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Sienci Labs LongMill MK2 Extension Kit Assembly Manual

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LongMill MK2 48" Extension Kit

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Summary of Contents for Sienci Labs LongMill MK2 Extension Kit

  • Page 1 LongMill MK2 48” Extension Kit...

  • Page 2: Table Of Contents

    Table of Contents 48” X-axis rail box unpacking Hardware box Drag chain & cable box Y-axis gantry plate box Tools you’ll need Missing/broken parts? Assembly tips Drag chain and wiring disassembly Disassembling the drag chains Disconnecting wiring Parts to be reused X-axis disassembly Dismounting machine X-axis motor and leadscrew removal...

  • Page 3: 48" X-Axis Rail Box Unpacking

    Congratulations on getting your LongMill MK2 48” extension kit! In just a few steps, you’ll soon have a much larger CNC with 56% more cutting area than before, as well as the ability to pass full width 4’ sheets of material through.

  • Page 4: Drag Chain & Cable Box

    EX Drag chain & cable box MK2 EX hardware box...

  • Page 5: Y-Axis Gantry Plate Box

    EX Y-axis gantry plate box Tools you’ll need You’ll need these tools on hand for assembly. Most people will have these in their shop: ● Metric Allen keys (we provide) ● Metric wrenches, metric socket set, or adjustable wrenches. ● A small flat head screwdriver We don’t recommend you use an impact driver for assembly except when mounting the machine because you won’t save much time and some assemblies are prone to damage if they’re overtightened Missing/broken parts?

  • Page 6: Assembly Tips

    (https://sienci.com/contact-us/) and see if there are any other areas of assembly you can continue with in the meantime. We’ll get back to you as soon as we can. Assembly tips 1. Take breaks when needed The disassembly and reassembly process can take a few hours. Pace yourself and enjoy the process. 2.

  • Page 7: Drag Chain And Wiring Disassembly

    Drag chain and wiring disassembly Disassembling the drag chains On the Y-axis drag chain, start unclipping any of the clips securing the wires along the Y-axis. Detach the start and end links from this drag chain, then remove the drag chain entirely.
  • Page 8 Disconnect the X-axis motor connector. On the X-axis drag chain, unclip the clips securing the wires along the X-axis. Detach the start and end links from this drag chain, then remove the drag chain entirely.

  • Page 9: Disconnecting Wiring

    Disconnecting wiring Disconnect the motor cables going to the Z-axis motor and X-axis motor. Disconnect and remove any other add-ons such as limit switches or laser if installed. Disconnect any of these cables from your control box as well.
  • Page 10 Remove the router from the router mount by loosening the two M5 screws at the front of the router mount. Slide the router body out and remove any zip ties holding the router power cord if applicable. Set the router aside for re-installation later on.

  • Page 11: Parts To Be Reused

    Parts to be reused Set aside any cables removed, router, as well as the shorter Y-axis drag chain. Discard the longer X-axis drag chain - this won't be reused during reassembly.

  • Page 12: X-Axis Disassembly

    X-axis disassembly Dismounting machine Before beginning the disassembly and replacement of components which make up the X-axis of the machine, start by unmounting the machine from your current wasteboard. Undo each of the eight wood screws installed on the left and right sides of your machine.

  • Page 13: X-Axis Motor And Leadscrew Removal

    X-axis motor and leadscrew removal Working backwards from how your LongMill was assembled, we’ll first start by removing the X-axis motor, then X-axis lead screw. First, loosen the coupler clamping screw at the lead screw side as shown. Unscrew each of the four M5-50mm screws holding the motor onto the Y-gantry plate. While doing so, be careful not to lose any of the nylon washers or aluminum standoffs which may slide off the four screws.
  • Page 14 On the removed X-axis motor assembly, loosen the coupler screw at the motor side, and remove this coupler from the motor. At the left side of the machine where the motor assembly was removed, slide the flange bearing out of the Y-gantry plate and off of the lead screw.
  • Page 15 At the opposite side, pull the brass ACME locking nut and lead screw to slide the XZ gantry and lead screw to the right and out of the left Y-gantry plate. Turn the lead screw counter-clockwise by hand to unthread it from behind the XZ gantry assembly. Once fully unthreaded, remove the leadscrew from the machine by removing it from the right side.

  • Page 17: X-Axis Rail Disassembly

    X-axis rail disassembly Remove the four M5-25mm screws on the left Y-gantry plate as shown, leaving the X-axis rail to rest on the drag chain mount. Lift the X-axis rail slightly, then pull out the entire left Y-axis rail and gantry from underneath. Rest the X-axis rail on the wasteboard for now.
  • Page 18 Slide XZ gantry assembly to the left, removing it from the X-axis rail entirely.
  • Page 19 At the right Y-gantry plate, undo the four M5-25mm screws to completely detach the X-axis rail. Remove the drag chain mount and drag chain end link from the left side of the X-axis rail by loosening all three M5-10mm bolts and sliding the components off. Set the X-axis rail and drag chain mount with screws aside. The drag chain mount and drag chain end link will be getting reused later, but the X-axis rail will of course not be.

  • Page 20: Y-Axis Gantry Disassembly

    At this point, you’ll want to transfer the two Y-axis rail assemblies and XZ-gantry assembly onto your larger MDF waste board since the soon-to-be 48x30” machine likely will not fit on your existing wasteboard anymore. Y-axis gantry disassembly Since the left and right Y-axis rails are perfectly mirrored assemblies, repeat any of the steps for this section on both Y-axis rail assemblies.
  • Page 21 Next, remove the upper two V-wheels from the Y-gantry plate to allow the Y-gantry plate to detach from the rail. Once both Y-gantry plates are detached from the rails, remove the lower set of V-wheels as well and set all V-wheels aside with their associated washers and nuts.

  • Page 22: Parts To Be Reused

    Parts to be reused At the end of the disassembly of the X-axis, stop to make sure you haven’t lost any parts which will be reused later. These are all shown below, any other parts not shown can be discarded.

  • Page 23: 48" Extension X-Axis Assembly

    48” Extension X-axis assembly EX Y-gantry plate assembly On the new Y-gantry plates included in the extension kit marked ‘EX’ , begin installing the V-wheels into the upper holes of the Y-gantry plates. Make sure the eccentric nuts are rotated so that the V-wheels are in their highest ‘open’...
  • Page 24 Rest the Y-gantry plates onto the Y-axis rails and install the lower V-wheels into the Y-gantry plate to secure the Y-gantry plate on the rail. Check to make sure the gantries roll/slide easily along the rail.
  • Page 25 If the two M5-nylock nuts have fallen out of the Y-axis anti-backlash delrin nuts, you’ll want to re-install these. If you find that they fit loose and are continuously falling out, you can apply a small piece of tape to the back of the delrin nut to hold these in place as shown below.
  • Page 26 Slide the Y-gantries to line up the highlighted two holes in the plate with the Y-axis delrin nuts. Fasten the Y-gantry to the delrin nut by using the two M5-25mm screws removed during disassembly. Only tighten these screws until snug.

  • Page 27: Ex X-Axis Preparation

    EX X-axis preparation On the new 48” X-axis rail extrusion, slide the reused drag chain end link assembly into the T-slot using the T-nut. Slide this end link ~10” away from the end of the X-axis rail, then tighten the screw. Slide in the drag chain mount by sliding in the two T-nuts into the T-slot of the rail.
  • Page 28 Grab the XZ gantry that was previously removed from the original X-axis rail. To accommodate the larger X-axis lead screw the Delrin nut on the back of the XZ gantry will need to be swapped out with the much larger EX Delrin nut.
  • Page 29 Install these M5-nylock nuts into the larger EX Delrin nut. The EX delrin nut is now installed onto the XZ gantry using the two further holes circled below. Insert the M5-25 bolts into the front of the XZ gantry and into the EX Delrin nut.

  • Page 30: Ex X-Axis Rail Mounting

    Tighten these screws only until the spring lock washer has been flattened on the two M5-25mm bolts. These should only be snug as overtightening will not allow the Delrin nut to self-align and may bind up later on. EX X-axis rail mounting Attach the X-axis rail to the right Y-axis gantry plate using the four M5-25mm bolts.
  • Page 31 Lift up the left side of the X-axis rail and begin sliding the XZ gantry onto the rail. Lift the left side of the rail upwards and rest the drag chain mount on the left Y-gantry plate. Fasten the left Y-gantry plate onto the X-rail using four M5-25mm bolts.

  • Page 32: X-Axis Motor Mounting

    X-axis motor mounting Slide a flange bearing into the left Y-gantry plate. Grab the X-axis stepper motor assembly that was previously removed during disassembly. Slide the large EX coupler over the motor shaft. Do not tighten the bolts on the coupler, this will be left loose until the lead screw is installed.

  • Page 33: X-Axis Lead Screw Installation

    Mount this assembly onto the left Y-gantry plate, keeping the flange bearing in place. Orient the motor so the wires are facing towards the rear of the machine. X-axis lead screw installation...
  • Page 34 Pass the EX lead screw through the right Y-gantry plate towards the XZ-gantry assembly. Be careful not to bend the lead screw while doing this or handling it otherwise. Begin threading the lead screw into the X-axis delrin nut. Continue threading the lead screw until it sticks out from the left side of the X-axis gantry. Slide the lead screw and X-axis gantry towards the left and pass the end of the lead screw into the flange bearing and into the motor coupler.
  • Page 35 Tighten the motor coupler onto the lead screw. Use the allen key + handle to do this as this bolt must be very tight.
  • Page 36 Remove the bolt from the other end of the coupler completely. Pass the included smaller allen key through this hole of the removed bolt to lock the coupler against the motor standoffs from rotating. Alternatively, a small screwdriver, bolt, or rod can be passed through instead. Locking the lead screw from rotating will allow for easier installation of the ACME locking hex nut at the opposite side.
  • Page 37 At the opposite side of the lead screw on the right Y-gantry plate, slide a flange bearing over the lead screw and into the Y-gantry plate. Grab the EX ACME locking hex nut and begin threading this onto the lead screw.
  • Page 38 Using a 19mm, ¾” , or adjustable wrench, tighten this ACME nut only until the lead screw no longer has any side-to-side play. Then install the M5 locking bolt into the brass ACME locking nut to secure this. Turn the lead screw by hand afterwards to make sure it spins freely. If you feel any significant resistance, undo the M5 locking bolt and loosen the brass ACME locking hex nut a small amount.

  • Page 39: Drag Chain And Wiring Installation

    Drag chain and wiring installation Attaching drag chains Reinstall your router into the router mount and optionally use the top left hole on the X-gantry as a zip tie point to keep your router wire out of the way during operation. If using a zip tie, ensure the cord has some extra slack to allow the router to travel all the way down during use.
  • Page 40 Grab one of the two motor cables which were previously disconnected and connect it to the plug on the Z-axis NEMA 23 motor.
  • Page 41 Connect the remaining motor cable to the plug on the X-axis NEMA 23 motor. Grab the EX drag chain and position this running along the X-axis with the correct end of the drag chain oriented to clip on to the start and end links along the X-axis. Seat the Z-axis motor cable and router power cord into this drag chain.
  • Page 42 Grab the router power extension cable and motor extension cable from the EX drag chain & cable box in the X-axis rail box. Connect the power extension and motor extension cables to the router power cord and Z-axis motor cable coming out from the X-axis drag chain.
  • Page 43 Grab a motor cable and connect it to the X-axis motor. Begin routing these cables into the Y-axis drag chain, fitting these cables underneath the drag chain mount. Allow the connectors to sit outside of the Y-axis drag chain as shown. This excess bundling of cable will be organized neatly in the next step.

  • Page 44: Organizing Excess Cable Lengths

    Secure the cables inside the drag chain by re-clipping each clip, then Attach the drag chain onto the start and end links mounted on the machine. Organizing excess cable lengths Grab the two ‘cable hangers’ from the EX hardware box. Align the clip portion of these into the T-slot on the X-rail and press directly downwards firmly to clip these in place.
  • Page 45 Get two zip ties from the X-axis EX hardware bag and insert these into the lower hole in each of the drag chain mounts.
  • Page 46 Straighten out the excess cabling into one bunch, then fold this in half.
  • Page 47 The folded bunch of excess cables can then be secured into both cable hangers. Tighten the two zip ties at each hanger. Trim the excess length from the zip ties once finished. Adjust any of the cabling so it fits well within these two hangers and nothing hangs below the X-axis rail, then tighten the zip ties fully.
  • Page 48 If you’ve unplugged the two cables for the Y-axis stepper motors, plug these back in now. Bring the cables around to the left of the machine so they’re now all bundled together (pictured). You’ll be plugging the motors cables into the control box shortly but otherwise the machine wiring is now complete!

  • Page 49: Reconnecting Control Box

    Reconnecting control box Plug the X-axis motor cable, Z-axis motor cable extension, and the two Y-axis motor cables into the control box as shown. Re-connect any other cables which may have been disconnected during earlier disassembly. Note: if you’ve installed a Z-axis limit switch and its respective extension cable, plug this into the Z-axis limit port. Tuning movement Before the LongMill can be mounted onto the larger wasteboard, the V-wheels and Delrin nuts on the X and Y axes will need to be tuned to ensure the machine’s axes will all self-align when moved.
  • Page 50 Congratulations on finishing the installation of your LongMill MK2 48” extension kit! While the operation of your LongMill will stay largely the same, we hope you can take advantage of the extra cutting real estate and benefits that come with the larger X-axis material capacity. Good luck and happy making! -The Sienci Labs team...

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