Nophead Mendel90 User manual

Mendel90 Kit Instructions
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The build is broken down into sub assemblies that can be worked on sequentially by one person, or
in parallel if there is more than one person building. For this reason each assembly begins on a new
page so the instructions can be separated.
All the diagrams can be viewed in Open CAD allowing real time zooming, rotating and panning to
get the best view.
25/04/14 First release of this manual.
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Table of Contents
1.General Build Tips........................................................................................................................6
Tools Required............................................................................................................................7
Recommended........................................................................................................................7
Consumables .........................................................................................................................7
2.Frame Assembly...........................................................................................................................8
Vitamins......................................................................................................................................8
Printed parts................................................................................................................................8
Assembly.....................................................................................................................................9
3.Bed Fan Assembly......................................................................................................................11
Vitamins....................................................................................................................................11
Printed part................................................................................................................................11
Assembly...................................................................................................................................11
4.X Idler Assembly........................................................................................................................12
Vitamins....................................................................................................................................12
Printed.......................................................................................................................................12
Assembly...................................................................................................................................13
5.X Motor Assembly......................................................................................................................14
Vitamins....................................................................................................................................14
Printed parts..............................................................................................................................15
Assembly...................................................................................................................................16
6.Z Motor Assemblies....................................................................................................................21
Vitamins....................................................................................................................................21
Printed parts..............................................................................................................................21
Assembly...................................................................................................................................22
7.Z Axis Assembly.........................................................................................................................24
Vitamins....................................................................................................................................24
Printed parts..............................................................................................................................24
ub-assemblies..........................................................................................................................24
Assembly...................................................................................................................................25
8.Y idler assembly.........................................................................................................................27
Vitamins....................................................................................................................................27
Printed parts..............................................................................................................................27
Assembly...................................................................................................................................27
9.Y motor assembly.......................................................................................................................29
Vitamins....................................................................................................................................29
Printed parts..............................................................................................................................29
Assembly...................................................................................................................................30
10.Y Carriage Assembly................................................................................................................31
Vitamins....................................................................................................................................31
Printed parts..............................................................................................................................31
Assembly...................................................................................................................................32
11.Y Heatshield Assembly.............................................................................................................34
Vitamins....................................................................................................................................34
Assembly...................................................................................................................................34
12.Print bed assembly....................................................................................................................35
Vitamins....................................................................................................................................35
ub-assemblies..........................................................................................................................35
Bed Wiring................................................................................................................................36
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Assembly...................................................................................................................................38
13.Y Axis Assembly.......................................................................................................................39
Vitamins....................................................................................................................................39
Printed parts..............................................................................................................................39
ub-assemblies..........................................................................................................................39
Assembly...................................................................................................................................40
14.X Carriage Fan Assembly.........................................................................................................42
Vitamins....................................................................................................................................42
Printed parts..............................................................................................................................42
Assembly ..................................................................................................................................42
15.X Carriage Assembly................................................................................................................43
Vitamins....................................................................................................................................43
Printed parts..............................................................................................................................43
Assembly ..................................................................................................................................44
16.Hot end assembly......................................................................................................................45
Vitamins....................................................................................................................................45
Assembly...................................................................................................................................45
17.Extruder connection pcb assembly...........................................................................................47
Vitamins....................................................................................................................................47
Assembly..................................................................................................................................47
18.Extruder Motor Assembly.........................................................................................................48
Vitamins....................................................................................................................................48
Printed parts..............................................................................................................................48
ub-assemblies..........................................................................................................................48
Assembly...................................................................................................................................49
19.Extruder Assembly....................................................................................................................51
Vitamins....................................................................................................................................51
Printed parts..............................................................................................................................51
ub-assemblies..........................................................................................................................51
Assembly...................................................................................................................................52
20.X Axis Assembly......................................................................................................................55
Vitamins....................................................................................................................................55
ub-assemblies..........................................................................................................................55
Assembly...................................................................................................................................56
21. pool holder assembly..............................................................................................................58
Vitamins....................................................................................................................................58
Printed parts..............................................................................................................................58
Assembly...................................................................................................................................59
22.P U assembly...........................................................................................................................60
Vitamins....................................................................................................................................60
Printed parts..............................................................................................................................60
Wiring........................................................................................................................................61
ummary...................................................................................................................................62
Assembly...................................................................................................................................63
23.Electronics Assembly................................................................................................................64
Vitamins....................................................................................................................................64
Printed Parts..............................................................................................................................64
Assembly...................................................................................................................................64
24. oftware....................................................................................................................................68
Marlin Firmware.......................................................................................................................68
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Arduino IDE..............................................................................................................................68
Pronterface................................................................................................................................68
25.Testing.......................................................................................................................................70
Jumpers.....................................................................................................................................70
Power up...................................................................................................................................70
Limit switches...........................................................................................................................70
Motors.......................................................................................................................................70
Heaters......................................................................................................................................71
Fan.............................................................................................................................................71
26.Calibration................................................................................................................................72
Bed Levelling............................................................................................................................72
Extruder Calibration..................................................................................................................73
Z Home Point............................................................................................................................73
First Print...................................................................................................................................74
licing with keinforge.............................................................................................................75
Extrusion Limits........................................................................................................................76
27.Operating Instructions...............................................................................................................77
Heated Bed................................................................................................................................77
Changing filament.....................................................................................................................77
Removal................................................................................................................................77
Insertion................................................................................................................................78
Different types of filament ..................................................................................................78
Cleaning the hobbed bolt..........................................................................................................79
Using Other oftware Tools......................................................................................................80
28.Notes for printers......................................................................................................................83
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1. General Build Tips
•X is left / right. Y is backwards / forwards. Z is up / down.
•Bar lengths: The longest and shortest bars are the Y bars. Of the two pairs left, the longer
ones are the X axis and the shorter two the Z axis.
•The longer belt is for X and the shorter one is for Y. They are supplied cut to the right
length.
•De-grease the rods that come with packing grease. Acetone or methylated spirit works. The
grease will be scraped off by the bearings anyway and will prevent the bar clamps from
getting a firm grip.
•All screws have a plain washer where they meet the plastic, to spread the load and prevent
the plastic being chewed up by the rotation of the screw head. Most fixings have a captive
Nyloc nut to prevent them vibrating loose. It is very important that the nut is fully seated
in the nut trap while the screw is inserted. They are quite a tight fit, so sometimes it is
necessary to pull or push them in with a long screw. The M3 x 45mm screws in the kit are
handy for this.
•The X and Y bar clamps should not be over tightened, i.e. do not close the gap fully or the
parts will break. The Y and Z bars only need a light clamping force because the only force
trying to slide them is the bearing friction.
•Washers tend to have a smooth side and a side with a burr from being stamped out. Make
sure the smooth side faces bearings and belts.
•Ribbon clamp notation is <number of wires>_<hole size>. There are three lengths: the short
ones are 14 way for the X axis, the medium ones are 20 way for the Z axis and the long ones
are 26 way for the bed. An N suffix denotes with nut traps. B denotes no slot.
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Tools Required
•panners: 5mm, 5.5mm, 7mm & 13mm.
•Allen keys: 1.5mm, 2mm, 2.5mm, 3mm & 6mm.
•PZ 1 Pozidriv screw driver.
•PH 1 Philips screw driver.
•mall flat blade screw driver (for Melzi screw terminals).
•Vice (to close IDC D type connector).
•Wire cutters.
•Wire strippers.
•Needle nose pliers.
•oldering iron.
•Digital callipers.
•quare (to messure if things are 90º, just to be safe :-D )
Recommended
•Multi-meter with thermocouple attachment
•Dial gauge
•Wire brush
Consumables
•ticky tape, oil, white lithium grease, glass cleaner (e.g. vinegar), lint free wipes.
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2. Frame Assembly
Vitamins
2 MDF sheet 166mm x 586mm x 12mm
1 MDF sheet 485mm x 436mm x 12mm
1 MDF sheet 485mm x 586mm x 12mm
39 No6 pan wood screw x 16mm (4mm shank & 9mm head)
39 Washer M4 x 9mm x 0.8mm
39 tar washer M4 x 0.8mm
Printed parts
2 cable_clip_AB.stl 2 cable_clip_AD.stl
1 cable_clip_CA.stl 10 fixing_block.stl 3
1 ribbon_clamp_20_40.stl 1 ribbon_clamp_26_40.stl
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Assembly
Note that this view is from the back of the machine.
1. Attach the 6 fixing blocks to the base with a kebab of No6 pan wood screw and M4 Washer
and a M4 star washer, the star washer goes on the screw first and the washer last so when
screwed in the washer will touch the fixing block first. You might want to stop just before
the washer grabs the fixing block so you can push it later on.
2. Attach the 4 fixing blocks to the gantry with the same kebab of washers and screw
3. tand the gantry sheet on the base and screw it in at the 4 fixing blocks with the same kebab
of screw and washers and stop screwing in just as before.
4. Take one stay and screw it to the fixing blocks in the base and gantry in just the same way
5. Repeat with the other stay
6. Now with a square tighten the screws in so they are just tight. DO OT OVER-
TIGHTE . tart with the gantry then the stay. They should be 90º to each other by design
but might need some help hence the square
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7. Loosely attach the two ribbon clamps. The longer one goes at the back of the base for the
bed wires. The shorter one goes at the top of the gantry for the X axis cable.
8. Loosely attach the two AB Cable Clips. One at the front and one at the foot of the gantry
9. Loosely attach the CA cable clip near the long ribbon clamp at the back.
10. Loosely attach the AD cable clips at the top of the gantry at each side.
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3. Bed Fan Assembly
The bed fan speeds up the cool down period when the parts are finished.
Vitamins
4 M4 cap screw x 25mm
1 Fan 80mm x 38mm
4 Nyloc nut M4
4 Washer M4 x 9mm x 0.8mm
Printed part
1 fan_guard.stl
Assembly
Make sure the fan is blowing inwards. This is usually indicated by an arrow on the frame and is
often the side with the label.
The four screws pass through a plain washer, the fan guard, the left stay, the fan and finally a nyloc
nut. There isn't a washer behind the fan because fan frames tend not to have room for one.
The Melzi doesn't have a second fan output but you can easily add one on a spare I/O pin as
described here: hydraraptor.blogspot.co.uk/2012/07/sanguinololu-fan-hack. It can be controlled
with M42
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4. X Idler Assembly
Vitamins
2 Ball bearing 624 4mm x 13mm x 5mm
8 M3 cap screw x 20mm
1 M4 cap screw x 45mm
2 LM8UU linear bearing
8 Nyloc nut M3
1 Nyloc nut M4
8 Washer M3 x 7mm x 0.5mm
2 Washer M4 x 9mm x 0.8mm
2 Washer M5 x 20mm x 1.4mm
Printed
1 x_idler_bracket.stl
2 x_end_clamp.stl
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Assembly
1. Insert the two linear bearings by pushing the end which is towards the outside in first. Then
slide it up against the shelf at the end before pushing in the other end. The bearings should
be a snug fit. If for some reason they are loose wind a layer or tape around them.
2. Insert a rod to check they are aligned well.
3. Insert all the nyloc nuts into their nut traps.
4. Fit the M3 x 20mm cap screws with washers through the bar clamps loosely.
5. Make the washer and bearing kebab on the long M4 bolt that forms the idler axle, but leave
it loose to allow the X bars to be inserted later.
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5. X otor Assembly
Vitamins
6 M3 cap screw x 16mm
10 M3 cap screw x 20mm
2 M3 cap screw x 45mm
1 15 way D IDC socket
1 M3grub screw x 6mm
2 LM8UU linear bearing
1 NEMA17 x 47mm stepper motor
1 Nut M3
14 Nyloc nut M3
2 Nitrile O-ring 2.5mm x 1.6mm
1 Polypropylene strip 408mm x 18mm x 0.5mm
1 Polypropylene strip 677mm x 25mm x 0.5mm
2 M3 pan screw x 8mm
4 No2 pan wood screw x 13mm (2mm shank -
5mm head)
1 Ribbon cable 20 way 1455mm
1 Microswitch
4 Heatshrink sleeving ID 2.4mm x 15mm
4 Washer M2.5 x 5.9mm x 0.5mm
22+5 Washer M3 x 7mm x 0.5mm
2 tar washer M3 x 0.5mm
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Printed parts
1 d_shell.stl 1 d_shell_lid.stl 1 ribbon_clamp_14_33.stl
1 ribbon_clamp_14_33NB.stl 1 ribbon_clamp_20_33.stl 1 x_motor_bracket.stl
1 x_motor_ribbon_bracket.stl 2 x_end_clamp.stl 1 pulley.stl
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Assembly
1. Cut the two polypropylene strips to the lengths shown in the vitamins list.
2. Insert the linear bearings and bar clamp screws as described above for the X idler assembly.
3. Insert the two M3 nyloc nuts for the ribbon clamp, two in the ribbon_clamp_14_33NB and
the remaining two in the x_motor_ribbon_bracket.
4. Crop the motor wires to 45mm and retain the surplus wire for connecting limit switches and
the bed thermistor.
5. Push the M3 nut in the pulley
6. Fit the pulley to the motor shaft ensuring the grub screw locates on the flat of the shaft.
Position it so that 3mm of the shaft protrudes beyond the pulley.
7. Look at the back of the motor orient it at 45 degrees with the wires pointing up and left.
Remove two screws from the back of the motor at the 12 o'clock and 3 o'clock positions.
ote these are Philips head screws, not Posidriv.
8. crew the x_motor_ribbon_bracket to the back of the motor using an M3 x 45mm cap screw
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and a washer.
9. Fit the motor with the ribbon bracket at the top and secure it to the front of the motor bracket
with two M3 x 8mm pan screws, star washers and plain washers.
10. Motors have a ± 1mm tolerance on their length so the bracket at the back will have rome for
a washer between 0 and 2mm clearance. Pack this gap with M3 washers using between 1
and 5. crew the second M3 x 45mm cap screw through the hole in bracket, the washers and
into the motor. The head of the screw will hold the back corner of the motor in the bracket.
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11. The next task is attaching the 20 way ribbon cable. Peel back the first two wires at the red
edge and the last four wires at the opposite edge. Insert the remaining fourteen wires into the
first fourteen pins of the D type socket. i.e. pin 3 of the cable mates with pin 1 of the
socket. Pin 8 of the socket is unused. ee the photo below: -
Pin 1 is top left in this photo, the unused pin 8 is at the bottom left.
12. Ensure the cable goes all the way through the connector and is aligned straight so both rows
of pins connect.
13. Close the socket using a vice to make the IDC connections. Clip the strain relief clip on the
back but do not pass the cable through it (strain relief is provided by the printed parts but
the clip is needed to lock the connector closed).
14. Insert into the d_shell in the orientation shown below: -
15. ecure the connector by screwing on the d_shell_lid with two No2 x 13mm pan screws with
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M2.5 washers.
16. Clamp down the cable with the thinner polypropylene strip under it (against the D shell)
using the ribbon_clamp_14_33NB, M3 x 16mm cap screws and M3 washers (from the
underside).
17. Complete the D connector by adding M3 x 20mm retaining screws and washers and then
secure them in place with the rubber O rings.
18. Peel back the 6 loose wires along the length of the polypropylene strip until just past the end
furthest from the connector. Then clamp the 14 way cable and the wider strip in the ribbon
clamp on the top of the X motor bracket with the red edge at the top using the
ribbon_clamp_14_33, M3 x 16mm cap screws and M3 washers. Form the cable and strip
into a loop as shown in the diagram above before tightening the clamp fully. This is
necessary because the cable needs to be a bit longer than the strip to go round the outside of
the curve.
19. Pass the full 20 way part of the cable through the ribbon_clamp_20_33 attached to the
x_motor_ribbon_bracket at the back of the motor and clamp it with the second
polypropylene strip on top using M3 x 16mm cap screws and M3 washers.
20. Add loops of sticky tape (not provided) to fasten the middle of each cable to the middle of
its cable strip.
21. Pass the first two loose wires through the large hole in the top of the motor bracket and out
through the small hole for the limit switch. older the switch on (use the two outer pins) and
then mount it with two No2 x 13mm pan wood screws with M2.5 washers. N.B. The micro
switch must be oriented with the button towards the bottom.
22. older the remaining four lose wires to the motor wires using the heat shrink sleeving to
cover the joins. Use the following connection scheme: -
Ribbon wire 17 X motor red
Ribbon wire 18 X motor blue
Ribbon wire 19 X motor green
Ribbon wire 20 X motor black
Thread the heatshrink sleeving onto the motor wires before soldering and keep them well
way from the joint so the heat of the soldering does not shrink them prematurely. lide the
heatshrink over the joints after they have cooled and shrink by holding them over the barrel
of the soldering iron, close but not touching. If you have a heat gun use that instead.
ee the picture below: -
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