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Darkly Labs Emblaser Core User & Assembly Manual

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Darkly Labs
R
Kit Rev. 1.0
User Assembly Manual
English
Emblaser Core Assembly Manual Rev 1.32

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Summary of Contents for Darkly Labs Emblaser Core

  • Page 1 Darkly Labs Kit Rev. 1.0 User Assembly Manual English Emblaser Core Assembly Manual Rev 1.32...
  • Page 2 IMPORTANT SAFETY GLASSES MUST BE USED The Emblaser Core contains a Class 4 laser device. This device could cause damage to your eyesight or blindness. Always wear your safety glasses when operating your machine.
  • Page 3 IMPORTANT BANNED MATERIALS PVC, VINYL, ABS, FIBERGLASS, COATED CARBON FIBER, ANY MATERIAL CONTAINING CHLORINE Using these materials within your machine will produce extremely toxic fumes, leading to severe health issues and machine damage. If you do not know what your material contains, DO NOT USE IT.

  • Page 4: For Your Safety

    If any part of the Emblaser Device is damaged, contact your reseller or Darkly Labs directly before operation. Darkly Digital Pty Ltd (Darkly Labs) reserves ● the right to change the specifications of the hardware and software described in these manuals at any time and without prior notice.

  • Page 5: Getting Started

    GETTING STARTED Preparation A medium size table should be enough space to construct your Emblaser Core. Allow yourself 2-3 hours to complete the kit assembly. Use powered drivers at your own risk! We recommend using hand tools supplied, as some parts may be damaged by overtightening.
  • Page 6 CONTENTS Misc. Parts 1x Power Supply 1x USB cable 1x Getting Started Card 1x Safety Glasses 4x Cutting Mats 1x Lens cleaning liquid dispenser 1x Magnifier PARTS STAGE 1 Frame Assembly 1x Top Panel 1x Front Panel 1x Rear Panel 2x Side Panel 8x Corner Bracket 4x Cable Management Clip...
  • Page 7 PARTS STAGE 2 Gantry Assembly 1x Homing Trigger 2x Belt 1x Belt Hub 4x Rail Bracket 2x Motor Bracket 2x Motor 2x Motor Pulleys 18x M3x30mm Screw 18x M3 Washer 10x M3 Nut 8x Shoulder Bolt 4x M5 Nut 4x M5 Lock Nut 4x M5 Washer 16x Flanged Bearings 4x Spacer...
  • Page 8 PARTS STAGE 3 Driver Board 1x Driver Board Cover 1x Driver Board 1x Laser Unit 1x M3x12mm Screw 4x M3x8mm Screws PARTS STAGE 4 Button PCB 1x Button PCB 1x Button PCB Cover 1x Enable Button 1x Power Button 1x Ribbon Cable 2x M3x12mm Screw 2x M3 Washer 2x M3 Nut...
  • Page 9 PARTS STAGE 5 Controller Board 1x Controller Board 1x Controller Board Cover 2x Motor Cables 4x Standoff 4x M3x12mm Screw 4x M3 Washer PARTS STAGE 6 Assembly Completion 1x Base Plate 10x Rubber Feet 8x M3x12mm Screw 8x M3 Washer 8x M3 Nut...
  • Page 10 PARTS Air Assist Accessory (OPTIONAL) 1x Air Assist Pump 1x Air Assist Hose 1x Intake Filter 2x M4x6mm Screw 2x M4 Washer 3x Air Assist Hose Clips PARTS Workspace Camera Accessory (OPTIONAL) 1x Workspace Camera 2x M3x12mm Screw 2x M3 Washer 2x M3 Nut...
  • Page 11 STAGE 1 FRAME ASSEMBLY Lay out the parts listed below. Refer to the ‘PARTS Stage 1’ section. • Top Panel • 2x Side Panel • Front Panel • Rear Panel **Remove protective film from panels before starting construction** • 8x Corner Bracket •...
  • Page 12 Step 1.02 Place the Front Panel on the table with the logo facing down. Attach 4x Corner Brackets to the Front Panel. Step 1.03 Attach the two Side Panels.
  • Page 13 Step 1.04 Place the 4x Cable Management Clips in the recesses on the Rear Panel.
  • Page 14 Step 1.05 Attach the Top Panel. Important: Keep the holes indicated in green to the right. M3 x 12mm SCREW M3 WASHER M3 NUT...
  • Page 15 Step 1.06 Attach the Panel Brackets to the Front, Rear and Side Panels. . You do not need nuts for this step. M3 x 12mm SCREW M3 WASHER Attach the Panel Brackets to the Top Panel.
  • Page 16 STAGE 2 GANTRY ASSEMBLY Lay out the parts listed below. Refer to the ‘PARTS Stage 2’ section. • Homing Trigger • 10x M3 Nuts • 2x Belts • 8x Shoulder Bolts • Belt Hub • 4x M5 Nuts • 4x Rail Bracket •...
  • Page 17 Step 2.02 Place a Motor Pulley onto one of the Motors. Position the small screw in the Motor Pulley over the flat face of the Motor shaft and fasten using the 2.0mm Hex Tool. Important: Leave approx. 0.5mm gap between the Motor Pulley and the Motor. Flat face of motor shaft Place the second Motor Pulley upside down over the shaft of the remaining Motor.
  • Page 18 Step 2.03 Attach the Motors to the underside of the Top Panel with the Motor Brackets. Make sure the Motor connectors are facing the centre of the machine. Take note of Motor Bracket orientation. M3 WASHER M3 x 30mm SCREW...
  • Page 19 Step 2.04 Attach two Rail Brackets to the underside of the Top Panel. Make sure the arrow on the Rail Bracket points towards the Top Panel. M3 NUT M3 WASHER M3 x 30mm SCREW...
  • Page 20 Step 2.05 Attach the Homing Trigger to the underside of the Top Panel. M3 NUT M3 WASHER M3 x 30mm SCREW...
  • Page 21 Step 2.06 Assemble the four Idle Pulleys.
  • Page 22 Step 2.07 Attach the Idle Pulleys to the underside of the Top Panel. Important! Correct placement of UPPER and LOWER Idle Pulleys is critical to the function of your Emblaser device. M5 LOCK NUT...
  • Page 23 Step 2.08 Your kit may have shipped with pre-assembled Gantry Carriages. If so, please proceed to Step 2.10. Otherwise, follow the steps in 2.08 & 2.09. Carefully connect a pair of Gantry Carriage Housings at their hinging point. Insert two Linear Bearings and hinge the Gantry Carriage Housings completely closed.

  • Page 24: Shoulder Bolt

    Step 2.09 Insert a pair of Flanged Bearings and fasten with Shoulder Bolt and M5 Nut. Repeat this step on opposite side. NOTE: The shoulder bolts may be a tight fit into the gantry carriages and need to be screwed in. FLANGED BEARING SHOULDER BOLT M5 NUT...
  • Page 25 Step 2.10 Insert the two Long Rails into one of the Gantry Carriages. Slide the Laser Carriage onto the two Long Rails. Important! Orientate the Laser Carriage so its motor is at the bottom. Note: Laser Carriage should only contain 3 linear bearings.
  • Page 26 Step 2.11 Slide the Laser Carriage back and forth the motion should be smooth and constant. If it feels tight near the gantry carriages can adjust the tightness of the shoulder bolts in the Gantry Carriages accordingly. Insert the two Short Rails into the Gantry Carriages and attach the remaining Rail Brackets as shown.
  • Page 27 Step 2.12 Pick up the assembly from the previous step and place it in the Frame Assembly as shown. Take note of arrow direction in the diagram. Insert the Gantry Assembly into the Rail Mounts attached to the Top Panel.
  • Page 28 Step 2.13 Attach the final two Rail Brackets to the underside of the Top Panel. M3 NUT M3 WASHER M3 x 30mm SCREW...
  • Page 29 Step 2.14 Keep the Frame Assembly upside down and held up by the small boxes. The Front, Rear and Side Panels have been hidden in the following illustrations. This is by far the trickiest part of the kit to assemble but don’t worry! Here is a list which guarantee success.
  • Page 30 The diagrams below highlights the position of Belt Pulleys. There are Upper Position pulleys and Lower Position pulleys.
  • Page 31 Step 2.15 Thread one end of a Belt through the Gantry Carriage indicated in the diagram. The teeth of the Belt should be touching the Flanged Bearing.
  • Page 32 Step 2.15 The front of the Belt Hub (indicated by the circle) always faces the Front Panel. Insert the end of the Belt into the channel in the bottom of the Belt Hub next to the GREEN tab as shown in the image below.
  • Page 33 Step 2.16 Route the Belt around the two Lower Position Idle Pulleys as shown.
  • Page 34 Step 2.17 Pass the Belt straight through the Gantry Carraige and around the Motor Pulley.
  • Page 35 Step 2.18 Route the Belt behind lower position pulley in the Gantry Carriage.
  • Page 36 Step 2.19 Bring the Belt around behind the Laser Carriage. Move the Gantry Carriages to the front of the machine so that both are touching the Top Panel.
  • Page 37 Pull the belt tight. This should cause the left hand side Gantry Carriage to pull away from the Top Panel. Apply just enough tension to the belt so the gap between the left hand side Gantry Carriage and the Top Panel is approximately 5mm.
  • Page 38 Remove the Green Tab from the Belt Hub and insert the loose end of the Belt into that channel. Check the position of the Gantry Carriages again. When the left hand Gantry Carriage is touching the Top Panel, the left hand Gantry Carriage should be 5mm away from the Top Panel.
  • Page 39 Step 2.20 Thread one end of the second Belt through the Gantry Carriage indicated in the diagram. The teeth of the Belt should be touching the Flanged Bearing.
  • Page 40 Step 2.21 Insert the belt into the channel in the top of the Belt Hub. Use the empty channel, NOT the channel containing the yellow tab.
  • Page 41 Step 2.22 Route the Belt around the two Upper Position Idle Pulleys as shown.
  • Page 42 Step 2.23 Pass the Belt through the Gantry Carraige and around the Motor Pulley.
  • Page 43 Step 2.24 Route the Belt behind lower position pulley in the Gantry Carriage.
  • Page 44 Step 2.25 Step 2.26 Move the Gantry Carriages to the front of the machine. If the first belt has been tensioned correctly, the left Gantry Carriage will sit 5mm back from the Top Panel when the right Gantry Carriage is touching the Top Panel.
  • Page 45 Pull the belt tight. This should cause the left hand side Gantry Carriage to get closer to the Top Panel. Apply just enough tension to the belt to remove the gap between the left hand side Gantry Carriage and the Top Panel. Remove the yellow belt tab and and press the Belt into the Belt Hub as shown in the diagram.
  • Page 46 Step 2.27 Take this oportunity to check the Belts for twists and to make sure the correct pulleys are used for each Belt and that the gantry carriages meet the front of the Top Panel without any gaps. Flip the Frame Assembly back over onto its feet and test one last time that the Gantry Carriages meet the Top Panel at the same time.
  • Page 47 IMPORTANT: If the Gantry is not square, your designs will not be square. If the Gantry is not square, your machine may fail to home correctly. The Gantry is not square if the Gantry Carriages do not touch the Top Panel at the same time when pushed backwards and forwards.
  • Page 48 STAGE 3 DRIVER BOARD Lay out the parts listed below. Refer to the ‘PARTS Stage 3’ section. • Driver Board Cover. • Driver Board • 1x M3x12mm Screws • 4x M3x8mm Screws • Laser Unit You will also need a 2.5mm Hex Tool. Step 3.01 Attach the Laser Unit to the Laser Carriage.
  • Page 49 Step 3.02 Familiarise yourself with the Driver Board Cover using the diagrams below. DRIVER BOARD COVER TAIL CABLE MANAGEMENT FLAP LATCHES...

  • Page 50: Driver Board

    Step 3.03 Place the Driver Board over the Driver Board Cover and attach to the Laser Carriage. Note: Don’t allow any cables to be trapped under the Driver Board or the Cover. DRIVER BOARD DRIVER BOARD COVER M3 x 8mm SCREW...
  • Page 51 Step 3.04 Route the Laser Unit cables around the side of the Laser Carriage and under the Cable Management Flap illustrated in Step 3.02. Important: Cables must pass around the side of the Laser Carriage, not over the top. Connect the cables to the Driver Board sockets indicated in the diagram below.
  • Page 52 Step 3.07 Fold the Driver Board Cover as shown in the diagram.
  • Page 53 Connect the FFC to the Driver Board connector socket indicated in the diagram below. Clip In Latches.
  • Page 54 STAGE 4 BUTTON PCB Lay out the parts listed below. Refer to the ‘PARTS Stage 4’ section. • Button PCB • Button PCB Cover • Enable Button • Power Button • Ribbon Cable • 2x M3x12mm Screws • 2x M3 Washer •...
  • Page 55 Step 4.02 Turn the Frame Assembly upside down. Use the small boxes again to raise it off your table.
  • Page 56 Step 4.03 Attach the Button PCB Cover to the Rear Panel. M3 x 12mm SCREW M3 WASHER M3 NUT Step 4.04 Completely remove the hexagonal nuts from the Power Button and the Enable Button.

  • Page 57: Enable Button

    Insert the buttons into the indicated holes in the Top Panel. Return the hexagonal nuts to the buttons and tighten by hand. ENABLE BUTTON POWER BUTTON Connect the Power and Enable Buttons to the Button PCB.
  • Page 58 STAGE 5 CONTROLLER BOARD Lay out the parts listed below. Refer to the ‘PARTS Stage 5’ section. • Controller Board **Do not remove from anti-static bag until instructed** • Controller Board Cover • 2x Motor Cables • 3x Support Strip Clips •...
  • Page 59 When the Contoller Board Cover is fully folded; the lines on the back face should be visible from the outside.
  • Page 60 Step 5.02 Pull the Driver Board Cover Tail through the gap between the Top Panel and Rear Panel. Pull the white flexible cable part of the Driver Board Cover Tail through the hole in the Controller Board Cover. The black part of the tail should sit outside the Controller Board Cover. Expose the adhesive on the black part of the tail and stick it between the lines on on the Rear face.
  • Page 61 Step 5.03 Pull the Diver Board Cover Tail back down through the Top Panel until the cover is resting on the top panel. Attach the Controller Board Cover to the Rear Panel. M3x12mm SCREW M3 WASHER PCB STANDOFF...
  • Page 62 Step 5.04 Taking care not to put creases in the flexible cable, hold it up against the Top Panel to prevent it getting trapped underneath, then clip the Controller Board to the standoffs in the Rear Panel.
  • Page 63 Step 5.06 Insert flexible cable into Controller Board socket indicated in the diagram below. Note: To avoid damage, position FFC as squarely as possible to the connector before inserting.
  • Page 64 Step 5.07 Move the ferrite rings on the Motor Cables all the way to the indicated connector. Connect the Motor Cables to the Motors and the indicated sockets in the Controller Board. Slip the loose cables into the Cable Clips to keep them tidy.
  • Page 65 Step 5.08 Connect the Ribbon Cable to the Button PCB and to the indicated socket in the Controller Board. Slip the loose cables into the Cable Clips to keep them tidy.
  • Page 66 STAGE 6 ASSEMBLY COMPLETION Lay out the parts listed below. Refer to the ‘PARTS Stage 8’ section. • Base Plate. • Rubber Feet. (10x) • 8x M3x12mm Screws. • 8x M3 Washers. • 8x M3 nuts. You will also need a 2.5mm Hex tool. Step 8.01 Close Controller Board Cover.
  • Page 67 Step 8.02 Align Base Plate to the Corner Brackets making sure the holes indicated by the green arrow are in the orientation as shown. Attach the Base Plate to the Corner Brackets. M3 x 12mm SCREW M3 WASHER M3 NUT...
  • Page 68 Step 8.03 Attach the Rubber Feet to the Base Plate as shown below.
  • Page 69 AIR-ASSIST ACCESSORY (OPTIONAL) Only perform this stage if you have purchased the Air-Assist accessory. Lay out the parts listed below. Refer to the ‘PARTS Stage 6’ section. • Air assist pump • Air Assist hose • 3x Air Assist hose clips •...
  • Page 70 Step 02 Attach the end of Air-Assist Hose to the OUTPUT of the Air Assist accessory. The output is indicated by an arrow pointing out of the compressor. Step 03 Attach the Air-Assist pump to the baseplate using the two M3x6mm screws and washers provided.
  • Page 71 Step 04 Connect Air-Assist cable to the Controller Board. Step 05 Attach the additional rubber foot supplied with the Air-Assist Accessory to the base plate between the fasteners as indicated.
  • Page 72 Step 06 Route the free end of the Air-Assist Hose through the Driver Board Cover as shown. Step 07 Remove the Aperture Nozzle Plug and insert end of Air-Assist Hose into the Aperture Nozzle.
  • Page 73 Step 08 Attach three Air-Assist Hose Clips in the positions shown below. The air-assist hose catch on the clips should face downwards. Attach the air-assist hose into its clips.
  • Page 74 WORKSPACE CAMERA ACCESSORY (OPTIONAL) Only perform this stage if you have purchased the Workspace Camera accessory. Lay out the parts listed below. Refer to the ‘PARTS Stage 7’ section. • Workspace Camera • 2x M3x12mm Screw • 2x M3 Washer •...
  • Page 75 Step 02 Pull the Workspace Camera cable through slot in Top Panel as shown. Attach Workspace Camera to the Top Panel as shown. M3 x 12mm SCREW M3 WASHER M3 NUT...
  • Page 76 Step 03 Connect Workspace Camera cable to the Controller Board socket indicated.
  • Page 77 Your next step is to work through the User Manual. Go to this link to get started: darklylabs.com/e2start Technical support If you need more inforamtion about the assembly or operation of your Emblaser Core, check the Help Centre: darklylabs.com/help Otherwise, please email us at: support@darklylabs.com...