Build From Kit

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THESE INSTRUCTIONS ARE VERY PRELIMINARY (but should help for those wishing great detail) Image references are from: Additional images yet to be indexed:

Gigabot 2.0 Assembly from Parts Pack

The Basics

Tools and Parts

Tool Picture from Flat pack DSC 0916

Step 1 - Coordinate System and Terminology

Need picture with coordinates identified Left and Right if facing the completed bot Front or Rear / Upper or Lower BHCS - Button Head Cap Screw SHCS - Socket Head Cap Screws

Step 2 - T-Nut Instructional

Use video and instructions from flat pack

Step 3 - Base Assembly Preparation 

Locate 4 Corner Plates with no identifiers or logos. Insert an M5 x 8mm BHCS in all 7 holes and fasten loosely with T-nuts. (DSC_0929)

Locate 4 Triangle Braces. Insert 2 M5 x 12mm BHCS in each Triangle Brace, use 2 M5 washers per BHCS. Loosely fasten a T-nut on the opposite end. (DSC_0935)

Locate 2 Cross rails (33.5” extrusion that has 2 tapped holes on each side ). Note: DO NOT use Cross rails with “Gigabot” label until instructed to. This will be the bottom/back Cross portion of the frame. (DSC_0925)

Assembly of Frame

Step 4 - Base Assembly - Rear/Lower Rail 

Install 2 Corner Plates to each end of of one Cross rail (this will be the rear/lower cross rail) Slide in Corner Plate with T-nuts loosened, ensure edges are lined up, bracket edges are flush with the bottom and end of each rail … fasten down the bolts to secure. (DSC_0931)

Insert 2 T-nuts in what will be the top channel of rail (DSC_0934)Secure for temporarily with 2 M5 x12mm BHCS and 2 M5 washers per BHCS . (These will be used later to fasten vertical rails that hold the power box)

Fasten Triangle Brace to each end of rail (lower channel). Place near end and keep T-nuts loose for now to allow for adjustment (DSC_0937)

Step 5 Base Assembly – Rear / Lower Cross Rail Panduit Installation

Locate 30.5” length Panduit.

Fasten 3 M5x8 mm BHCS and 3 T-nuts to the Panduit piece. (DSC_0970)

With bolts loose slide the Panduit to the top inside channel of the rail. Tighten bolts. (DSC_0973) Use this final picture to ensure proper orientation of 2 T-nuts on upper channel corner Triangle braces with respect to Corner plates.

Step 6 Base Assembly – Side Plate/Rail Preparation 

Locate 2 Side Plates and observe orientation of bolt hole patterns. (DSC_0918) Locate 2 Common Rails Locate 2 12” Panduit pieces (shallow Panduit)

On each side plate insert 4 M5 x 8mm BHCS, loosely put on T-nuts ((DSC_0920) The 4 BHCS should be inserted in opposing directions on each plate (see pic for orientation of front

Slide 1 common rail on what will be inside of each side plate. Center the rail. (DSC_0924)

Step 7 Base Assembly – Side Plate/Rail Preparation 

Install Panduit on each side rail - Fasten 2 M5x 8mm BHCSs and 2 T-nuts to the Panduit piece. With BHCSs loose slide the Panduit to the top, inside channel of the rail. DO NOT tighten bolts at this time. Repeat for other side. Picture shows orientation. (DSC_0979)

Insert 2 T-nuts into the top channel of each Common Rail installed on the side plates In the same picture these T-nuts can be seen in the top channel near the end of the Panduit

Step 8 Base Assembly  & Front/Lower Cross Rail Preparation

Orient each slide rail on table and connect with the Rear / Lower Cross Rail assembled in Steps 5 & 6. (DSC_0976)

With all BHCSs still loose in corner, square the corner and screw in 2 M5 x 12mm BHCSs on each end of the Cross rail. (these are the 2 tapped holes on each end of the rail) (DSC_0977)

Assemble Front/Lower Cross Rail (similar to rear assembly, using parts already located) Install 2 Corner Plates to each end of Cross rail - Slide in Corner Plate with T-nuts loosened, ensure edges are lined up, bracket edges are flush with the bottom and end of each rail … fasten down the bolts to secure.

Fasten Triangle Brace to each end of rail (lower channel). Place near end and keep T-nuts loose for now to allow for adjustment(DSC_0937)

Step 9 Base Assembly – Installing Front/Lower Cross Rail

Position front/lower Cross rail assembly in front to complete the square of the frame base. Square the corners without tightening any bolts. Insert 2 M5 x 12mm BHCs thru the side plates into the ends of the Cross rail (these are the 2 tapped holes on each end of the rail). Do not tighten yet. (DSC_0979)

Square up frame and then tighten bolts in this order: While compressing the front to back of each side, tighten M5 x 12mm BHCs (4 /side or 8 total). Next tighten M5 x 8mm bolts on each side plate. (4 /side or 8 total) Next tighten both bolts in each of the 4 triangle braces. While tightening make sure to pull brace into the corner to ensure it is flush against each Cross and Common rail (8 total) (DSC_0980) (DSC_0981)

Step 10 Z-Upright Preparation and Installation

Locate the 4 Z-Uprights. These have the notch cut on one end.

Insert 6 M5 x 8mm BHCSs in each bottom side plate (DSC_0979) Attach T-nuts, leave loose.

Install each Z-upright with the notch facing up and inside frame. After the extrusion is in place, center it with respect to the bolts (while loose move back and forth and feel for the center position). Square each one at a time and tighten bolts. (DSC_0954) (DSC_0983)

Step 11 Z- Upper Side Plate assembly preparation

Locate 2 Side plates. Insert 10 M5 x 8mm BHCSs with T-nuts into each side plate. These will be used to fasten to the Z-uprights. (DSC_0959)

Locate 2 Runway Rails (Y-axis). Note: each rail has a single hole on one side and 2 holes on the other.

Slide one Runway Rail to each side plate. See picture and note location of holes on the Runway Rails with respect to the hole pattern on the side plate. (DSC_0960) (DSC_0961)

Step 12 Z- Install upper side plate assemblies

Slide right plate onto vertical supports. Leave BHCSs loose. (DSC_0961) (DSC_0962)

Slide left plate onto vertical supports. Leave BHCSs loose.

Insert 2 M5 x 8mm BHCSs into remaining 2 holes at each end of each bottom slide plate. (8 total)

Insert 2 M5X8 bolts into 2 holes (mirror to holes from previous step) at each end of each top slide plate. See picture. (8 total) (DSC_0965)

Step 13 Install 4 Vertical Supports (Common Rails)

Locate 4 Common Rails – (vertical supports for each corner of frame) Locate 1 31.5” Deep Panduit Locate 1 31.5” Shallow Panduit

For each corner – slide common rail vertically down starting at top of frame. (DSC_0967) Starting with the 2 T-nuts at top corner on the side plate, slide down the rail to mate up with the 5 exposed T-nuts in each corner. Once in place, loosely tighten up 5 BHCSs in each lower corner (3 BHCSs on Corner Plate and 2 BHCSs on Side Plates). (DSC_0984) Do not fully tighten.

Install Panduit on each vertical rail - Note: Shallow Panduit for right support and Deep Panduit on left support. (DSC_0992)

Fasten 3 M5 x 8mm BHCSs and 3 T-nuts each Panduit piece. With bolts loose slide the Panduit to inner channel of the vertical. Tighten bolts at this time.

Step 14 Preparation for Front & Rear / Upper Cross Rails

Locate 4 Corner Plates Note: 2 of these are unique. 1 has the Gigabot logo and 1 has the Serial number.

Locate 2 Cross rails (33.5” extrusion that has 2 tapped holes on each side ). Note: If one of the 2 remaining Cross supports located has a “Gigabot” label, this Cross rail will be used for the front.

Insert an M5 x 8mm BHCS in each of 7 holes of each of the 4 Corner plates and fasten loosely with T-nuts. (DSC_1002)

Step 15 Assemble and attach Upper Cross Rails

Front Cross Rail Preparation: Slide in Corner Plate with T-nuts loosened. Ensure edges are lined up, bracket edges are flush with the edge and end of each rail … fasten down the bolts to secure. Note: Attach the re:3D Logo Corner plate to the left and blank Corner Plate to the right.

Rear Cross Rail Preparation: Prior to installing corner plate, 2 T-nuts on the outside/upper channel and 1 T-nut to the outside/lower channel. Attach the rear filament guide / bracket. (DSC_1003)

Attach the Serialized Corner Plate to the left and the blank Corner Plate to the right. Ensure edges are lined up; bracket edges are flush with the edge and end of each rail. (DSC_1002)

Place 2 T-nuts in the bottom channel of rear / upper cross rail. Note: when this Cross Rail is installed these T-nuts will mirror the 2 T-Nuts on the bottom Cross Rail. Secure with 2 M5 x 12mm BCHSs and 2 washers each.

Slide in rear and front Cross rail assemblies to the respective sides of the frame from the top. Do not tighten. (DSC_0994)

Step 16 - Panduit and Complete top of Frame

Install Panduit on right plate. Use 7” length “shallow” Panduit for right support For this installation hold Panduit in position and insert 2 M5 x 8mm BCHSs from outside and fasten with 2 M5 hex nuts from the inside. Tighten bolts at this time. (DSC_0997)

Insert 2 M5 x 12mm BCHSs bolts thru side plates into end of each Cross rails (8 total) DO NOT tighten. (DSC_0998)

Insert 3 M5 x 45mm BCHSs on each side of top side plate. 2 go thru side plate and Runway Rail (Y-axis), near the rear of frame and 1 goes thru side plate and Runway Rail (Y-axis), near the front of frame. Placement is to ensure frame is aligned. These bolts will be removed in later step and will be used to attach the Y-Axis motors. (DSC_1000)

Ensure top of Runway Rails (Y-axis) matches the top of the corner uprights then tighten bolts in this order (this is a 2 person operation): While compressing the front and rear of each side, tighten M5 x 12mm BCHSs (8 total). Next tighten 4 M5 x 8mm BCHSs on each side plate. (8 total) Next tighten 3 loose bolts in each of the 4 corner plates. Next tighten all bolts on the mid section of the side plate (10 each side) Remove the 3 M5 x 45mm BCHSs from each side

At this point all bolts on the frame should be tight. The frame should be square.


Step 17 - Z-axis Rod assembly preparation

Locate: 2 Lower Bearing Blocks, 2 Upper Bearing Blocks, 2 Z-rods, Z Motor Pulley, 2 XML Belts (Z-axis), 2 ACME threaded rods, 2 threaded rod pulleys

Install the Lower bearing blocks on each side (right and left). Use the 2 T-nuts already installed and 2 M5 x 12mm BCHSs. Position as shown in picture. Keep bolts loose. (DSC_1005)

Install nut cup on ACME Rod towards bottom of rod (end with 2 flat edges on tip). See picture for orientation of nut cup. (DSC_1007) Repeat for second rod.

Step 18 - Z-axis Rod assembly installation

Repeat the following for left and right side: Install Z motor pulley on same end of ACME rod. (end with 2 flat edges on tip) Tighten 2 set screws against the flat edges of Z-rod. Loop XML belt around pulley (DSC_1009) Install this Z-rod subassembly by first inserting pulley end into lower bearing. Install upper bearing block onto Z-rod subassembly. Using 2 M5 x 12mm BCHSs, fasten the upper bearing to the inside of the side plate. Tighten. (DSC_1010) Prior to tightening the lower bearing block “eyeball” the vertical alignment by using the two sight holes on the bottom side plate (see picture). DSC_1013) Tighten.

Step 19 - Z-Axis Motor Installation

Locate 2 Stepper Motors with ground shaft, 2 Z-motor shelf, 2 Z-motor pulleys, 8 M3 x 8 mm Socket Head Cap Screws (SHCS), 8 M3 washers, 4 M5 x 8mm BCHSs DSC_1016)

Repeat the following instructions for left and right Z-axis motor installation. NOTE: Use picture to properly orient the Z-motor shelf with respect to motor. Left and right orientations are different.

Put shelf in place and attach with 4 M3 x 8 mm SHCSs using 1 washer per screw. Leave screws slightly loose to allow for slop during belt installation. DSC_1017)

Install Z-motor pulley per picture, tighten set screw against flat part of shaft. When installed you should be able to feel the shaft of the motor just barely extending beyond the pulley. DSC_1018) Position motor assembly in installation location, slip belt around the pulley. Fastens shelf to side plate using 2 M5 x 8mm BCHSs. Tighten down. Pull motor away from Z-rod assembly to put tension on the XML Belt (Z-axis) and tighten down the 4 M3 x 8 mm SHCSs . DSC_1019)

X and Y Axis

Step 20 - V-Groove Wheel  Instructional (Generic)

Use Video

Step 21 - Bridge Assembly, endtruck subassembly

Locate: Left and Right endtruck plates, 8 V-groove wheels, 4 round spacers, 4 eccentric spacers, 8 M5 x 25mm BCHSs, 8 M5 washers

NOTE: see picture to distinguish left vs. right plate and clocking of round spacers vs. eccentric spacers. DSC_1021) V-Groove wheels with round spacers are inboard (right side of Left assembly and left side of the Right Assembly in the picture) Although pictures may show 4 V-Groove wheels installed, initially only install the V-Groove wheels with round spacers.

For each V-Groove wheel installation; install bolt thru V-groove wheel and then the round spacer. Then attach to plate and fasten using 1 M5 washer and 1 M5 x 25mm BCHS. Tighten down. At this time only attach the round spacer wheel assemblies. DSC_1024)

Step 22 - Bridge Assembly

Locate Bridge Rail (X-axis)

Attach the Right end plate to rail using 2 M5 x 12mm Flat head screws. See picture for orientation. Make sure rails on extrusion are facing the slot on the plate. Attach the left plate in a mirror fashion. DSC_1031)

Step 23 - Belt subassembly preparation Part 1

Belt sub assemblies (3 total belts – 2 longer belts are for Y-Axis, 1 shorter belt is for X-Axis)

Locate the 2 Bridge Belt (Y-axis) (equal length) and 1 Trolley Belt (X-axis) , 3 Threaded tensioner blocks, 3 Un-threaded tensioner blocks, 3 M6 x 60mm BHCSs, 3 M5 x 20mm Flat head screws (DSC_1033)

Note: When this sub-assembly is complete the head of each M6 x 60mm BHCS in the picture is adjacent to un-threaded tensioner block.

Attach belt ends , 1 to threaded and 1 to un-threaded (see picture) by bending over the belt and squeezing into slot. Make sure there is no more than ¼” of the belt end protruding from the block. (DSC_1034) Make sure belt is not twisted when attaching each end.

Step 24 - Belt subassembly preparation Part 2

Use the 4 mm Allen wrench to expand the hole in the belt opening (DSC_1036) Press in a M5 x 20mm Flat head screw into hole and screw in completely so the head of the screw is flush. (DSC_1037) Repeat tensioner block installation for each of the 3 belts. (DSC_1038)

Put aside the Timing Trolley Belt (X-axis) for now.

Step 25 - Y-Axis Stepper Motor / Mount and belt installation

Locate 2 Stepper motors (ground or ungrounded shaft?), 2 motor mounts, 2 Black GT2 timing pulleys (plastic), 8 M3 x 8mm SHCS (DSC_1040 )

Note: the left and right Y-Axis motors are assembled in unique orientation.

Place Pulley on shaft and fasten. The shaft should be level with the bottom of the bevel on the pulley. (see picture) Attach the blocks using the 4 M3 x 8mm SHCS (see picture for orientation of block for left and right side)

Install belt onto motor. Note: Use pictures to ensure proper orientation of the tensioner. Bolts should face internal. (DSC_1045) (DSC_1046)

With the teeth facing in, pull the belt around the pulley thru the gap in the motor block (see picture). It is best to pull belt and push down at same time to get belt to slip in place between the pulley and motor block.

Step 26 - Y-Axis Stepper Motor Installation

Locate: 2 idler wheels

Attach left Y-axis motor using 2 M5 x 45mm BHCSs to rear left corner of frame. Fully tighten DSC_1048 Install idler pulley, place bolt thru side plate and sandwiching the pulley with 2 M5 washers (between plate and pulley) and 1 M5 washer between pulley and M5 nut. Tighten down. DSC_1050

Note: Pulley is oriented with recessed end facing internal to the Gigabot

With Bridge assembly placed on the Y-axis rails install the tensioner blocks to the side plates of the bridge. Use 2 M5 bolts to tighten the tensioner to the bridge side plate (using the screws protruding thru the tensioner blocks). DSC_1052

Pull the belt around the idler pulley.

Repeat for right side

Step 26 - Y-Axis Stepper Motor Installation

Locate: 2 idler wheels

Attach left Y-axis motor using 2 M5 x 45mm BHCSs to rear left corner of frame. Fully tighten DSC_1048 Install idler pulley, place bolt thru side plate and sandwiching the pulley with 2 M5 washers (between plate and pulley) and 1 M5 washer between pulley and M5 nut. Tighten down. DSC_1050

Note: Pulley is oriented with recessed end facing internal to the Gigabot

With Bridge assembly placed on the Y-axis rails install the tensioner blocks to the side plates of the bridge. Use 2 M5 bolts to tighten the tensioner to the bridge side plate (using the screws protruding thru the tensioner blocks). DSC_1052

Pull the belt around the idler pulley.

Repeat for right side

Step 27 - Eccentric wheel install on end trucks

Get to know your wheels – insert new video Get wheel info Install eccentric wheels Note to make sure eccentric spacers are inserted and fully seated into the hole

Step 28 - Assembly of Trolley Plate

Install Extruder shelf onto trolley plat using M5 X 12 Flat head Install two wheels with round spacers using M5 nut and one M5 washer per wheel Attach tensioner to trolley plate using 3rd belt from step XX Hang trolley plate on the bridge rail Attach eccentric wheels using M5 nut and one M5 washer. While attaching make sure belt is between the wheels

Attaching the x pulley idler Refer to picture from other idler for parts and orientation

Attach idler pulley. Tighten down (make sure pulley is oriented so depression is outside with 2 washer and nut

X-motor installation

Locate stepper motor with ground shaft, block, 4 bolts Tighten mount using 4 bolts, tighten. Attach pulley (same as Y motors)

Attach belt to motor mount / pulley Attach motor to bridge rail with two M5 X45mm BHCS

Adjust eccentric wheels on trolley and end trucks to ensure contact of wheels to the rail while also maintaining smooth motion. Using 8mm wrench and allen wrench turn spacers and feel for good contact. Tighten nut to lock in the proper clocking of the eccentric spacer.

Manually move bridge rail back and forth checking for smooth motion and good contact of wheels to the rail. Repeat for trolley and adjust eccentric spacers as needed.

Next tighten the X and Y belts using the 4 mm allen wrench turn bolt on tensioner. Belts should be in tension but ???

Electrical System

Installation of Terminal Box

Remove screws securing box cover and set aside cover. Inside box should be a terminal strip secured by 2 M3 X 18mm SHCS

Advance these bolts by ~6 turns, enough so that when placed on trolley plate bolts protrude thru back of plate. Carefully place front filament guide on opposite side of trolley plate. Ensure the tapped holes on the extruder guide match the picture, and are offset toward the right. Holding box and guide in place, tighten the 2 bolts.

Temporarily , reattach box cover.

Extruder Assembly – gear and motor assembly

Locate extruder parts – 2 baggies, 1 with brown or black plastic parts and 1 with met

To assemble these items use instructions at:

Note: Use 3rd stepper motor ground shaft for the extruder assembly

Hot End Sub-assembly 

To assemble these items use instructions at:

get youtube link

Cut 15 inches of wire and use this for next set. See pic for final sub assembly.

Attach extruder to trolley / extruder shelf

Insert hot end through shelf and lock into place using wooden spacer.

Place extruder on shelf and attach using 2 M5 X 25 BHCSs. Keep bolts slightly loose. Attach fan by wedging in metal plate between the wooden spacer and the extruder shelf. Fully tighten BHCS.

Before next step be sure to identify fan wires (red and black). Use small piece of tape.

Cut 6 in. of Spriralite starting at bottom, use spiralite to constrain both the thermistor and heater wires. Using 2 Zip ties attach this to the trolley plate (see pictures) Snip off ends of unused zip tie.

(keep frame on table for now)

Electrical Box Preparation (installation of common rails)

Locate 2 common rails (last 2 remaining rails), power box w/ wires and viki and 4 M5 x 8mm and 4 T-nuts.

Using fingers, needle-nose pliers or hemostats put M5 BHCS into the holes inside power box. Put on T-nuts on each bolt (2 turns). Slide common rail on to T-nuts using outside T slot. Common rail edge and power box side should be flush. Before tightening, slide rail to within 3 inches of base of power box (side with black wire bundles) Repeat for second common rail. Fully tighten all 4 BHCSs

Electrical Box Preparation (common rail hardware installation)

Locate 4 triagular braces. 8 M5 x 12 mm, 16 M5 washers Attach triangular braces to outboard end of each common rail, using 2 washers on each 12mm M5 screw. Attach bottom triangular braces so that they are flush with bottom edge of rail ends. Prior to attaching upper triangular braces, insert 2 T-nuts to outboard T slot of each common rail. (these will be used later to fasten the filament spool holder). Attach top triangular braces such that they do not extend beyond the rails, temporarily tighten in place.

Prepare Panduit – Locate 31.5” Deep Panduit. Attache 3 M5 x 8mm BHCSs with T-nuts (loosely attached). Prepare Filament Rod Holders – Install 2 M5 x 12 w/ 2 washers per BHCS and T-nut loosely fastened

Pick up power box with rails and place in rear of frame. Start by aligning bottom end of rails to cross rail. Cleats on edge of triangular braces should catch into the top T slot of lower cross rail.

Prior to fastening upper triangular braces and while holding assembly in place insert Panduit from top on internal T slot on the left common rail. (see picture). Next insert the Filament Rod holders into the outside T slot.

Position top of common rails into position

Fasten upper triangular braces in this order: 1. Loosen BHCS going into the common rail (vertical rail). 2. Slide triangular brace up to contact cross rail 3. Tighten BHCS going into the upper cross rail 4. Tighten BHCS going into the common rail (vertical rail) 5. Repeat for other upper triangular brace

Fasten bottom triangular braces ensuring good contact to both the common (vertical rail) and cross rail.

Slide each filament rod holder to a position 8” from top and tighten BHCSs.

Run Wiring

Note: All wires are labeled on ends.

Pull all wires into center of frame except for the USB cable and power cable. (see picture)

Motor cables (black 6 wire)

Remove tooth on Panduit to allow for cables to X –axis Pull X motor cable thru deep panduit on vertical cross rail. Pull Ext motor cable thru same slot

Y L and Y R thru vertical Panduit on rear of left and right side of frame. Connect Y motor connectors to Y stepper motors..

Z R / Z L thru left and right. Connect Z motor cables to Z stepper motors.

Limit Switch wires (grey) Run Ext Limit wire up thru deep Panduit (same used for X Motor and Ext Motor) Run X limit up wire up thru deep Panduit (same used for X Motor and Ext Motor)

Run Y limit wire up left (short Panduit) Run Z limit wire up right (short Panduit)

Install limit switches

Z-limit switch On top right side panel put in 2 M2 x 18mm SHCSs and electrical isolator , insert limit switch and fasten with 2 M2 washers.

X Limit switch install – using �2 M2 x 10mm SHCSs�, fasten limit switch to motor mount block of X-axis motor on the left endtruck.

Y Limit switch install - using �2 M2 x 10mm SHCSs�, fasten limit switch to motor mount block of left Y-axis motor

Limit switch connections (all 3) For all limit switches connect the red wire to the center post. Connect the black wire to the post adjacent to the fulcrum of the lever. (see picture)

Ensure both Y and both Z motor connections in place

Extruder Wire Containment

Position bridge towards back of frame Connect X -axis stepper motor cable Connect Ext stepper motor cable

Locate 6” steel rod Cut 9 “ section of Spiralit

Place one end of the steel rod adjacent to front edge of the left endtruck. Holding the X-limit switch and the X-axis stepper motor cable together with the steel rod, wrap the spiralite around.

Once completely wrapped, zip tie this bundle to the left endtruck using 2 zip ties and holes located on the top of the endtruck. Snip the extra tie off once fastened in place.

After this step put a slight bend in the steel rod (see picture). This will ensure the bundle clears the Y stepper motor and limit switch in the home position.

Electronic Box – Wiring

Note: “left” and “right” terms are still in reference when looking at the frame from the front.

Take back cover off of terminal box. Remove the right cable grommet. Insert heater / thermistor wire bundle thru grommet. Pull wires through right opening and pull thru. Loosely screw back in the right grommet.

Install wires (6) into the top row of screw terminals using diagram as a guide. For each wire loosen the screw terminal, insert wire or post and tighten screw. (If this is difficult then it is okay to remove terminal strip by loosening the 2 SHCSs)

Need picture for wire connectivity

Insert the head wire bundle thru the left grommet. It is best to do this by inserting 2 wires at a time. Then push the same wires (2 at a time) through the left grommet pass through on the box. Pull through enough wire to allow connection to the terminal block.

Connect the wires using the same method, this time to the bottom row of the terminal block.

Put the back cover back on the junction box.

Extruder Wire Bundle Containment

Position extruder head to front right of frame

Look down filament guide hole on filament guide shelf (installed during terminal box attachment). Ensure hole is directly above filament entrance to extruder. If it is offset, remove terminal box and flip filament guide shelf such that filament will guide directly into extruder.

Locate push fittings (2) from snappy box.

Screw one plastic push fitting into filament guide shelf, and one into rear filament guide shelf. Push plastic filament guide into each of the push fittings.

Install filament guide rod (with curved end) through bottom of rear filament guide shelf. Loop hook around a M5x12mm BHCS and tighten.

Starting ~3 inches from extruder head, wrap extruder motor and limit switch wires, and head wiring with Spiralite. At center of wire bundle loop, X-motor and X-limit switch wiring will enter Spirilite bundle. Filament guide rod will also enter bundle. At ~2 in from rear filament guide shelf, plastic filament guide and filament guide rod will exit spiralite bundle. Continue wrapping remainder of bundle until reaching ~6 inches inside Panduit track.

Use two 4 inch lengths of spirilite to constrain x motor and x limit switch cabling at convenient points in the bundle.

Bed Assembly 

Locate 2 bed side plates, 2 bed cross rails, 8 V groove wheels, 8 M5 x 25mm, 4 M5 x 45mm, 3 blocks, 3 square leveling blocks, 1 limit switch leveling block, 4 round spacers, 4 eccentric spacers, 20 M5 X 12mm, ~20 M5 washers, 4 leveling springs, 12 M5 washers, 4 M5 X 8mm, 4 bed plate angles, 8 T-nuts, 4 Flat Head x 20mm

!! Place 2 T-nuts into top T Slot Note: Bed plat angle holes are unique. For the next step use the holes that are centered to attach angles to the rail. Using M5 x 8mm fasten 2 bed plate angles to each bed cross rail. (see picture)

Attach 2 round spacer wheel sets to the back end (closest to notch in plate). Place washer between plate and nut. Tighten down.

Attach leveling block using 2 M5 X 12mm, tighten down.

Attach nut, block, spring, washer, then T-nut to M5 x 45mm BHCS (need new picture)

Repeat above for second square leveling block. Attach this to the front side of bed plate, again using 2 M5 x 12mm BHCSs.

Install left bed plate to back bed rail by first inserting T-nut to bottom T-slot of rail. Then position end of rail to bed plate to line up 2 threaded holes on end of rail with with 2 holes on plate. Fasten w M5 x 12mm BHCSs and washer. (need new picture)

Repeat for above for front side of left plate

Place 2 T-nuts in top T slot of front rail and attach bed angles on front rail.

Repeat the above step/steps for the right side plate. With one exception, for the right plate a limit switch leveling block for the back / right position (instead of the square leveling block) will be installed.

Attach Bed Plate to Frame

Position bed assembly in the frame, resting the notched area on the Z-axis stepper motors.

Position the nut cup assembly by turning do align holes with bed plate sides. Using 2 M5 x 12mm, attach nut cups to sides. Hand tighten.

Attach 1 V-groove wheel using round spacers to the top / front edge of each side plate.

Turn both Z-rods (threaded acme rods) to lift the bed plate assembly off of the Z-axis stepper motors. Lift the bed about 1.5” This will better access to install the remaining V-groove wheels.

Install the bottom eccentric V-groove wheels.

Manually lower the bed plate by spinning the Z-rods, again. Allow the notch edge of each plate to rest on Z-axis stepper motors. This will ensure bed is close to level prior to other adjustments.

Tighten BHCSs (2 each side) holding nut cup assemblies to bed side plates. Make sure the V-groove wheels with round spacers (back wheels on each side) are tight.

Tighten the eccentric V-groove wheels in front to where they are “just barely” finger tight. (prior to adjustment) Adjusting the Eccentric wheels While pushing from back of bed, use wrench on eccentric spacer to adjust contact of V-groove wheel to V guide rail edge. Adjust for slight contact of wheel to the rail. Adjust both eccentric wheels on both sides of the bed plate. Note: the more contact force the more rigid. If contact is too little, there will be excessive movement in the bed during operation. However if contact force is too high, the friction will be such that the Z-axis stepper motors will not be able to move the table up and down freely (or will strain motors).

Tighten the eccentric wheels on the X axis carriage and the Y axis trucks. Insert the allen wrench into the access hole in the side plate to reach the M5 x 25 screw head.

Insert picture here

tension the X axis and Y axis belts using the 4mm allen wrench. Careful not to tighten too much or the motors will stall during use. Once the belt tension is set then tighten the M5 nuts that fix the tensioner blocks to the bridge trucks.

Attaching the bed plate

Bed plate support structure should still be resting on motors.

Position the bed plate in place . Hole spacing is 16” right to left and 18” front to back. Turn plate and position angles on the bed plate structure until holes in both are aligned.

Loosely attach the bed plate to the angles using the 4 Flat Head x 20mm bolts. Angles (previously secured by T-nuts) should also be loose at this time.

Make sure rails are properly secured to bed plate

To do this, loosen the 2 BHCSs on each end of the rails. Tighten bolts (going through angles) that fasten the bed plate to the rails

In each corner, position the rail in the center of the “travel” with respect to the holes in the side bed plates and then tighten the M5 BHCSs

Grease threaded rods Apply a light coat of grease from the packet supplied, along the length of the threaded rod.

Filament spool installation

Wrap 2 turns of electrical tape or similar onto ends of filament spool rod. Push rubber end caps onto end of taped filament rod. Install filament spool onto filament rod with filament feeding up from inside of spool. (Caution: when releasing wrapped filament for first time, be sure that end does not wrap beneath other loops. This will cause binding while feeding filament.) Place rod on holder.

Using a knife, angle cutters, or pencil sharpener, create an angled tip on the end of the filament.

Insert filament all the way into the tube and draw end down into extruder. Ensuring two M3 bolts on extruder are removed, feed filament into small extruder hole. Install M3 bolts onto extruder, ensuring washer and spring are present. Tighten each ~8.5 turns to obtain good pressure on filament to knurled bolt.

Electrical box activation

Orient Viki LCD to view display conveniently.

Plug in electrical box to 120V AC current. (warning: if your local mains voltage is 220V, ensure that your power supply has been set to 220V input – switch located on side of power supply, or as indicated by inspection sticker)

Switch electrical box to “ON”. Ensure Viki LCD shows “Gigabot Ready” on display, and temperature displays approximately the ambient temperature in the room in degC.

Perform steps in software installation quick start guide at and close related applications before next step. Plug in Gigabot's USB cable to computer. Open Pronterface (Printrun). Ensure communication rate is at 250000. Ensure correct comm port is selected (usually highest of possible selections in pull-down menu). Click on “Connect” button.

Observe firmware feedback on right side of the screen. Look for “Connecting..” and “Printer is now online.” In the lower-right corner, type the manual G-code command: “M119”to check the limit switches. All switches should return “open”.

Test limit switches

Using your finger, depress Z-limit switch lightly until it clicks. Hold this position and “Send” the same M119 command via Pronterface. Observe “TRIGGERED” on the “zmin” limit switch . Repeat this test for Y (“y_max”) and X (“x_min”) limit switches.

Slightly loosen the two M5 x 8 bolts securing the bed side plate to the nut cup on both the right and left sides.

Using your hand push the print head and bridge rail to the rear of their travel. We will be raising the bed next and this will move the delicate hot end tip clear of the bed in case the bed raises too far.

Double check that both the right and left bed side plates are resting on the Z axis motors to ensure the side plates are at the same height. If adjusting one side yo must hold the motor belt on the other side to make sure it doesn't rotate.

In Pronterface click on the Z axis home button. This will raise the bed until the Z limit switch stop attached to the bed side plate comes into contact with the Z limit switch lever arm. Once this happens the bed should move down slightly and then slowly re-contact the switch again.

At this point you can retighten the two M5 x 8 screws holding the bed side plates to the Z axis Nut Cups. Using either the Graphical user interface or the command line input in pronterface move the bed in the positive direction (down) the to the extent of it's travel and then back up to the home switch to ensure smooth and free movement of the bed mechanism. This will also help distribute the grease along the length of the Z axis lift screw.

Next home the X axis using the Pronterface home button. The carriage should travel to the left and contact the home limit switch. Using either the Graphical user interface or the command line input in pronterface command the trolley to move both positive and negative the full limit of their travel to ensure smooth operation.

Repeat for the Y axis. Note the limit switch is located on the positive extent of the travel as apposed to the X and Z axis where the limit switch is on the negative limit of travel.

Bed Leveling

Next we will level the bed and set the Z axis bed height. To level the bed we use the supplied dial indicator and dial indicator block. Attach the dovetail mount to the dial indicator and tighten. Insert the cylindrical end of the dovetail mount into the dial indicator block and fix in place using the supplied M3 screw.

Move the Z-axis in the positive direction approximately 10mm using Pronterface or the Viki. Command the motors off using Pronterface (button on left side of screen).

Place dial indicator block over the head of the main extruder bolt and fix into place using the second M3 screw. Next swivel the dial indicator feeler arm to form a ~20 deg angle to the bed plate as viewed from the side. While admiring the side view please ensure the dial indicator feeler arm is lower than the hot end so that it contact the bed surface and not the hot end.

Place the print head near the back left corner of the table and slowly raise the bed until it contacts the dial indicator, and moves the needle approximately 0.010” (or ~90 degrees of needle movement). Using your hand to push on the trolly plate and not the extruder itself move the print head near all four corners of the bed. Determine the lowest corner. By adjusting the bed leveling nut on the underside of the bed you will be able to pull the three highest corners of the bed down to make the bed level. [NOTE: The long M5x45mm hex bolt will remain tight and bottomed out on the bed rails at all times.] You will have to repeat this procedure several times to make the bed perfectly level. Once you get close to being level (within 0.005”) add slightly more tightness to the M5 x 12 screws fixing the bed side plates to the bed support rails. Once your bed is level, finish tightening these M5 x 12mm screws and check level one more time. Looks good doesn't it. You can remove the dial indicator and return it to it's case. Remove the screws from the indicator holder block and place all items into the indicator case.

Apply a layer of blue painter's tape to the bed. PLA will stick well to the blue painter's tape.

Again move the print head to the rear of it's travel in preparation of setting the bed home position. Using pronterface home the Z axis. Inspect the gap between the hot end nozzle and the bed. Adjusting the screw that comes into contact with the Z limit switch down will raise the bed and advancing the screw in will lower the bed. Ensure the lock nut is secured after each adjustment. The goal is to achieve a gap equal to the thickness of a piece of copy paper. This is a rough setting. You will be able to make the final adjustment once you print a single layer and measure the result to ensure the bed home position is set correctly.

Next we will test the extruder operation. Using Pronterface set the extruder temp to 190 deg C and wait for it to heat up. Once the hot end is at temp then extrude 5mm of PLA. Watch the filament going into the extruder to ensure it is feeding smoothly. Keep extruding 5mm of PLA until you can see it exiting the bottom of the hot end.

Rough Extruder Calibration

Observe the point at which the filament travels into the rear filament guide. Lightly pull any slack out of the length of filament between this point and the extruder. Make a mark with a pen or marker ~100mm before the filament enters the guide. If using a caliper, zero it from this point. Using Proterface, command 80mm of extrusion at 10mm per click (at ~100mm/min extrusion rate). Pause briefly between each extrusion. Once 80mm of filament has been commanded into the system, measure what was actually moved.

Send the following command to Pronterface: M503

Look for the line of data immediately following “Steps per unit”. The number following the “E” is the current calibration for steps per mm. Using the following formula, calculate the new steps per mm:

new steps per mm = current steps per mm * commanded move / actual mm traveled

Enter the following command into Pronterface: “M92 Exxxx” (where xxxx is the new steps per mm) This line of code will be part of your personal Gigabot's calibration data, and will need to be received as part of this start gcode, or updated manually with an M92 command, after each restart of Gigabot. Note: This number can also change when changing filament, or adjusting spring tension in the extruder. You can further refine this number with other print-based tests.

Repeat the steps above for marking and measuring filament to verify that your calibrated number is now registered in the firmware.

Open the Slic3r application. Select the profile for each of the settings tabs, such as from the config.ini file available on the Gigabot Quick Start wiki page.

Load a small calibration print into the Slic3r interface