Bfb RapMan 3 User manual

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RapMan 3
Hot End Manual RapMan V3.1.0

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RapMan V3.0.0 Hot End Kit
Contents
How to use this manual...............................................................................................................................................2
Included in the kit .......................................................................................................................................................3
Making up the un-insulated nichrome.........................................................................................................................4
Making up the insulated nichrome..............................................................................................................................7
Making up the thermistor ...........................................................................................................................................9
Nozzle assembly........................................................................................................................................................11
Wrapping the un-insulated nichrome........................................................................................................................13
Wrapping the insulated nichrome .............................................................................................................................14
Fitting the thermistor................................................................................................................................................16
Moulding the final shape ..........................................................................................................................................18

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RapMan V3.0.0 Hot End Kit
How to use this manual
This manual is for the Bits from Bytes hot end kit.
Please read the manual fully before starting the build as a little prior knowledge can be very useful!

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RapMan V3.0.0 Hot End Kit
Included in the kit
1 Nozzle 0.5mmØ or 0.25mmØ depending on kit
1 Stainless steel 2mm laser-cut nozzle holder
1 PEEK insulator support
1 Aluminium heat sink tube
1 PTFE insulator tube
1 MDF insulator
1 Insulation retainer
1 200K thermistor
1 Nichrome wire
o300mmnichrome un-insulated wire size 34
oor 690mm nichrome insulated size 25
1 tub fire-cement
3 M3 x 40 stainless steel spacers
3 M3 x 16 cap head bolts
3 M3 nuts
4 Bootlace ferrules
140mmyellow silicone sleeve
1 Silicone nozzle insulator (not shown)
PEEK insulator
Aluminium heat sink
Nozzle
Fire-cement
M3 nuts
Nichrome wire
PTFE insulator
M3 x 16 bolts
Thermistor
Nozzle holder
M3 x 40 spacers
Bootlace ferrule
Silicone sleeve
MDF insulator
Insulation retainer

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RapMan V3.0.0 Hot End Kit
Making up the un-insulated nichrome
1
2
3
4
5
Cut nichrome wire 210mm

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RapMan V3.0.0 Hot End Kit
6
7
8
9
10
11
Strip 30mm of insulation from the end of both 2m grey wires
Cut 4 x 35mm yellow heat proof sleeve

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RapMan V3.0.0 Hot End Kit
12
13
14
15
16
Check the resistance of the wire is between 4.5Ω and 5.5Ω

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RapMan V3.0.0 Hot End Kit
Making up the insulated nichrome
1
2
3
4
5
6
Cut 4 x 35mm yellow heat proof sleeve
Check nichrome is 690mm long
Strip 5mm insulation from each end
Crimp connection

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RapMan V3.0.0 Hot End Kit
7
8
Repeat from step 5 at the other end
Check the resistance of the wire is between 4.5Ω and 5.5Ω

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RapMan V3.0.0 Hot End Kit
Making up the thermistor
1
2
3
4
5
Strip 30mm of insulation from the end of both 2m purple wires
Use the heat-proof sleeve cut previously

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RapMan V3.0.0 Hot End Kit
6
7

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RapMan V3.0.0 Hot End Kit
Nozzle assembly
1
2
3
4
5
6
Push the PEEK insulator into the aluminium nozzle until only 15mm sticks out
Cut the end of the PTFE to 90o

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RapMan V3.0.0 Hot End Kit
7
8
9
10
Cut the PTFE flush to the MDF

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RapMan V3.0.0 Hot End Kit
Wrapping the un-insulated nichrome
1
2
3
Use the clips provided to hold the wires
Ensure no wires are touching
Fire-cement the wires into place and cook in an oven at 100oC for 15 minutes or leave overnight in a warm place

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RapMan V3.0.0 Hot End Kit
Wrapping the insulated nichrome
1
2

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RapMan V3.0.0 Hot End Kit
3
4
5
Connect the heater to the fan connector on the PCB –this is a convenient source of 12V
Coat the nichrome wire with fire-cement
Turn on PCB for 3 minutes - this will cook the fire-cement

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RapMan V3.0.0 Hot End Kit
Fitting the thermistor
1
2
3
4
Put a small amount of fire-cement into the thermistor mounting hole and push the thermistor into the fire-cement

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RapMan V3.0.0 Hot End Kit
5
6
Check the resistance of the thermistor –it should be between 200kΩ and 300kΩ at room temperature
Cook the fire-cement for 2 minutes

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RapMan V3.0.0 Hot End Kit
Moulding the final shape
1
2
Mould the final shape so the nozzle end is slightly larger to hold the silicone insulator in place