Assembling a Linear Servo Arrayer
     From plans originally by Joe DeRisi
Partial Parts List
Inventory, unpacking stages, assembly of Parframe, and mounting of Y-stage
Parframe angle brackets
Mounting of Z-stage motor
Mount Z-stage to Y-stage
Assemble Fuse Box
Relay Box Assembly
Mount X-stage
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Startup and Troubleshooting

Inventory, unpacking stages, assemblely of Parframe, and mounting of Y-stage

Beginning with stuff in boxes:
  • Identify and label all boxes.
  • Unpack stages
    • The Y-stage is the biggest
    • The metal bands that surround the boxes are held together by crimps. A screwdriver can be used to insert between the bands where they are crimped together and with a twist of the wrist the crimps can be broken apart to pop the straps open.
    • The boxes are sealed by wood screws. A reversible drill with a phillips head bit is very handy for removing all the screws.
    • Save the packing crates until the stages have been verified to work without problems.

For clarification: the X-stage lies flat on the table, the Y-stage is perpendicular to the X-stage and held up by the parframe. The Z-stage is the smallest and attaches to the Y-stage platter. The Z-stage holds the printing arm and does the pin tapping.

Assemble Parframe

You can get a sense of the spacing of the parframe using the aluminum plates, however the plates will be attached to the Y-stage prior to attaching them to the parframe.
The parframe cross members are attached to an upright with butterfly connectors. In the background you can see the Y-stage, upside down for attachement of the aluminum plates.
The Parframe upright has been modified by drilling access holes so you can insert a hex wrench to tighten the nuts that bear down on the butterfly connectors.

Fastener Summary. A variety of fasteners can be used to assemble the arrayer. Parker may or may not send you all the right ones. It's wise to have a a stock of extra bolts of many sizes on hand. Make sure whatever bolts you use for a particular purpose aren't bottoming out.

The econo fastener tabs in the diagram are used to hold the Y-stage adaptor plates to the parframe. They can be set into the parframe grooves with tweezers, or by using a wire to get underneath them. When dropped in by hand they don't fall flat but need to be rotated slightly such that they fall into place. With the parframe flat on the table, the fasteners can be aligned roughly for the spacing of the adaptor plates.

Lift the Y-stage onto the parframe and attach with M6x12 bolts. The bolts should be just long enough to be able to "pick up" the fastener with rotation as the fasteners sit in the grooves. When trying to pick up fasteners in this way when you don't have direct access to the bolt with your fingers, a nifty method is to rotate the bolt counterclockwise until you sense a click as the threads rotate past the point at which they would catch if rotated clockwise. Once you sense the click, rotate the bolt clockwise and it will almost always pick up the fastener properly. As always, take care to avoid cross threading.

With the Y-stage mounted to the parframe, the assembly can be raised and mounted to the table breadboard. Attach the feet to the parframe PRIOR to raising it, since it's easiest to attach the feet connectors while you have access to the open ends of the parframe, but keep the connectors finger tight and slide them up towrads the Y-stage. Thus when you raise the parframe for mounting you can loosen them as need and slide them down to the table.
Enlist hapless postdocs to help. Use washers with the screws that go through the feet and into the table.

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Wiring Diagrams:

Power Supply Wiring Diagram (PDF)

ICM2900 Motor I/O wiring diagram for 50 Pin cables (PDF)