SeeMeCNC Rostock MAX v2 User manual

Rostock MAX v2 Assembly Guide
Welcome to the Assembly Guide for the Rostock MAX v2.0 3D printer.
ersion 1.68, September 28th, 2016
Repetier-Host Edition
Copyright 2014 by Gene Buckle
Licensed as Creative Commons Attribution-ShareAlike 3.0
Questions or corrections should be emailed to [e-mail]
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Rostock MAX v2 Assembly Guide
Read Me First!
This document is your instruction manual for your new SeeMeCNC® 3D printer machine.
Before using your new 3D printer, thoroughly read and understand this manual for safe and effecti e
operation of the machine.
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Warning
Adult supervision required. Children under 18 years of age require supervision.
Risk of Fire. Do not leave machine unattended.
Use genuine parts manufactured or designated y SeeMeCNC.
Keep a copy of this manual near the machine, easily accessi le to all operators.
Use of this machine is at your own risk.
Personal property damage, serious injury or death can result from not following
instructions or warning in the manual or misuse of the machine.
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 e hazardous. Disconnect power efore
servicing this machine.
The hot end of the machine can reach very high
temperatures of 700F and can cause serious urns.
The heated print surfaces (heated ed) can also reach
temperatures high enough to cause severe urns. Allow
oth to cool for 20 minutes after turning off power.
Use caution near moving parts of the machine. Keep
ody and loose articles clear.
Poisonous gas, smoke, or fumes could e emitted y some materials you could
use with the machine. In such case, you should install ventilation.
Choking Hazard. This machine contains small parts and
can produce small parts which can e a choking hazard
to children.
Visit http://www.seemecnc.com to contact us if you have any questions.

Rostock MAX v2 Assembly Guide
Table of Contents
READ ME FIRST!.....................................................................................................................................2
0 – Introduction and Acknowledgments....................................................................................................6
1 – Required and Optional Tools And Materials........................................................................................7
2 – isual Bill of Materials......................................................................................................................11
3 – Prepping the Hot End and Power Supply...........................................................................................24
Preparing the Hot End....................................................................................................................24
Preparing the Power Supply...........................................................................................................27
4 – Building the Base...............................................................................................................................31
Installing The Feet..........................................................................................................................33
Preparing the ertical Supports......................................................................................................34
Installing the ertical Supports and Power Supply........................................................................37
Installing the Drive Gears on the Stepper Motors..........................................................................42
Assembling the Tower Supports.....................................................................................................43
Installing the Top Plate...................................................................................................................49
5A – Installing the Rev2 Onyx Heated Bed.............................................................................................51
Installing the Thermistor, LED and Power Wires...........................................................................52
Mounting the Onyx Heated Bed to the Base..................................................................................59
5B – Installing the Rev3 Onyx Heated Bed.............................................................................................62
Installing the Thermistor, LED and Power Wires...........................................................................63
Mounting the Onyx Heated Bed to the Base..................................................................................71
5C – Installing the Rev5/6 Onyx Heated Bed..........................................................................................74
Installing the Thermistor, Power LEDs and Power Wires..............................................................75
Mounting the Onyx Heated Bed to the Base..................................................................................84
6 – Installing the Towers & Tower Wiring...............................................................................................88
Threading the Towers.....................................................................................................................88
Setting the Towers..........................................................................................................................94
7 – Assembling the Top Section...............................................................................................................97
Prepping the Upper Tower Mounts.................................................................................................98
Installing the Upper Tower Mounts................................................................................................99
Installing the End Stop Switches..................................................................................................102
Installing the Upper Tower Mounting Hardware..........................................................................105
8 – Assembling and Installing the Cheapskate Carriages......................................................................106
Assembling the Cheapskate Rollers.............................................................................................106
Assembling the U-Joint Carriers..................................................................................................107
Installing the U-Joints...................................................................................................................110
Installing the Belt Clip T-Nuts......................................................................................................114
Assembling and Installing the Cheapskate Carriages...................................................................115
Adjusting the Cheapskate Carriages.............................................................................................119
9 – Installing the Top Plate and Idler Bearings......................................................................................120
10 – Wiring the End Stop Switches.......................................................................................................124
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Rostock MAX v2 Assembly Guide
Wire Routing.................................................................................................................................126
11 – Installing the Drive Belts................................................................................................................129
Belt Routing..................................................................................................................................130
Installing the Belt Clamps............................................................................................................131
Adjusting the Belt Tension...........................................................................................................136
12 – Assembling the EZStruder and Filament Holder...........................................................................137
Preparing the EZStruder...............................................................................................................138
Mounting the EZStruder...............................................................................................................141
Installing the EZStruder Mount and Filament Holder..................................................................143
Wiring the EZStruder's Stepper Motor.........................................................................................145
13 – Wiring & Assembling the Hot End, Bowden Tube........................................................................148
Preparing the Hot End Wiring......................................................................................................148
Attaching the Hot End to the Hot End Mounting Plate................................................................154
Installing the Bowden Tube..........................................................................................................156
14 – Installing the Effector and Delta Arms...........................................................................................157
Assembling the Effector Platform................................................................................................157
Installing the Delta Arms..............................................................................................................159
15 – Installing the Hot End....................................................................................................................161
16 – Finishing the Top End....................................................................................................................164
Installing the Spool Holder Mount...............................................................................................165
Installing the Top Plate.................................................................................................................168
17 – Assembling & Installing the LCD Panel Mount............................................................................174
Assembling the Front Panel..........................................................................................................175
Installing the LCD Trim Panels....................................................................................................177
18 – Installing & Connecting the RAMBo Controller...........................................................................180
Installing the RAMBo Cooling Fan..............................................................................................181
Mounting the RAMBo Controller................................................................................................182
Soldering the Cooling Fan............................................................................................................183
Assembling the RAMBo LCD Interface Adapter.........................................................................184
Assembling the End Stop Connectors..........................................................................................184
Installing the Hot End Thermistor Connector..............................................................................186
Wiring the RAMBo Controller – Terminal Block........................................................................187
Wiring the RAMBo Controller – Plug-In Connectors..................................................................190
19 – Final Assembly Tasks.....................................................................................................................198
Attaching the Base Covers & LCD Panel.....................................................................................198
Attaching the Power and USB Cables..........................................................................................200
Installing the Acrylic Cover Panels..............................................................................................202
20 – Driver and Software Installation....................................................................................................209
Installing the RAMBo Driver.......................................................................................................209
Installing the Arduino IDE............................................................................................................211
Configuring the Arduino IDE.......................................................................................................212
Test Upload...................................................................................................................................213
Uploading Repetier-Firmware......................................................................................................215
The LCD and Front Panel Controls..............................................................................................217
21 – Installing Repetier-Host and Calibrating the Printer......................................................................220
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Rostock MAX v2 Assembly Guide
Downloading, Installing, and Configuring Repetier-Host............................................................220
Initial Function Tests....................................................................................................................223
Printer Calibration........................................................................................................................226
Setting the Z Height......................................................................................................................233
Adjusting The End-Stops..............................................................................................................235
22 – Tonkabot's Missing Chapter...........................................................................................................240
23 – First Print: PEEK Fan Shroud........................................................................................................241
erifying Extruder Stepper Operation..........................................................................................241
Configuring Slic3r........................................................................................................................242
Loading Filament..........................................................................................................................245
Preparing the Heated Bed.............................................................................................................246
Printing the PEEK Fan Shroud.....................................................................................................247
Installing the PEEK Fan Shroud...................................................................................................248
24 – Second Print: Layer Fan Shroud....................................................................................................252
25 – Repetier-Host.................................................................................................................................256
Appendix A: Quick Disconnects in Your Rostock MAX v2..................................................................266
Wiring the EZStruder Extension Cable........................................................................................266
Wiring the Fans, Hot End, and Thermistor Connectors................................................................268
Installing Connectors on the Thermistor and Heating Resistors..................................................270
Attaching the Hot End to the Hot End Mounting Plate................................................................274
Installing the Bowden Tube..........................................................................................................276
Appendix B: Maintenance and Troubleshooting...................................................................................277
Print Layer Issues.........................................................................................................................278
Machine Won't Move!..................................................................................................................280
Belt Damage or The Delta Arm Blues!.........................................................................................280
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Rostock MAX v2 Assembly Guide
0 – Introduction and Acknowledgments
I’d like to welcome you to the Rostock MAX v2 assembly guide!
Even if you've built an original Rostock MAX v1 3D printer, you'll want to read this manual
carefully. There are no common Melamine parts from the v1 design. The construction has been greatly
streamlined and should prove to be a shorter build. The design changes made will ensure that you've
got a long lasting, easy to calibrate, delta configuration 3D printer.
Please read this entire guide before you begin assembly of your new Rostock MAX v2! It will
help you avoid any unpleasant surprises and will ensure that you’ve got everything you need BEFORE
you need it! Understand that the photographs in this assembly guide do NOT tell the whole story of
each step! Make sure you read and understand the accompanying text for each step!
A quick note on the RAMBo, the controller for your Rostock MAX. The RAMBo is static
sensitive, so please don't take it out of the static bag it ships in until you're ready to use it.
The 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. Note that the connector polarity is clearly marked on the board for
the “MOSFET Outputs”.
Acknowledgments
I'd like to thank the gentleman that runs http://minow.blogspot.com.au/ for his excellent guide
on calibrating delta configuration 3D printers.
I'd also like to thank the whole gang over at the SeeMeCNC forums for providing excellent
feedback. This would be a much lesser creation without their contributions and insights.
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Rostock MAX v2 Assembly Guide
1 – Required and Optional Tools And aterials
Before you begin assembly of your Rostock MAX v2, please make sure you’ve got everything
on the following list of tools and additional materials.
•P1 & P2 sized Phillips screwdrivers
•Standard flat head screwdriver
•3/32” Allen (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
•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
•5/16” open-ended wrench (Used primarily on the nuts that hold the Cheapskates together)
•2 7/16” open end wrenches. (used to adjust Cheapskate Bearings)
•11/16” open-ended wrench (used for hot-end mount)
•PermaTex Ultra Copper High Temp RT
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Rostock MAX v2 Assembly Guide
•A small razor knife like an X-Acto knife. This will be handy for cleaning the flashing off the
injection molded parts.
•1/2” wide roll of Kapton tape
•Uninsulated crimp on connectors, sized for 22-18ga wire.
Radio Shack P/N 640-3036 is an excellent choice.
•A digital caliper. These can be purchased from Harbor Freight tools for around $10.
•A small squeeze clamp that can open at least 2”
•Crimping tool (Jameco P/N 159266 is a good choice)
•Battery powered screwdriver. If you ever needed an excuse to buy one of these, THIS IS IT.
•Pencil.
•40W Soldering Iron.
•Blue thread locking compound (Loctite or Permatex Threadlocker Blue)
•A small file.
•Elmer's Glue Stick – must be marked “Disappearing Purple”.
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Rostock MAX v2 Assembly Guide
The following is a list of optional things that can make your life easier in the long run.
•Electrician's tape.
•Waxed lacing cord. You can use this in place of wire ties in pretty much any application. You
can 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. :)
•.100” (2.54mm) Latching Polarized Male Housing (1x4) and matching crimp pins. This is used
to add a connector to the end of the EZStruder extension cable and makes life a lot easier. You
can purchase 2 of these connectors and their associated crimp pins from Hansen Hobbies
(http://www.hansenhobbies.com/products/connectors/pt1inlpconnectors/pt1in_lp_1x4/) very
inexpensively. The link for the pins is shown in the description for the male housing.
If you want to be able to change your hot end easily, I would highly recommend getting quick-
disconnect connectors for the hot end as well as the PEEK and layer fans.
For the hot end, I'd recommend these four connectors:
This is a four pin, latching polarized male connector housing. This should be
used on the hot-end heating resistor wires and thermistor wires. I'll illustrate the
correct installation in the chapter that covers those steps.
This is a four pin, latching polarized female connector housing. This should be
attached to the wires coming from the power supply. The female connector is
used here in order to prevent accidental shorting of the power and thermistor
leads. Some of these are included in the RAMBo box.
This is a female JST connector. These are very nice connectors for both the
PEEK and layer fans. These would be fitted to the power leads of the fans.
This is a male JST connector. Just as with the male hot end connector, these
would be attached to the power wires coming up from the RAMBo.
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Rostock MAX v2 Assembly Guide
The use of these connectors is entirely optional! This is how I like to rig my printers and it's
entirely okay to not do this. The pre-assembled printers from SeeMeCNC don't include these
connectors, so don't feel obligated to use them. Now that being said, having a quick-disconnect hot end
is just cool. :)
The JST connectors can be purchased from Hansen Hobbies as well – just make sure you order
the right pins! Read the description pages carefully.
The JST connectors can be found here:
http://www.hansenhobbies.com/products/connectors/miscconnectors/
The Latching Polarized connectors can be found here:
http://www.hansenhobbies.com/products/connectors/pt1inconnectors/
If you don't already have a crimping tool, the one shown above will do the job, but the best
choice would be a ratcheting crimp tool like this one from Pololu: http://www.pololu.com/product/1928
That's the tool that I use on my projects. It's reasonably priced at $34.95.
There was a great discussion on the SeeMeCNC forums recently on how to properly use this
kind of crimping tool. I recommend you check it out if you haven't used this kind of tool before.
http://forum.seemecnc.com/viewtopic.php?f=36&t=4342
As an additional resource, Hansen Hobbies has produced an excellent wire crimping tutorial
here: http://www.hansenhobbies.com/products/connectors/Connectors.pdf
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Rostock MAX v2 Assembly Guide
2 – Visual Bill of aterials
Your Rostock MAX v2 kit should contain four laser cut Melamine sheets, a large box
containing hardware, injection molded parts, the RAMBo controller and the required wiring. The box
will also contain a 450W ATX style power supply.
The Melamine parts are held in place with masking tape in order to protect them during
shipping. The parts are also covered with a special cutting mask that prevents the laser cutting
operation from depositing cutting residue on the Melamine surface. You'll need to remove all of this
material before beginning construction.
Included in the three laser cut sheets is an
additional smaller sheet that contains a component
that's part of the printer's upper section, as seen in
Fig. 1-2.
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Fig. 1-1: Shipping box contents.
Fig. 1-2: Laser cut parts.

Rostock MAX v2 Assembly Guide
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 out from the front of the sheet. The
front and back of the sheet is easily identifiable – the front of the sheet will have very dark laser cut
lines with “flash” deposits to either side of the laser cut line. The back of the sheet will have much
fainter marks.
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Fig. 1-3: Sheet #1 parts.
Fig. 1-4: Sheet #2 parts.
Fig. 1-5: Sheet #3 parts.

Rostock MAX v2 Assembly Guide
The cardboard box contains all the non-melamine components required to build 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
[email protected] with the subject line of “Missing Parts!”. Note that the uantities shown in
the photographs may not necessarily match the uantity listed to the right. When it doubt, follow the
uantities listed in the text!
For those that aren't sure how to identify the various screw types, Bolt Depot has made available
some excellent references. I would recommend Fastener Basics (http://www.boltdepot.com/fastener-
information/Printable-Tools/Fastener-Basics.pdf) and their Fastener Type Chart
(http://www.boltdepot.com/fastener-information/Type-Chart.aspx).
Hardware Package #1
Rubber foot pack. Contains 6 each of the following components:
(___) #10-32, 5/8” Nylon Pan Head Screws
(___) #10-32 Nylon Finish Nuts
(___) Injection molded legs (black)
(___) Soft rubber feet
(___) 9 each, #10-32, 3/4” Knurled Nylon Thumb Screws.
These are for the right & left base covers as well as the LCD panel.
(___) 4 each, #6-32, 1/2” Slotted Pan Head Screws (Nylon).
These are used to mount the 450W ATX power supply
(___) 31 each, #6-32, 1” Phillips Pan Head Screws. Used for general
assembly.
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Rostock MAX v2 Assembly Guide
(___) 6 each, #6-32, 5/8” Socket Head Cap Screws. Used for mounting
the U-Joint plates to the Cheapskate plates.
(___) 12 each, #6-32, 1-3/4” Phillips Pan Head Stainless Steel screws.
Used for 608 idlers in the motor mounts as well as the hot end standoffs.
(___) 63 each, #6-32 Stainless Steel Nylon Lock Nut – covers all #6-32
screws.
(___) 14 each, #6-32, 2” Phillips Pan Head Stainless Steel screws. Used
for Cheapskate plates and EZStruder mount.
(___) 15 each, #6-32, 1/2” 18-8 Stainless Steel Flathead screw. Used
inside of base and top side plates, to retain acrylic panels and the three
end-stop triggering screws installed in the Cheapskate U-Joint mounts.
(___) 25 each, #¼-20, 1/2” Stainless Steel Button Head Cap Screws.
Used for T-Slot mounting.
(___) 25 each, #¼-20 nut plates. Used for T-Slot mounting.
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Rostock MAX v2 Assembly Guide
(___) 10 each, #4-40 T-Nuts. Used for belt clamps and RAMBo
mounting.
(___) 4 each, #4-40, 3/4” Phillips Flat Head Machine screws. Used for
mounting the RAMBo Controller.
(___) 6 each, #4-40, 1/2” Stainless Steel Socket Head Cap screws. Used
for the belt clamps.
(___) 14 each, #2-56, 5/8” Pan Head Phillips Machine screws. Used for
LCD mounting and end-stop switch mounting.
(___) 14 each, 2-56 Finish Nuts. Used for LCD mounting and end-stop
switch mounting.
(___) 14 each, #4, 3/8” Phillips Pan Head Sheet Metal screws. Used for
LCD sides and tower alignment guides.
(___) 12 each, M3x.5, 10mm Pan Head Machine screws. Used for
mounting the stepper motors.
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Rostock MAX v2 Assembly Guide
(___) 18 each, #6 Stainless Steel Flat washers. Used on the 608 bearings
that go in the top & bottom t-slot rails.
(___) 6 each, #4 Stainless Steel Flat washers. Used with the belt clamp
screws.
(___) 21 each, 608ZZ Ball Bearings. Used in the Cheapskates and belt
idlers.
(___) 1 each, #10-32, 5/8” Socket Head Cap Screw. Used as a tap for the
#10-32 Nylon thumb screws.
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Rostock MAX v2 Assembly Guide
Hardware Pack #2
(___) 18 each, 608 Cheapskate Idler Bearing Spacer. Used for belt idlers.
(___) 12 each, 608 Cheapskate Carriage Bearing Spacers (black).
(___) 12 each, 608 Cheapskate Eccentric Bearing Spacers (gray).
Your kit may include Acetal u-joints instead of the machined aluminum
version. In that case you will NOT have the aluminum ones listed below.
(___) 12 each, Universal Joints (Injection Molded Acetal)
(___) 12 each, Universal Joints (machined aluminum).
(___) 6 each, 3-1/8” Steel Universal Joint axle shafts.
(___) 3 each, 1” long machined aluminum hot end platform spacers.
Hardware Pack #3
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Rostock MAX v2 Assembly Guide
(___) 10 each, Plastic Bearing Rollers. 4 are used for mounting the
RAMBo and six are used for the belt clamps.
(___) 12 each, Wire ties. Used for wire management or Barbie
Handcuffs.Your call.
(___) 1 each, GT2 2mm pitch belt pulley pack. Includes six grub screws
and hex wrench.
(___) 3 each, Carriage base for U-Joints. Outer tabs have been removed
to allow for spring clips.
(___) 1 each, Effector Platform (spring clip style).
(___) 6 each, U-Joint Spring Clips.
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Rostock MAX v2 Assembly Guide
(___) 1 each, 15 Tooth Gear. Used for manually operating extruder
motor.
(___) 6 each, Binder Clips. Used to hold the Borosilicate glass build
plate to the Onyx heated bed.
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Rostock MAX v2 Assembly Guide
Rostock MAX v2 Electronics and Hardware Pack #4
(___) 1 each, RAMBo Electronic Control Board with screw terminals and
end stop wires.
(___) 1 each, USB Cable.
(___) 1 each, Onyx Heated Bed Kit.
(___) 1 each, LCD Smart Controller with SD card, LCD to RAMBo
Adapter Kit and 1 Soft Touch 5mm knob.
(___) 4 each, NEMA 17 Stepper Motors (4800cgm holding torque). Used
for three motion axes and extruder drive.
(___) 1 each, Rocker switch, including spade lug crimp terminals.
(___) 1 each, 25x25x10mm 12 DC fan. Used to cool the PEEK section
on the hot end.
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