screw positions of the 12V PSU assembly is shown with blue arrows.
Place the 12V PSU assembly and align the 12V PSU top bracket as shown in photo.
Align the M4 T-nut to the screw hole located on 12V PSU top bracket with the help of allen key.
Insert 1 piece of M4-8mm socket head screw to the marked hole and tighten it fully.
Rotate the machine upside down. Align the M4 T-nut to the screw hole located on 12V PSU bottom bracket with the help of allen key.
Insert 1 piece of M4-8mm socket head screw to the marked hole and tighten it fully.
Repeat the whole step for the other screw hole as well.
