Take your time. You don't need to complete everything in one night.

I took 2-3
hours on this myself. So relax and make sure every step is done properly. I
am always here to help.

Each step has a number, such STEP X-01,02. If you have question, please
mention this number.

Here is the package you are going to receive.

The package includes two small boxes, one contains the frame and another contains the hardware,
including motors, leadscrews and screws.
After you receive the package, the first thing is to check whether there is any damage to the box during
the shipping. If you found any, please inform us as soon as possible. The shipment is insured through
UPS.

After you open the package, you will need to count the parts according to the content list below. For this
new model, we have engraved the part number directly on the PVC frame to make it easy for you to
identify.
Frame Parts:
1. Clamp (Not used in machine construction) - 2
2. Motor Support -3
3. End Ball Bearing Holder -4
4. Z Axis Slide Support, Upper -1
5. Z Axis Slide Support, Lower -1
6. X Axis Slide Support, Near Motor Side - 1
7. X Axis Slide Support, Far Motor Side -1
8. Z Frame Support, Far Motor Side -1
9. Z Frame Support, Near Motor Side -1
10. Y Axis Slide Support, Near Motor Side -1
11. Y Axis Slide Support, Far Motor Side -1
12. Motor Side Support -6
13. Y Axis Frame Support, Far Motor Side -1
14. Y Axis Frame Support, Near Motor Side -1
15. Y Axis Side Frame -2
16. Cutting Mounting Plate -1
17. X Axis Vertical Frame, Left Outter -1
18. X Axis Vertical Frame, Left Inner -1
19. X Axis Vertical Frame, Right Outer -1
20. X Axis Vertical Frame, Right Inner -1
21. Z Axis Back Support -1
22. X Axis Back Support -1
23. Working Table -1

24. Cutter holder bracket (If you have Fordom Flex Shaft Handpiece, 1 inch diameter, you can use,
otherwise, you will need to make you own holder). -2

Hardware:
1. Step motor flex coupling -3
2. XY Axis Glide Rod -4
3. Z Axis Glide Rod -2
4. XY Axis Lead Screw -2
5. Z Axis Lead Screw -1
6. Anti Backlash Assembly(Front, Rear and Spring combo) -3
7. Stepper Motor (2 Phase, 6 wire) -3
8. Stepper Motor Connection Wire -3
9. Linear Ball Bearing X,Y and Z - 12
10. Leadscrew end support ball bearing -6

Screws:

A - M3 x 10 Pan Head Machine Screw

B - M4 x 20 Hex Machine Screw

C - M6 x 15 Hex Machine Screw

D - M6 x 24 Hex Machine Screw

E - M3 x 20 Wood Screw

Install Y Axis:

STEP Y-01:
First of all, let's lay out all parts for the Y Axis.

Front and side frame, slide support frams, lead screw, guide rods, linear ball bearings and screws.

Screw Used:

A - 4 (Motor & #2)

B - 6 (#3 & #14; #3 & #13, Anti Backlash Nut $ #10)

C - 4 (Guide Rod & #13, Guide Rod &#14)

E - 16 (#13 & #15, #14 & #15, #14 & #12)

STEP Y-02:
Here is a close up photo of the parts.
STEP Y-03:
Here is another close up photo:
STEP Y-04:
A close up on far motor side:

STEP Y-05:
A close up on the near motor side:
STEP Y-06:
The shorter shaft of the lead screw will be pushed into the end ball bearing holder (3). It is a tight fit. Hope
you will have a long clamp to do this job. I am using a drill press so that I can align them properly before
the push. You need to apply the pressure straight into the hole, be very careful not to bend the lead
screw. This probably the most critical part of the entire installation. The longer shaft of the lead screw has
a loose fit with the ball bearing.
STEP Y-07:
Here is how I push the linear ball beaing into the slide support frame. A bench vise will do the job very
well. Make sure you push the bearing to the bottom of the hole. Don't use a hammer here, no matter how
skillful you are with hammers.

STEP Y-08:
After four linear bearings get installed into the sliding support frame, you can assmeble the guide rod.
Sorry, this photo came in early, a few more steps before this.
STEP Y-09:
This picture shows all linear bearings have been installed onto slide support frame. Notice the orientation
of the parts. Two bearings must be on the same side of the frame. Which side does not matter.

STEP Y-10:
Now, slide the lead screw through the Y Axis frame support, far motor side, as shown below. No need to
install screws at this moment.

STEP Y-11:
Get parts aligned now. It is better do this every step. Sometimes mistake you made is not very obivious,
and when you find it, you will have to roll back a few critical step. Slow down and check often.
STEP Y-12:
Now, let's put anti backlash nut together. First, screw the small end into the lead screw half way. Then put
the spring on. After that, put the bigger on and apply some pressure to the spring. How much pressue to
apply? Leave the gap between two parts about 1/8 inch will be fine. You need to check whether you can
turn the lead screw easily in the nuts. Too much pressure will help remove the backlash, but it will cost
the lift time of the leadscrew and nuts because of the extensive friction. Apply some lube to the lead
screw before you operate the machine.

STEP Y-13:
Here is the anti backlash nuts installed on the lead screw.
STEP Y-14:
Now you can screw the anti back lash nuts to the slide support frame. Remember, do NOT make the
screw too tight at this point, you will need to adjust the alignment later.

STEP Y-15:
You need to clean the rod before install. It can be cleaned by putting a little bit
of WD-40 on to it, and then wipe it off with a paper towel. The WD-40 can also
be used as prime lubrication on lead screw.

We are ready to install the guide rod into the linear bearings.

STEP Y-16:
During this step, be very gentle when you push the guide rod into the bearings. Adjust the direction and
turn the rod slowly during the push. If the little ball come out of the bearing, it is no fun to find them on
the floor and even harder to put them back in.
STEP Y-17:
Here is when two guide rods have been installed for Y axis.
STEP Y-18:
Now, screw the rod and frame together. Remember, not too tight, we will need to adjust the alignment
later.

STEP Y-19:
The screws are now installed.

STEP Y-20:
Now we are ready to install the near motor side frame and side frames. Layout and double check before
continue.
STEP Y-21:
Slowly ...

STEP Y-22:
Here comes the end ball bearing holder(3). On this end the lead screw shaft and ball bearing have a
loose fit.

STEP Y-23:
At this step, you should check whether you can turn the lead screw easily with your hand. If you feel too
much resistance, check the alignment on linear ball bearings and anti backlash nuts assembly.
STEP Y-24:
Now you can install side frame.

STEP Y-25:
Using a powered screw driver will save you a lot of muscle strength, but be sure, don't make the screw
too tight or ruin the screw.
STEP Y-26:
Check the squareness often. Out machine usually aligns itself very well. But double check won't hurt.

STEP Y-27:
Ready for motor assembly now. Here are two motor side support frame.

STEP Y-28:
The motor will be mounted onto a motor support frame (2).
STEP Y-29:
Motor mounted onto the motor support(2) frame.

STEP Y-30:
Now, ready for the final motor assembly attachment. Make sure the set screws on the coupling are
loosen before put them together.
STEP Y-31:
Screw the motor support (2) to motor side support frame.

We almost there for theY Axis. For other two axies, steps will be very similar to this.
STEP Y-32:
Now the motor is mounted to the frame. Let's finally check the alignments and make sure the leadscrew
can be turned by hand easily.

STEP Y-33:
Here is your Y Axis assembly, just need to put on the working table.
STEP Y-34:
Now let's tighten all screws up, remember, not too tight. Some screw holes on the frame are made very
tight, you will probably screw the screws into it.
STEP Y-35:
Time to attach working table to the Y Axis, not much to say here, screw them in. The screws are pretty
soft, so make sure do it slowly. You don't need to put the working table on at this time, it will make it
easier for your test if you have the access to all moving parts.

Install X Axis:

STEP X-01:
Now we can start our X Axis assembly. As before, lay out the parts first. We use two side frames on each
side to increase the strength of the machine, the machanism of holding the ballbearings are little different
from the Y and Z axis. The ball bearings are directly pushed into one of the side frame, and other frame
will close it up. The rest will be pretty much same as the Y Axis.

Screw Used:
A - 4 (Motor & #2)

B - 2 (Anti Backlash Nut & #6)

C - 4 (Guide Rod & #17,#18; Guide Rod & #19,#20)

D - 4 (#17,#18,#19,#20 & #15)

E - 24 (#20 & #12; #12 & #2; #17,#18 & #22; #19,#20 & #12)

STEP X-02:
Motor side close up view.
STEP X-03:
Otherside close up view.
STEP X-04:
Leadscrew, guide rod, linear ball bearing and slide support frames...

STEP X-05:
Here is the method I use to push the leadscrew shaft into the ball bearing. The short shaft has a tight fit
with ball bearing. You probably don't have this type of equipment, use some other tool you think will do
the job. Again, no hammer during the entire process !!.
STEP X-06:
Pushed half way in.
STEP X-07:
Here it is, the short shaft of the lead screw has been installed onto the far motor side frame. If you found
the fit is loose, don't worry, use a center punch slightly make a dent on the shaft and that will make the fit
tight again.

STEP X-08:
Put other piece of the frame on.
STEP X-09:
Now ready for the slide support installation. Lay out the parts with correct orientation.
STEP X-10:
Slide the left side onto the lead screw.

STEP X-11:
Same as Y Axis, put anti back lash nuts together on the lead screw.
STEP X-12:
Ready to put on other side of the frame for X Axis.
STEP X-13:
Screws the guide rod into the frame. Do make it tight yet, we need a final alignment check before that.
STEP X-14:
The motor willl be attached to this side of the frame.

STEP X-15:
The motor side support (12) will be inserted into those square holes for X Axis.
STEP X-16:
The motor side supports are installed onto the frame.
STEP X-17:
Same as Y Axis, install the motor to the motor support (2).

STEP X-18:
Here you go.
STEP X-19:
Ready for putting on the motor. Remember, loosen the set screws on the flex coupling first. Be careful
push the coupling into the shaft, it might tight. Turn it slowly and don't bend it too much.
STEP X-20:
Now ready for putting on the back support (22) of the X Axis.

STEP X-21:
The back support is on now.
STEP X-22:
Now the time to tighten all screws. Leave the anti back lash nut screws the last. Make sure you can turn
the lead screw within the nuts easily before you tighten this screws up.
STEP X-23:
Here is the back suport of Z Axis(21)

STEP X-24:
Screw it on to the X Axis slide support frame.
STEP X-25:
Now, you can put X,Y Axis together see whether they will fit. I am sure they will ;)
 To be continued with Z Axis ... Can you try it without instruction?

Install Z Axis:

STEP Z-01:
Here is the lay out of Z Axis parts.

Screw Used:

A - 4 (Motor & #2)

B - 2 (Anti Backlash Nut $ #4;#3 & #8; #3 & #9)

C - 4 (Guide Rod & #8; Guide Rod & #9)

E - 8 (#9 & #12; #2 & #12)

STEP Z-02:
First, need to push in the leadscrew shorter shaft into the ball bearing, which is already installed into a
end ball bearing holder(3).

STEP Z-03:
Now, we need to slide the lead screw into the far motor end of the Z Axis frame(8)
STEP Z-04:
Lay out the parts again, make sure the orientation of all parts are correct. The ant back lash nuts will be
installed on the slide support (4), which is on the motor side.
STEP Z-05:
The guide rod linear ball bearing have been pushed into the slide support frame (4,5).

STEP Z-06:
First step of installing anti backlash nuts. Put the small nut onto the leadscrew, notice the direction.
STEP Z-07:
Put the sprint on.
STEP Z-08:
Put the bigger nut onto the shaft.

STEP Z-09:
Apply pressure and push in the big nut toward the small nuts. A gap between two nuts shold be aound
1/8 inch.
STEP Z-10:
Anti backlash nuts installed onto the slide support frame. The photo didn't show that you should leave the
screws loose, prepare for the later alignment adjustment.
STEP Z-11

:Guide Rods have been slided in. Becareful, turn the rod slowly and don't push hard if it stucks.

STEP Z-12:
Ready for the motor parts, here are the motor side support (12) and motor side Z frame (9).
STEP Z-13:
Motor side support frame (12) has been screwed to the Z Axis near motor frame (9).
STEP Z-14:

Attention!!. In this photo, the orientation of the slide support of motor side is wrong. It is very easy to
make this mistake. Fix it now. I didn't do this on purpose, but I want to show you this photo to get your
attention.
STEP Z-15:
Ready for Z Axis motor

STEP Z-16:
Again, Motor install.

STEP Z-17:
Motor mounted. You decide the wire connector orientation based on how you want to connect the
machine to your stepper motor driver. For Z Axis, I like to face the connector backwards.
STEP Z-18:
More on motor.
STEP Z-19:
Now we can put all Z Axis parts together.

STEP Z-20:
One more...
STEP Z-21:
Before you tighten up all screws, make sure you check the alignment, and you can turn lead screw easily
with you hand. Check often will save you trouble when you start test motor and driver.
STEP Z-22:
You can attach the cutter plate later after you purchase you cutter. I have included a cutter bracket in the
package, which can be used with Fordom Flex Shaft hand piece No. 31. But you can easily make your
own with material available to you, like plywood, plastic scraps or even metal.

STEP Z-23:
Now, you have completed the most part on X, Y and Z axis. Only a few more steps to put them together. I
suggest wait for your driver and cutter to come before you do this. The electrical wiring do challenge us
sometime, and leave the mechanical components seperately will help to identify the issues later.

Stepper Motor Wire Identification: (more photos to come).

The package includes three stepper motors for three axis. They are two phase six wires stepper motors.
Some drivers will require only 4 wire to be connected, and some drivers require all 6 wires to be
connected.
Six wires will be referred to A, A', A0 and B, B' B0. Put the motor shaft upward, and let the connector face
to you. From left to right it will be in the order of A, A0, A', B, B0 and B'. It really doesn't matter whether it
is A or B, you will need to use Mach3 configuration to set the motor moving direction.

Mach 3 Software

Configuration File Location and format:

Configure Mach3 port and pin

Please follow the instruction of the driver you purchased.

Configure Mach3 motor setting:

Lead screw used for this machine has a pitch of 1.25 mm. That means one turn of the lead screw will
make a 1.25 mm on that axis.

Depending on the driver you are using for the stepper motor, you will need to configure the motor in
Mach3 software. Usually, you driver will have microstep setting for full, 1/2, 1/4 or 1/8. If it is set to full, it
takes 200 steps to make turn, if it is 1/2, 400 steps make one turn and so on.

We suggest you set it to 1/8 for all axises, not for accuracy, but for a smoother motor movement.

If you set it to 1/8, that means 200x8 = 1600 steps make one turn, which will move 1.25mm.

In Mach3, you need to set the number of turns to make one unit movement. If you are using English unit,
it is Inch, if you are using IS, it is milimeter.
If you are using mm, this number should be 1600/1.25 = 1280.

If you are using inch, this number should be 1600/(1.25/25.4) = 32512

You need to set this number for all axis.

Another value to set for the motor is the velocity. Start with the small number until you feel comfortable
with the capacity of the cutter you choose.

Set the machine coordination

Set the home and limits

Some basic g-code syntex

Mount the work piece

Recommended cutters for this machine

Engraving
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Current by Zen - Jul 24

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Latest 3 messages about this page (6 total) - view full discussion

Jul 23 2009 by tomlaw@okladefender.com

Zen

I have ll three axis completed. However, I have two parts marked"1"

that are left over and don't appear to go anywhere. I have two prts
marked "24" which i under stand are Foredom clamps. Also how does the
gantry attach to the X base? I don't have and bolts long enough to
complete this step!!! Help!!!
Jul 23 2009 by Scott
Xin got back to me. The adjustment is to allow for different cutting
tools that may need to be positioned differently to fit the work
pieces.

I'm slowly picking up this stuff.

Scott
Jul 22 2009 by Scott
I have the y-axis assembled and the x-axis/z-axis gantry done also.
The y-axis has elongated holes for mounting the gantry. Why the
variability? Should I mount the gantry in the middle, front, back of
the holes? Thanks.

Scott
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