Hot End Manual RapMan V3.1.0
RapMan 3 Hot End Manual RapMan V3.1.0
Document No: D100242
RapMan V3.0.0 Hot End Kit
Contents How to use this manual...............................................................................................................................................2 Included in the kit .......................................................................................................................................................3 Making up the un-insulated nichrome.........................................................................................................................4 Making up the insulated nichrome ..............................................................................................................................7 Making up the thermistor ...........................................................................................................................................9 Nozzle assembly........................................................................................................................................................ 11 Wrapping the un-insulated nichrome ........................................................................................................................ 13 Wrapping the insulated nichrome ............................................................................................................................. 14 Fitting the thermistor ................................................................................................................................................ 16 Moulding the final shape .......................................................................................................................................... 18
Document No : D100244
Page: 1
RapMan V3.0.0 Hot End Kit
How to use this manual This manual is for the Bits from Bytes hot end kit. Please read the manual fully before starting the build as a little prior knowledge can be very useful!
Document No : D100244
Page: 2
RapMan V3.0.0 Hot End Kit
Included in the kit 1 Nozzle 0.5mmØ or 0.25mmØ depending on kit 1 Stainless steel 2mm laser-cut nozzle holder 1 PEEK insulator support 1 Aluminium heat sink tube 1 PTFE insulator tube 1 MDF insulator 1 Insulation retainer 1 200K thermistor 1 Nichrome wire o 300mm nichrome un-insulated wire size 34 o or 690mm nichrome insulated size 25 1 tub fire-cement 3 M3 x 40 stainless steel spacers 3 M3 x 16 cap head bolts 3 M3 nuts 4 Bootlace ferrules 140mm yellow silicone sleeve 1 Silicone nozzle insulator (not shown)
Nozzle PEEK insulator
Aluminium heat sink
M3 x 40 spacers Bootlace ferrule
Silicone sleeve Insulation retainer
Fire-cement M3 nuts
MDF insulator
Thermistor Nichrome wire PTFE insulator
Nozzle holder
M3 x 16 bolts
Document No : D100244
Page: 3
RapMan V3.0.0 Hot End Kit
Making up the un-insulated nichrome 1
Cut nichrome wire 210mm
2
3
4
5
Document No : D100244
Page: 4
RapMan V3.0.0 Hot End Kit
6
7
8
9
10
Strip 30mm of insulation from the end of both 2m grey wires
11
Cut 4 x 35mm yellow heat proof sleeve
Document No : D100244
Page: 5
RapMan V3.0.0 Hot End Kit
12
13
14
15
16
Check the resistance of the wire is between 4.5Ω and 5.5Ω
Document No : D100244
Page: 6
RapMan V3.0.0 Hot End Kit
Making up the insulated nichrome 1
Check nichrome is 690mm long
2
Strip 5mm insulation from each end
3
Cut 4 x 35mm yellow heat proof sleeve
4
5
6
Crimp connection
Document No : D100244
Page: 7
RapMan V3.0.0 Hot End Kit
7
Repeat from step 5 at the other end
8
Check the resistance of the wire is between 4.5Ω and 5.5Ω
Document No : D100244
Page: 8
RapMan V3.0.0 Hot End Kit
Making up the thermistor 1
Strip 30mm of insulation from the end of both 2m purple wires
2 Use the heat-proof sleeve cut previously
3
4
5
Document No : D100244
Page: 9
RapMan V3.0.0 Hot End Kit
6
7
Document No : D100244
Page: 10
RapMan V3.0.0 Hot End Kit
Nozzle assembly 1
Push the PEEK insulator into the aluminium nozzle until only 15mm sticks out
2
3
Cut the end of the PTFE to 90 o
4
5
6
Document No : D100244
Page: 11
RapMan V3.0.0 Hot End Kit
7
8
Cut the PTFE flush to the MDF
9
10
Document No : D100244
Page: 12
RapMan V3.0.0 Hot End Kit
Wrapping the un-insulated nichrome 1
2
Use the clips provided to hold the wires
Ensure no wires are touching
3
Fire-cement the wires into place and cook in an oven at 100 oC for 15 minutes or leave overnight in a warm place
Document No : D100244
Page: 13
RapMan V3.0.0 Hot End Kit
Wrapping the insulated nichrome 1
2
Document No : D100244
Page: 14
RapMan V3.0.0 Hot End Kit
3
Coat the nichrome wire with fire-cement
4
Connect the heater to the fan connector on the PCB – this is a convenient source of 12V
5
Turn on PCB for 3 minutes - this will cook the fire-cement
Document No : D100244
Page: 15
RapMan V3.0.0 Hot End Kit
Fitting the thermistor 1
Put a small amount of fire-cement into the thermistor mounting hole and push the thermistor into the fire-cement
2
3
4
Document No : D100244
Page: 16
RapMan V3.0.0 Hot End Kit
5
Check the resistance of the thermistor – it should be between 200kΩ and 300kΩ at room temperature
6
Cook the fire-cement for 2 minutes
Document No : D100244
Page: 17
RapMan V3.0.0 Hot End Kit
Moulding the final shape 1
Mould the final shape so the nozzle end is slightly larger to hold the silicone insulator in place
2
Document No : D100244
Page: 18
Document No: D100242
RapMan V3.0.0 Hot End Kit
Contents How to use this manual...............................................................................................................................................2 Included in the kit .......................................................................................................................................................3 Making up the un-insulated nichrome.........................................................................................................................4 Making up the insulated nichrome ..............................................................................................................................7 Making up the thermistor ...........................................................................................................................................9 Nozzle assembly........................................................................................................................................................ 11 Wrapping the un-insulated nichrome ........................................................................................................................ 13 Wrapping the insulated nichrome ............................................................................................................................. 14 Fitting the thermistor ................................................................................................................................................ 16 Moulding the final shape .......................................................................................................................................... 18
Document No : D100244
Page: 1
RapMan V3.0.0 Hot End Kit
How to use this manual This manual is for the Bits from Bytes hot end kit. Please read the manual fully before starting the build as a little prior knowledge can be very useful!
Document No : D100244
Page: 2
RapMan V3.0.0 Hot End Kit
Included in the kit 1 Nozzle 0.5mmØ or 0.25mmØ depending on kit 1 Stainless steel 2mm laser-cut nozzle holder 1 PEEK insulator support 1 Aluminium heat sink tube 1 PTFE insulator tube 1 MDF insulator 1 Insulation retainer 1 200K thermistor 1 Nichrome wire o 300mm nichrome un-insulated wire size 34 o or 690mm nichrome insulated size 25 1 tub fire-cement 3 M3 x 40 stainless steel spacers 3 M3 x 16 cap head bolts 3 M3 nuts 4 Bootlace ferrules 140mm yellow silicone sleeve 1 Silicone nozzle insulator (not shown)
Nozzle PEEK insulator
Aluminium heat sink
M3 x 40 spacers Bootlace ferrule
Silicone sleeve Insulation retainer
Fire-cement M3 nuts
MDF insulator
Thermistor Nichrome wire PTFE insulator
Nozzle holder
M3 x 16 bolts
Document No : D100244
Page: 3
RapMan V3.0.0 Hot End Kit
Making up the un-insulated nichrome 1
Cut nichrome wire 210mm
2
3
4
5
Document No : D100244
Page: 4
RapMan V3.0.0 Hot End Kit
6
7
8
9
10
Strip 30mm of insulation from the end of both 2m grey wires
11
Cut 4 x 35mm yellow heat proof sleeve
Document No : D100244
Page: 5
RapMan V3.0.0 Hot End Kit
12
13
14
15
16
Check the resistance of the wire is between 4.5Ω and 5.5Ω
Document No : D100244
Page: 6
RapMan V3.0.0 Hot End Kit
Making up the insulated nichrome 1
Check nichrome is 690mm long
2
Strip 5mm insulation from each end
3
Cut 4 x 35mm yellow heat proof sleeve
4
5
6
Crimp connection
Document No : D100244
Page: 7
RapMan V3.0.0 Hot End Kit
7
Repeat from step 5 at the other end
8
Check the resistance of the wire is between 4.5Ω and 5.5Ω
Document No : D100244
Page: 8
RapMan V3.0.0 Hot End Kit
Making up the thermistor 1
Strip 30mm of insulation from the end of both 2m purple wires
2 Use the heat-proof sleeve cut previously
3
4
5
Document No : D100244
Page: 9
RapMan V3.0.0 Hot End Kit
6
7
Document No : D100244
Page: 10
RapMan V3.0.0 Hot End Kit
Nozzle assembly 1
Push the PEEK insulator into the aluminium nozzle until only 15mm sticks out
2
3
Cut the end of the PTFE to 90 o
4
5
6
Document No : D100244
Page: 11
RapMan V3.0.0 Hot End Kit
7
8
Cut the PTFE flush to the MDF
9
10
Document No : D100244
Page: 12
RapMan V3.0.0 Hot End Kit
Wrapping the un-insulated nichrome 1
2
Use the clips provided to hold the wires
Ensure no wires are touching
3
Fire-cement the wires into place and cook in an oven at 100 oC for 15 minutes or leave overnight in a warm place
Document No : D100244
Page: 13
RapMan V3.0.0 Hot End Kit
Wrapping the insulated nichrome 1
2
Document No : D100244
Page: 14
RapMan V3.0.0 Hot End Kit
3
Coat the nichrome wire with fire-cement
4
Connect the heater to the fan connector on the PCB – this is a convenient source of 12V
5
Turn on PCB for 3 minutes - this will cook the fire-cement
Document No : D100244
Page: 15
RapMan V3.0.0 Hot End Kit
Fitting the thermistor 1
Put a small amount of fire-cement into the thermistor mounting hole and push the thermistor into the fire-cement
2
3
4
Document No : D100244
Page: 16
RapMan V3.0.0 Hot End Kit
5
Check the resistance of the thermistor – it should be between 200kΩ and 300kΩ at room temperature
6
Cook the fire-cement for 2 minutes
Document No : D100244
Page: 17
RapMan V3.0.0 Hot End Kit
Moulding the final shape 1
Mould the final shape so the nozzle end is slightly larger to hold the silicone insulator in place
2
Document No : D100244
Page: 18
