Bfb RapMan 3 Instruction Manual

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RapMan 3

Hot End Manual RapMan V3.1.0

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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

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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!

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RapMan V3.0.0 Hot End Kit

PEEK insulator

Aluminium heat sink

Nozzle

Fire-cement

M3 nuts

Nichrome wire

PTFE insulator

M3 x 16 bolts

Thermistor

Nozzle holder

M3 x 40 spacers

Bootlace ferrule

Silicone sleeve

MDF insulator

Insulation retainer

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)

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RapMan V3.0.0 Hot End Kit

Cut nichrome wire 210mm

Making up the un-insulated nichrome

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RapMan V3.0.0 Hot End Kit

Strip 30mm of insulation from the end of both 2m grey wires

Cut 4 x 35mm yellow heat proof sleeve

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7

8

9

10

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RapMan V3.0.0 Hot End Kit

Check the resistance of the wire is between 4.5Ω and 5.5Ω

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16

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RapMan V3.0.0 Hot End Kit

Cut 4 x 35mm yellow heat proof sleeve

Check nichrome is 690mm long
Strip 5mm insulation from each end

Crimp connection

Making up the insulated nichrome

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RapMan V3.0.0 Hot End Kit

Repeat from step 5 at the other end

Check the resistance of the wire is between 4.5Ω and 5.5Ω

7

8

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RapMan V3.0.0 Hot End Kit

Strip 30mm of insulation from the end of both 2m purple wires

Use the heat-proof sleeve cut previously

Making up the thermistor

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RapMan V3.0.0 Hot End Kit

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RapMan V3.0.0 Hot End Kit

Push the PEEK insulator into the aluminium nozzle until only 15mm sticks out

Cut the end of the PTFE to 90o

Nozzle assembly

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RapMan V3.0.0 Hot End Kit

Cut the PTFE flush to the MDF

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RapMan V3.0.0 Hot End Kit

Use the clips provided to hold the wires
Ensure no wires are touching

Fire-cement the wires into place and cook in an oven at 100oC for 15 minutes or leave overnight in a warm place

Wrapping the un-insulated nichrome

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RapMan V3.0.0 Hot End Kit

Wrapping the insulated nichrome

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RapMan V3.0.0 Hot End Kit

Connect the heater to the fan connector on the PCB – this is a convenient source of 12V

Coat the nichrome wire with fire-cement

Turn on PCB for 3 minutes - this will cook the fire-cement

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5

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RapMan V3.0.0 Hot End Kit

Put a small amount of fire-cement into the thermistor mounting hole and push the thermistor into the fire-cement

Fitting the thermistor

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RapMan V3.0.0 Hot End Kit

Check the resistance of the thermistor – it should be between 200kΩ and 300kΩ at room temperature

Cook the fire-cement for 2 minutes

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6

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RapMan V3.0.0 Hot End Kit

Mould the final shape so the nozzle end is slightly larger to hold the silicone insulator in place

Moulding the final shape

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