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FORTIS CNC Machine – Mechanical Assembly Instructions
1.0 Introduction
1.1 Getting Started
Before starting any build, it is good practice to get organised. Start by unpacking all parts received and checking each part off against the Bill of Materials mentioned below:
Some of the parts listed in the table above are used to make the FORTIS machine table mentioned in section 7.4.
1.2 Tools Required
- 5mm Allen Key
- 6mm Allen Key
- Builder‘s Square
1.3 Pre Assembly Notes
We recommend reading through the complete assembly guide before beginning the build, as this gives you a rough idea of how it all goes together. Before starting each step, make sure you have studied the drawings and fully understand the instructions. As you progress through your build, use the Builder’s Square to make sure everything is aligned before the final tightening of all bolts and nuts.
When attaching parts, if a part is requiring significant force to attach, stop, take it off, re-read the instructions, and try again. Do not over-tighten bolts as you may strip the thread or head. If you have any questions regarding the build, please contact us at https://www.makerstore.com.au/contact-us/sales, we are happy to help!
2.0 Y-Axis Assembly
Bill of Materials
The parts required to complete the Y-Axis and Y2/A Axis assemblies are listed above in the table. Start the assembly by unpacking the necessary parts, then follow the instructions below to complete the assembly.
2.1 Rack and Rail Assembly
Step 1:
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- Insert half the M4 Cap Head Bolts – 20mm (9) into the mounting holes of Linear Rail – HGR15 (44). Loosely attach half of the 40 Series Sliding T-Nuts-M4 (35) to these bolts (9). See Figures 2.1-1 & 2.
Step 2:
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- Carefully slide the above assembly into the top groove of 40 Series Extrusion- 4080 (59). Don’t tighten the bolts.
Step 3:
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- Insert half the M6 Cap Head Bolts – 20mm (16) into the mounting holes of Helical Gear Rack (33). Loosely attach half of the 40 Series Sliding T-Nuts-M6 (37) to these bolts (16). See Figures 2.1-5 & 6.
Step 4:
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- Carefully slide the above assembly into the bottom groove of 40 Series Extrusion- 4080 (59). Don’t tighten the bolts.
Step 5:
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- Use the Alignment Tool (91) to space the HGR15 Rail (44) correctly from the top of the 40 Series Extrusion- 4080 (59). Start at one end of the Y-Axis assembly, pushing the tool down onto the 40 Series Extrusion’s top, and tighten the M4 Cap Head Bolts – 20mm (9) into the M4 T-Nuts (35) around the tool. Slide the tool slowly down the HGR15 Rail to the centre, then opposite end, tightening the M4 Cap Head Bolts – 20mm as you go. Once aligned tighten remaining bolts. See the video below for reference.
- Once the HGR15 Rail (44) is in place, use the Alignment Tool (90) in exactly the same way to space the Helical Gear Rack (33) from the HGR15 Rail (See images above). Starting at one end of the Y-Axis assembly, tighten the M6 Cap Head Bolt – 20mm (16) into the M6 T-Nut (37) around the tool. Slide the tool slowly down the HGR15 Rail to the centre, then opposite end, tightening the M6 Cap Head Bolts – 20mm as you go. See GIF below for reference.
Step 6:
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- With the HGR15 Rail and Helical Gear Rack aligned, slide 2x HGH15CA Bearings (4) onto the HGR15 Rail (44). Make sure to face the bearings grease nipple outwards for easy application of lubricant.
Step 7:
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- Insert 4x 40 Series Sliding T-Nuts -M8 (38) into the bottom groove (closer to the rack) of the 40 Series Extrusion – 4080 (59). These T-Nuts will be used later to connect the base supports.
Note: If you are going to use the Maker Store Machine table install 6x 40 Series Sliding T-Nuts -M8 (38) into the bottom groove (closer to the rack) of the 40 Series Extrusion – 4080 (59), as shown below:
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Step 8:
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- Secure the Plasma Y Trigger Plate (66) and the Plasma Y End Plate (65) to each end of the Y-Axis 40 Series Extrusion – 4080 (59) with M8 Cap Head Bolts – 10mm (17).
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Step 9:
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- Repeat steps 1-8 to build the Y2/A-Axis. When securing the Plasma Y Trigger Plate (66) and the Plasma Y End Plate (65), reverse the plate placement so that the Plasma Y Trigger Plates for both axes are at the front of the machine, as shown above.
2.2 Base Assembly
If you are not using Maker Store Machine Table, follow Step 1 (a). Otherwise, follow Step 1 (b) below
Step 1(a):
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- Insert 2x 40 Series Sliding T-Nuts -M8 (38) one on each end of 40 Series Extrusion – 4040 (58).
- Attach 2-Hole Inside Gusset Corner Brackets (22) using M8 Cap Head Bolts – 16mm (18).
- Repeat above steps to create 3x assemblies.
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Step 1 (b):
Note: If you are going to use the Maker Store Machine table listed in section 7.4, create the following 2x assemblies, instead of the ones shown in Step 1 (a) above, using 2×2 Hole Inside Gusset Corner Bracket – 40 Series (23). Please see the images below.
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Step 2:
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- Grab one of the assemblies prepared in Step 1 and insert 2x 40 Series Sliding T-Nuts -M8 (38) one on each end of 40 Series Extrusion – 4040 (58).
- Similar to the above assembly, attach 2-Hole Inside Gusset Corner Brackets (22) using M8 Cap Head Bolts – 16mm (18) on the other side.
Step 3:
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- Attach the above shown extrusion such that the distance between the outer face of the first extrusion and face of this extrusion facing first extrusion is 480mm
Step 4:
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- Attach the above created 4040 extrusion assemblies to the Y/Y2 Axis assemblies as shown above using M8 Cap Head Bolts – 16mm (18).
- Please ensure to square the assembly using a Builders Square.
If you are building different machine sizes, see the images below:
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For FORTIS CNC Machine 1500×3000, Y-Axis extrusion lengths are 3050mm. The HGR15 Rails are 3000mm long, so to avoid the bearings from falling off the rails, an end stop assembly is installed on one end. See the steps below
Put a 40 Series M5 Spring Loaded T-Nut into the Y-axis extrusion groove. Then attach a M5 Cap Head 35mm Bolt and a 20mm Spacer into the above T-Nut a shown above. Repeat the same step for other Y-axis.
Please Note, this step is only required for 1500x3000mm size machine
Note: If you are going to use the Maker Store Machine Table listed in section 7.4, see the assembly image below
For other machines sizes, see the images below:
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Step 5:
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- Slide 2x 40 Series Sliding T-Nuts – M8 (38) into outer base support 4040 extrusion.
- Attach Leg Bracket – Left (20) to the above extrusion using M8 Cap Head Bolts – 10mm (17).
- Similarly attach the rest of Leg Bracket – Left and Right (20,21) to the Y-Axis assembly.
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For other machine sizes, see the images below:
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Note: If you are going to use the Maker Store Machine Table listed in section 7.4, see the assembly image below
Complete Base Assembly
For other machine sizes, see the images below:
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2.3 Y-Axis Pivot and Plate Assembly
Step 1:
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Detailed line view of above assembly
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- Attach the PLATE-Pivot (62) to the PLATE-Plasma Y (67) by sliding the components shown above onto the Shoulder Bolt – 20mm (50) and Shoulder Bolt – 35mm (52).
- Please ensure the pocket on the PLATE-Pivot (62) is facing towards the PLATE-Plasma Y as the Thrust Bearing – F6-12M (3) will sit in this pocket, sandwiched between the two plates.
- The slot in the PLATE-Plasma Y (67) allows the PLATE-Pivot (62) to move up and down in the slot via the Shoulder Bolt – 35mm (52). This mechanism is used to maintain a constant tension between the Helical Pinion and the Helical Rack.
Step 2:
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- Slide the components shown above in the illustrated sequence onto the Shoulder Bolts 20mm and 35mm (50,52).
- The Rod End Pivot (48) has a 8.20mm diameter hole that fits in 2x Brass Bushings (42), with their flanges resting on the Rod End Pivot (48) faces.
Step 3:
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- Place the Slot Washer – 15x5x2mm (88) in between the 90 Degree Angle Corner Connector (25) and the PLATE-Plasma Y (67). Attach this assembly to the plate (67) using M5 Low Profile Screw – 15mm (77).
Step 4:
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- Attach the Rod End Pivot (48) to the 90 Degree Angle Corner Connector (25) using the components shown above in the demonstrated sequence.
- Please ensure to use a M5 Jam Nut (46) in between 90 Degree Angle Corner Connector (25) and Rod End Pivot (48).
- After assembling, tighten the M5 Jam Nut (46) so that it sits on the Rod End Pivot (48). Don’t tighten the M5 Cap Head Bolt – 50mm (15) completely.
- Repeat the steps 1 – 4 to create similar assembly for Y2 Axis.
- Repeat the same steps for all other machine sizes.
2.4 Y-Axis Gantry Assembly
Step 1:
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- Line up the mounting holes of Linear Bearing – HGH15CA with the mounting holes of PLATE-Plasma Y and using 8x M4 Cap Head Bolts – 16mm (16) and 8x Precision Shim – M4 (80) attach the PLATE-Plasma Y (67) to the Linear Bearing – HGH15CA (4).
- Repeat this step to attach the above assembly to Y2-Axis.
- Repeat the same steps for all other machine sizes.
2.5 Motor and Gear/Pinion Assembly
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- Attach the Helical Gear – 20 Tooth (34) to the NEMA23 Stepper Motor (32) Shaft using the gear set screws.
- Please ensure the distance between the motor flange and gear/pinion is 2mm.
- Repeat this step to create three such assemblies. Two assemblies will be used for Y-Axis and one for X-Axis.
- Repeat the same steps for all other machine sizes.
2.6 Motor Installation
Step 1:
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- Attach the 2x motor assemblies created above to the Y/Y2 Axis Gantry assembly made in section 2.4 using M5 Cap Head Bolts – 20mm (12) and Metric Aluminium Spacers – 9mm (86).
- Tighten the M5 Cap Head Bolts – 50mm (15) attached to the Rod End Pivot (48). As you tighten the motor along with pinion will raise up and get engaged with the Helical Rack. Ensure that the pinion is properly engaged with the rack.
- Repeat this step for the Y2/A Axis.
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Complete Y/Y2 – Axis Assembly
Repeat the same process for all other machine sizes.
3.0 X-Axis Assembly
Bill of Materials
The parts required to complete the X-Axis Assembly are listed above in the table. Start the assembly by unpacking the necessary parts, then follow the instructions below to complete the assembly.
3.1 X-Axis Extrusion Configurations
- The PLATE-Plasma Y has been designed in such a way that it allows a user to connect the above bottom 40 Series Extrusions 4080 (59) of the X-axis in two different ways. These two different ways provide different clearances; 120mm and 160mm. See the images below.
- Based on your choice of configuration, follow the steps for that specific configuration.
In these configuration setups, the placement and attachment of Top 4080 Extrusion remains same. The only difference is the holes where bottom 4080 Extrusion is attached.
3.2 120mm Clearance Configuration
3.2.1 Bottom 4080 Extrusion preparation and mounting
Step 1:
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- Attach 2x M8 Cap Head Bolts – 16mm (18) and 2x 40 Series Sliding T-Nuts – M8 (38) to 1x 2×2 Hole Inside Gusset Corner Bracket – 40 Series (23) as shown above. Don’t screw in the T-Nuts completely.
- Make four such assemblies.
Step 2:
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- Slide in one of the assemblies prepared in Step 1 above onto the 40 Series Extrusion 4080 (59) at one of the ends as shown above. Tighten the M8 bolts of the assembly so that its secured onto the 4080 Extrusion.
- Slide in one of the assemblies prepared in Step 1 above onto the 40 Series Extrusion 4080 (59) at the other end as shown above. Tighten the M8 bolts of the assembly so that its secured onto the 4080 Extrusion.
Step 3
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- Attach the extrusion assembly to the PLATE-Plasma Y using 2x M8 Cap Head Bolts -16mm (18) and 2x Precision Shim 12x8x1mm (89) as shown above.
- Attach the 2-Hole Inside Gusset Corner Bracket – 40 Series (22) of the extrusion assembly to the PLATE-Plasma Y using 2x M8 Cap Head Bolts – 25mm (96), 2x Precision Shim 12x8x1mm (89) and 2x Nylon Insert Hex Locknut – M8 (97) as shown above.
- Repeat this step for the other PLATE-Plasma Y.
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Tip: Square the machine by moving the Y-Axis gantry to front of the machine, adjust the bolts of the base assembly brackets and retighten them. Then move the Y-Axis gantry to the back of the machine and repeat adjusting and tightening of base assembly bracket bolts at the back.
3.2.2 Top 4080 Extrusion, Rack – Preparation and mounting
Step 1:
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- Insert 8x M6 Cap Head Bolts – 20mm (16) into the mounting holes of Helical Gear Rack (33). Loosely attach 8x 40 Series Sliding T-Nuts-M6 (37) to these bolts (16).
Step 2:
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- Slide in one of the assemblies prepared in Step 1 of section 3.2.1 above onto the 40 Series Extrusion 4080 (59) at one of the ends as shown above. Tighten the M8 bolts of the assembly so that its secured onto the 4080 Extrusion.
- From one of the ends of above extrusion, slide in the Helical Rack Assembly prepared above into the first groove of the 40 Series Extrusion 4080 (59). Don’t tighten the bolts of the Helical Rack as they will be tightened later after alignment.
- Slide in fourth Bracket Assembly prepared in Step 1 of section 3.2.1 onto the above 40 Series Extrusion 4080 (59) at the other end as shown above. Tighten the M8 bolts of the assembly so that its secured onto the 4080 Extrusion.
Step 3:
- Use the Alignment Tool (90) to space the Helical Gear Rack (33) correctly from the front of the 40 Series Extrusion- 4080 (59). Start at one end and slide the tool slowly down the entire length of the extrusion and tighten the M6 Cap Head Bolts -20mm (16) of the Helical Gear Rack (33). See the video below for reference.
Step 4:
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- Attach the above extrusion assembly to the PLATE-Plasma Y using 2x M8 Cap Head Bolts -16mm (18) and 2x Precision Shim -12x8x1mm (89) as shown above. Don’t tighten the bolts completely.
- Repeat this step for the other PLATE-Plasma Y.
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- Attach the 2-Hole Inside Gusset Corner Bracket – 40 Series (22) of the extrusion assembly to the PLATE-Plasma Y using 2x M8 Cap Head Bolts – 16mm (18) as shown above.
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3.2.3 4080 Extrusions Spacing and Securing
Step 1:
- Place the 40 Series Extrusion 4080 – Offcut (91) in between the two 40 Series 4080 Extrusion -1000mm (59) and slide it closer to the PLATE-Plasma Y and tighten the M8 Cap Head Bolts -16mm as shown above.
- Repeat the same process for the other PLATE-Plasma Y.
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Follow the same steps for all other machine sizes.
3.3 160mm Clearance Configuration
3.3.1 Bottom 4080 Extrusion Preparation and Mounting
Step 1:
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- Repeat the Step 1 and Step 2 of Section 3.2.1 and create the assembly as shown above.
Step 2:
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Step 2: Repeat steps mentioned in section 3.2.2 to attach the top 4080 Extrusion and Helical Rack.
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3.3.2 4080 Extrusions Spacing and Securing
Step 1:
- Place the 40 Series Extrusion 4080 – Offcut (91) in between the two 40 Series 4080 Extrusion -1000mm (59) and slide it closer to the PLATE-Plasma Y and tighten the M8 Cap Head Bolts -16mm as shown above.
- Repeat the same process for the other PLATE-Plasma Y.
3.4 Linear Rail HGR15 Mounting
Step 1:
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- Insert half the M4 Cap Head Bolts – 20mm (9) into the mounting holes of Linear Rail – HGR15 (44). Loosely attach half of the 40 Series Sliding T-Nuts-M4 (35) to these bolts (9). See Figures 3.4-1 & 2.
- Prepare two such assemblies.
Step 2:
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- Through the slot of Y-Axis Plate, slide the Linear Rail HGR15 assembly prepared in Step 1 in the X-Axis Bottom extrusion. See Figure 3.4-3 for reference.
- Slide the 2x Linear Bearing – HGH15CA (4) onto the Linear Rail HGR15 as shown above.
Step 3:
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- Use the Alignment Tool (90) to space the HGR15 Rail (44) correctly from the top of the 40 Series Extrusion- 4080 (59). Start at one end of the X-Axis bottom Extrusion, pushing the tool down onto the 40 Series Extrusion’s top, and tighten the M4 Cap Head Bolts – 20mm (9) into the M4 T-Nuts (35) around the tool. Slide the tool slowly down the HGR15 Rail to the centre, then opposite end, tightening the M4 Cap Head Bolts – 20mm as you go. Once aligned tighten remaining bolts. See the GIF below for reference.
Step 4:
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- Repeat the above Step 2 to install Linear Rail HGR15 Assembly prepared in Step 1 onto the Top X-Axis Extrusion Don’t tighten the M4 Cap Head Bolts – 20mm (9) of this HGR15 Rail as they will be tightened later. See Figure 3.3-8 for reference.
3.5 X-Axis Plate/HGR15 Rail Assembly
Step 1:
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- Line up the Linear Rail HGR15 – 280mm (45) mounting holes with the mounting holes on the PLATE-X-Axis (64) as shown above.
Step 2:
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- Use the Alignment Tool (90) to align Linear Rail HGR15 – 280mm (45) on the PLATE-X-Axis (64). Start at one end of the PLATE-X-Axis (64), pushing the tool down onto HGR15 Rail – 280mm (45), and screw in the M4 Cap Head Bolts – 14mm (7) through the HGR15 Rail into into the PLATE-X-Axis. Slide the tool slowly down the HGR15 Rail tightening the M4 Cap Head Bolts – 14mm as you go. See the video below for reference.
- Repeat Step 2 for other Linear Rail HGR15 – 280mm installation. See Figure 3.5-6 below:
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3.6 X-Axis Motor Mount/Pivot Plate Assembly for 120mm Clearance Configuration
Step 1:
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- Attach the PLATE-Pivot (62) to the PLATE-X Motor Mount (63) as shown above. Follow the sequence for different components while assembling the system.
- 2x Brass Bushing – 6x8x5 – 12×1 (42) fit in the Rod End Pivot (48) and 2x Brass Bushing – 6x8x5 – 12×1 (42) fit in the pivot slot of PLATE-X Motor Mount Pivot as shown above.
- Please ensure to use correct Shoulder Bolts – 16mm & 30mm (49,51) for this assembly.
Step 2:
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- Attach the Belt Mount Plate – L Type (61) to the assembly prepared in Step 1 using 1x Metric Aluminium Spacers – 6mm (85) and 1x M5 Low Profile Screws – 12mm (76) as shown above.
- Slide in the different components onto 1x M5 Cap Head Bolts – 45mm (14) and screw in the M5 Cap Head Bolts – 45mm (14) into the Rod End Pivot (48) as shown above. Don’t screw in the bolt completely, keep it loosely attached.
- Please ensure to slide in 1x M5 Jam Nut (46) onto the M5 Cap Head Bolts – 45mm (14) placed in between the Belt Mount Plate – L Type (61) and Rod End Pivot (48).
Step 3:
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- Attach the 4x 90 Degree Angle Corner Connectors (25) to the PLATE-X Motor Mount (63) using 4x M5 Button Head Screws – 12mm (73). Pay attention to the mounting holes in which the screws are screwed in. See figures above for reference. The holes used for connecting the 90 Degree Angle Corner Connector on top and bottom of PLATE-X Motor Mount is different for 120mm and 160mm configuration. For 160mm configuration, follow Section 3.9 below.
3.7 X-Axis Plate/Motor Mount Plate Assembly for 120mm Clearance Configuration
Step 1:
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- Attach the assembly prepared in section 3.6 to PLATE-X-Axis (64) using 4x M5 Button Head Screws – 8mm (75) as shown above.
Step 2:
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- Attach the Limit Switch Trigger Plate (70) to the PLATE-X-Axis (64) using 1x M5 Button Head Screws – 8mm (75) as shown above.
- There are two holes for mounting the above plate for 120mm clearance configuration. Use any of the one holes on the side of PLATE-X-Axis as per your liking. The same side will trigger the Limit Switch which will be installed later.
3.8 X-Axis Plate Assembly Installation for 120mm Clearance Configuration
Step 1:
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- Attach the assembly prepared in section 3.8 to 4x Linear Bearing – HGH15CA (4) using 16x M4 Cap Head Bolts – 10mm (5) as shown above.
Step 2:
- Slide the above installed X-Axis Plate Assembly towards one end of the X-Axis and tighten the M4 Cap Head Bolts of the X-Axis Top HGR15 Rail. Keep sliding the assembly towards the right and go on tightening the bolts as you go. This will align and secure the X-Axis Top HGR15 Rail. See the GIF above for reference.
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Follow the same steps for all other machine sizes.
3.8 X-Axis Plate Assembly and Installation for 160mm Clearance Configuration
If you are assembling for 160mm clearance configuration, repeat steps in section 3.4, 3.5 and steps 1 & 2 of section 3.6. For 160mm clearance configuration, the difference lies in the way the X-Axis Plate/Motor Mount Plate Assembly and X-Axis Plate Assembly installation is executed (Sections 3.7 & 3.8). For 160mm clearance configuration follow the below steps:
Step 1:
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- Attach the 4x 90 Degree Angle Corner Connectors (25) to the PLATE-X Motor Mount (63) using 4x M5 Button Head Screws – 12mm (73). Pay attention to the mounting holes in which the screws are screwed in. See figures above for reference. The holes used for connecting the 90 Degree Angle Corner Connector on top and bottom of PLATE-X Motor Mount is different for 120mm and 160mm configuration.
Step 2:
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- Attach the assembly prepared in step 1 to PLATE-X-Axis (64) using 4x M5 Button Head Screws – 8mm (75) as shown above.
Step 3:
- Attach the Limit Switch Trigger Plate (70) to the PLATE-X-Axis (64) using 1x M5 Button Head Screws – 8mm (75) as shown above.
- There are two holes for mounting the above plate for 160mm clearance configuration. Use any of the one holes on the side of PLATE-X-Axis as per your liking. The same side will trigger the Limit Switch which will be installed later.
Step 4:
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- Attach the assembly prepared in step 3 to 4x Linear Bearing – HGH15CA (4) using 16x M4 Cap Head Bolts – 10mm (5) as shown above.
3.9 X-Axis Motor Installation
Step 1:
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- Attach the Helical Gear – 20 Tooth (34) to the NEMA23 Stepper Motor (32) Shaft using the gear set screws.
- Please ensure the distance between the motor flange and gear/pinion is 2mm.
Step 2:
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- Attach the motor assembly prepared in Step 1 to the PLATE-Pivot (62) using 4x M5 Cap Head Bolts – 10mm (10).
Congratulations, you have completed the X-Axis Assembly.
Repeat the same steps for all other machine sizes.
4.0 Z-Axis Assembly
Bill of Materials
The parts required to complete the Z-Axis Assembly are listed above in the table. Start the assembly by unpacking the necessary parts, then follow the instructions below to complete the assembly.
4.1 Z-Axis Brackets and Plate Assembly
Step 1:
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- Insert the 688Z Ball Bearing – 8x16x5 (2) into the Bracket – Ball Screw Bottom (26) as shown above.
- Attach this assembly to the bottom of PLATE-X-Axis using 2x M5 Cap Head Bolts – 16mm (11).
Step 2:
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- Slide 2x Linear Bearing – HGH15CA (4) onto the 2x Linear Rail – HGR15- 280mm (one on each) as shown above.
- The Bracket – Ball Screw Bottom assembly attached in Step 1 will prevent the HGH15CA bearings from sliding off the rails.
Step 3:
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- Attach the SFU1204 Nut Housing (92) to the SFU1204 Ball Screw (93) using 6x M4 Cap Head Bolts – 16mm (8) as shown above.
Step 4:
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- Attach the PLATE- Z-Axis Mount (69) to the assembly created in Step 3 using 4x M5 Button Head Screws – 16mm (74).
- Attach 1x Limit Switch Trigger Plate (70) to the PLATE- Z-Axis Mount (69) using 1x M5 Button Head Screws – 8mm (75).
- Place the above assembly in between the 2x Linear Rail – HGR15- 280mm by pushing the 8mm end of Ball Screw into the 688Z Ball Bearing – 8x16x5 (2). See Figures above for reference.
Step 5:
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- Line up the 2x Linear Bearing – HGH15CA (4) mounting holes with the holes of PLATE- Z-Axis Mount (69).
- Attach the PLATE- Z-Axis Mount (69) to the 2x Linear Bearing – HGH15CA (4) using 8x M4 Cap Head Bolts – 12mm (6).
Step 6:
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- Slide 1x Nylon Spacer 10.1x16x5mm (87) and 1x 6800 2RS Bearing (1) on the Ball Screw top end in the said order as shown above.
- Slide Bracket – Ball Screw Top (27) on the same top end and line up the mounting holes of the Bracket – Ball Screw Top (27) with the holes of PLATE-X-Axis.
Step 7:
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- Attach Bracket – Ball Screw Top (27) to the PLATE-X-Axis using 2x M5 Cap Head Bolts – 16mm (11) as shown above.
4.2 Z-Axis Motor Mount Assembly
Step 1:
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- Attach 4x 90 degree Angle Corner Connector (V-Slot) (25) to the PLATE- Z-Axis Motor Mount (68) using 4x M5 Button Head Screws – 12mm (73) as shown above.
- Pay attention to the holes where the above Corner Connectors (25) have been attached.
Step 2:
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- Slide the assembly created in Step 1 on the top of PLATE-X-Axis as shown above. The D Shaped hole of PLATE- Z-Axis Motor Mount (68) should face the front of the machine.
- Attach the front 2x Corner Connectors (25) to PLATE-X-Axis using 2x M5 Button Head Screws – 8mm (75).
Step 3:
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- Attach the back 2x Corner Connectors (25) to PLATE-X-Axis using 2x M5 Button Head Screws – 8mm (75) as shown above.
Step 4:
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- Slide the 8mm x 8mm Jaw Coupling (39) onto the top end of SFU1204 Ball Screw (93) and tighten the grub screw of the coupling to secure it on the Ball Screw.
- Attach 1x Nema 23 Stepper Motor – High Torque – 3.0Nm (32) to the PLATE- Z-Axis Motor Mount (68) using 8x Metric Aluminium Spacers – 9mm (81) (2 stacked together) and 4x M5 Cap Head Bolts – 30mm (13) as shown above.
Congratulations, you have completed the 120mm clearance configuration assembly.
Follow the same steps as above for 160mm clearance configuration.
Congratulations, you have completed the 160mm clearance configuration assembly.
Repeat the same steps for all other machine sizes.
5.0 Inductive Sensors Installation
Y-Axis:
Click on the image(s) to expand
- Attach 1x BRAC-Sensor Mount (30) to the PLATE-Plasma Y by removing one of the M4 Cap Head Bolts – 16mm and Precision Shim – M4, placing the BRAC-Sensor Mount (30) in between and putting the assembly back on. See Figures above for reference.
- Slide 1x Inductive Proximity Sensor – NPN NC- LJ12A3-AX (31) into the slot of BRAC-Sensor Mount (30).
- Attach the sensor to BRAC-Sensor Mount (30) by screwing the washers and nuts on.
- Similarly attach the other Inductive Proximity Sensor – NPN NC- LJ12A3-AX (31) to the other Y Plate.
- This sensor is triggered by the PLATE-Plasma Y Trigger (66).
X-Axis:
Click on the image(s) to expand
- Attach 1x Inductive Proximity Sensor – NPN NC- LJ12A3-AX (31) to the PLATE-Plasma Y (67) by pushing it through the above shown hole of PLATE-Plasma Y and securing it by screwing washers and nuts.
- This sensor is triggered by the Limit Switch Trigger Plate (70).
Z-Axis:
Click on the image(s) to expand
- Attach 1x Inductive Proximity Sensor – NPN NC- LJ12A3-AX (31) to the PLATE- Z-Axis Motor Mount (68) by pushing it through the above shown hole of PLATE- Z-Axis Motor Mount and securing it by screwing washers and nuts.
- This sensor is triggered by the Limit Switch Trigger Plate (70).
Follow the same steps for all other machine sizes.
6.0 Cable Drag Chains Installation
Note:
If you are building FORTIS Router CNC, you only need X and Y Axes Cable Drag Chains.
6.1 Z-Axis
Cable Drag Chains have two distinct ends as shown in the image above. Identify these ends and follow the steps below:
Step 1:
Click on the image(s) to expand
Step 2:
- Attach the Cable Drag Chain 10×20 End 1 (40) to the PLATE Z-Axis Mount using 2x M3 Button Head Screws – 6mm (71), as shown above.
Click on the image(s) to expand
- Attach the End 2 of Cable Drag Chain 10×20 (40) to the PLATE-X-Axis using 2x M3 Button Head Screws – 6mm (71). See the complete assembly below
6.2 X-Axis
Step 1:
Click on the image(s) to expand
- Attach 1x Cable Drag Chain Mounting Bracket – V3 (29) to the PLATE- X Motor Mount using 2x M5 Button Head Screws – 8mm (75) and 2x Precision Shim – 10x5x1mm (78).
- Attach 1x Cable Drag Chain Mounting Bracket – V3 (29) to the left side and 1x Cable Drag Chain Mounting Bracket – V3 (29) to the right side of the underside of bottom X-Axis extrusion and using 4x 40 Series Ball Spring T-Nuts -M5 (102) and 4x M5 Button Head Screws – 10mm (72). See images above.
- The Cable Drag Chain Mounting Bracket – V3 (29) to the left will be used as a support for Cable Drag Chain 25×50.
Step 2:
Click on the image(s) to expand
- Attach the Cable Drag Chain 25×50 (41) end to the Cable Drag Chain Mounting Bracket – V3 (29) as shown above.
Step 3:
Click on the image(s) to expand
- Attach the other end of Cable Drag Chain 25×50 (41) to the Cable Drag Chain Mounting Bracket – V3 (29) as shown above. See the complete assembly below.
Click on the image(s) to expand
6.3 Y-Axis
Step 1:
Click on the image(s) to expand
- Attach 1x Cable Drag Chain Mounting Bracket – V2 (28) to the PLATE-Plasma Y (67) using 2x Slot Washer – 15x5x2mm (89) and 2x M5 Button Head Screws – 10mm (72).
Step 2:
Click on the image(s) to expand
- Attach the Cable Drag Chain 25×50 (41) end to the Cable Drag Chain Mounting Bracket – V2 (28) as shown above.
- If you are not using the Maker Store Table, attach the other end of Cable Drag Chain 25×50 to the table top.
- If you are using the Maker Store table, please see section 7.4.
- The above steps remain the same for 160mm configuration.
Follow the same steps for all other machine sizes.
7.0 FORTIS Add Ons
⇒ If you are using the Plasma Torch Clamp, follow section 7.1
⇒ If you are using the Collision Detection System, follow section 7.2
7.1 Plasma Torch Clamp
The parts required to install the Plasma Torch Clamp on the FORTIS Plasma CNC are listed in the table above.
Step 1:
Click on the image(s) to expand
- Attach 4x 90 degree Angle Corner Connector (V-Slot) (3) to the Plasma Torch Clamp – MNT (2) using 4x M5 Button Head Screws – 8mm (4) as shown above.
Step 2:
Click on the image(s) to expand
- Loosely attach Plasma Torch Clamp – CAP (1) to the Plasma Torch Clamp – MNT (2) using 2x Precision Shim 10x5x1mm (6) and 2x M5 Cap Head Bolts – 35mm (5) as shown above.
Step 3:
Click on the image(s) to expand
- Attach the Plasma torch clamp assembly created in Step 2 to the PLATE- Z-Axis Mount (69) using 4x M5 Button Head Screws – 8mm (4). See above Figures for reference.
- Place the Plasma Torch in inside the above assembly and tighten the 2x M5 Cap Head Bolts – 35mm (5) to secure the torch.
Click on the image(s) to expand
FORTIS Plasma CNC with Plasma Torch Clamp
7.2 Collision Detection System
The parts required to assemble and install the Collision Detection System on the FORTIS Plasma CNC are listed in the table above.
Step 1:
Click on the image(s) to expand
- Place the Collision Detection Plasma Mounting Bracket (2) onto the Collision Detection Base Plate (1) by aligning the holes of former with those of the latter.
- Loosely screw the M6 Cap Head Bolt – 25mm (3) into the flange of Collision Detection Plasma Mounting Bracket (2). Place Precision Shim 12×6.4×1.6mm (4) in between.
Step 2:
Click on the image(s) to expand
- Attach the Collision Detection Plasma Mounting Bracket (2) to the Collision Detection Base Plate (1) using 3x M5 Cap Head Bolt – 50mm (13) and 3x Nylon Insert Hex Locknut – 5mm (10). Place Spring – 1x9x22mm (8) and Precision Shim – 10x5x1mm (7) in between as shown above.
Step 3:
Click on the image(s) to expand
- Screw in the 2x M5 Grub Screw – Point -20mm (6) into the Collision Detection Plasma Mounting Bracket (2) as shown above. These Pointed Grub Screws are used for aligning the Collision Detection Plasma Mounting Bracket onto the Collision Detection Base Plate after it has been lifted off during collision.
- Attach 3x 90 Degree Angle Corner Connector (V-Slot) (12) to the Collision Detection Base Plate of the above assembly using 3x M5 Button Head Screw – 8mm (14) as shown above.
Step 4:
Click on the image(s) to expand
- Carefully screw in 3x Inductive Proximity Sensor – NPN NC- LJ12A3-AX (5) into the threaded holes of Collision Detection Plasma Mounting Bracket.
Note: Install the sensor carefully without damaging the wires.
- The sensing tip of the sensors should be just above the Collision Detection Base Plate surface. You can check this by lifting the mounting bracket.
Step 5:
Click on the image(s) to expand
- Attach the assembly prepared in above step to the PLATE – Z-Axis Mount using 3x M5 Button Head Screw – 8mm (14).
Tip: First, loosely attach all three above screws and then tighten them one by one.
Step 6:
Click on the image(s) to expand
- Install the Plasma Torch into the Collision Detection Plasma Mounting Bracket (you might need loosen the M6 Cap Head Bolt – 25mm). Install a Nylon Insert Hex Locknut – 6mm (11) onto the M6 Cap Head Bolt – 25mm (3). Tighten the bolt so that the Plasma Torch is secured. To tighten the bolt you will have to tilt the Collision Detection Mounting Bracket (2) and gain access to the bolt head.
Click on the image(s) to expand
FORTIS Plasma CNC with Collision Detection System.
7.3 Spindle Mounting Bracket
If you are going to use FORTIS CNC’s Router function, its recommended to use the 160mm clearance configuration and install Maker Store 80mm Spindle Mounting Brackets. Unpack the Spindle Mounting Bracket hardware pack and follow the steps below:
- Assemble the 80mm Spindle Brackets and BRAC 90ANGS using 6x the M5 Button Head Screws – 8 mm.
- Attach the two assemblies to the Z-Axis Plate using 6x M5 Low Profile Screws – 10 mm.
- Slide the Spindle into the brackets and tighten the M5 Low Profile Screws 25mm. See the above figures for reference.
7.4 Knife Table
The parts required to assemble and install the Knife Table on FORTIS Plasma CNC machine are listed in the table above.
Step 1:
Click on the image(s) to expand
- Slide 3x 40 Series Sliding T-Nuts – M5 (7) into each of the Y-Axis base support extrusions.
- Attach 3x Maker Store Type 30 T-Track – Silver (4) to the base support extrusions at distances shown above, by screwing in 9x M5 Low Profile Screw -12mm (6) through the T-Track into the 40 Series Sliding T-Nuts – M5 (7).
Step 2:
Click on the image(s) to expand
- Slide 1x M8 T-Track Sliding Nut (3) into each of the Type 30 T-Track – Silver (4). Space them as shown above.
Step 3:
- Screw in 1x M8 Cap Head Bolt – 25mm (2) through M8 Round Spacers – 10mm (5) into each of the M8 T-Track Sliding Nuts as shown above.
- Insert 1x Steel 32x850x3 Flatbar (1) in between the above M8 Cap Head Bolts -25mm by placing one end ahead of the left side bolt. The middle bolt will have the Steel Flatbar sitting behind it. The right side bolt will have the Steel Flatbar sitting ahead of it. You will have to apply some force to bend the Steel Flatbar slightly so that it sits in between the Bolts securely.
- The above process will tension the Steel Flatbar.
- Repeat Steps 2 & 3 to insert a total of 10 M8 T-Track Sliding Nut/M8 Cap Head Bolt/ M8 Round Spacer assembly at distances of 90mm and install a total of 10 Steel Flatbars into each of Type 30 T-Tracks.
- See the complete assembly below.
Click on the image(s) to expand
7.5 Machine Table
The parts required to assemble and install the machine table for FORTIS Plasma CNC machine, are listed above in the table above.
Step 1:
Click on the image(s) to expand
- As mentioned in the Step 7 of section 2.1, if you are going to use Maker Store Machine Table ensure to install 6x 40 Series Sliding T-Nuts -M8 (38) into the bottom grooves (closer to the rack) of the Y/Y2 Axis 40 Series Extrusion – 4080 (59), and attach 4x 4 Hole Inside Gusset Corner Bracket – 40 Series (4) at the corners. See the above figures.
Step 3:
Click on the image(s) to expand
- Loosely attach 6x 40 Series Sliding T-Nuts – M8 (8) (one each) to 6x M8 Cap Head Bolts – 10mm (6) inserted through the holes of Leg Bracket.
- Loosely attach 40 Series Sliding T-Nuts – M8 (8) to M8 Cap Head Bolts – 16mm (7) inserted through 4x 4 Hole Inside Gusset Corner Bracket – 40 Series as shown above.
- Repeat this for all the machine corners
Step 4:
Click on the image(s) to expand
- Carefully slide Linear Rail – 40 Series – 40×40 – Silver – 750mm (1) across the above attached 40 Series Sliding T-Nuts – M8 (8) and tighten the bolts. You might need to carefully adjust the Sliding T-Nuts so that they slide on to the Linear Rail -750mm grooves.
- Repeat the same for all the machine corners
Congratulations, you have installed the legs.
Step 5:
- Using 2x Linear Rail – 40 Series – 40×40 – Silver -864mm (3) and hardware shown in the first two images, create two assemblies as shown in Figure 7.4-20.
- Insert 2x 40 Series Ball Spring T-Nuts -M8 (11) into the inside grooves of front side legs (one in each leg) as shown above.
- Attach the above assembly in between the two legs using 2x M8 Cap Head Bolts – 16mm (7) inserted through the 2-Hole Inside Gusset Corner Bracket – 40 Series into the inserted 40 Series Ball Spring T-Nuts – M8 (11) as shown above.
- Repeat the same at the back of the machine. See the assembly below.
Click on the image(s) to expand
Step 6:
- Using Linear Rail – 40 Series – 40×40 – Silver – 920mm (2) and associated hardware create two assembles shown above (use four 2-Hole Inside Gusset Corner Bracket – 40(5)).
Step 7:
- At the side of the machine insert 40 Series Ball Spring T-Nuts – M8 (11) into the inner grooves (two in each) of the two Linear Rail – 750mm (legs) as shown above.
Tip: Grab a helping hand for the next steps
- Slide in one of the Linear Rail – 920mm assemblies prepared above in between the legs and attach it to the legs using 4x M8 Cap Head Bolts – 16mm (7) as shown above.
- Repeat the same for other side of the machine. See the complete assembly below.
Click on the image(s) to expand
Step 8:
Click on the image(s) to expand
- Prepare the above Y-Axis Cable Drag Chain extrusion assembly using Linear Rail – 40 Series – 40×40 – Silver -1000mm (10)
- Attach this assembly to the side of the machine table that has the Cable Drag Chain Mounting Bracket – V2 mounted on the PLATE-Plasma Y, using 2x 40 Series Ball Spring T-Nuts – M8 (11) and 2x M8 Cap Head Bolts -16mm (7).
Step 9:
- Screw in 4x Adjustable Foot – M8 (9) into the tapped ends of Linear Rail- 750mm (legs) as shown above. See the complete assembly below.
Click on the image(s) to expand
Step 10:
Note: Part labels are based on the main Bill of Materials listed at the beginning of the manual.
Click on the image(s) to expand
- Attach the Cable Drag Chain Mounting Bracket – V2 (28) and Cable Drag Chain 25×50 (41) to the above connected Y-Axis Cable Drag Chain extrusion as shown above.
Step 11:
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- Attach the Cable Drag Chain Mounting Bracket – V3 (29) to the Y-Axis Cable Drag Chain extrusion as shown above. This will act as a support for the Cable Drag Chain 25×50. See the above figures.
For the other machine sizes, construction of the table is slightly different. Please see below:
FORTIS CNC 1000X1500mm Table:
Click on the image(s) to expand
- All the large sized FORTIS tables use 4080 extrusions as the legs with Heavy Duty Caster Wheels as shown above. The caster wheels are attached using the M12 Foot bracket that is attached to the 4080 extrusion using M8 Cap Head 16mm Bolts
Click on the image(s) to expand
- The large sized FORTIS tables use a 45-degree cross bracing made of 4040 400mm Tapped extrusion attached with 45 Degree Corner Brackets, as shown above. The brackets are attached to the extrusion using M8 Cap Head 16mm Bolts.
- The cross bracing is attached on the 1500 and 3000mm sides of the tables using 40 Series M8 Spring Loaded T-Nuts and M8 Cap Head 16mm Bolts.
FORTIS CNC 1500X1500mm Table:
Click on the image(s) to expand
The 1500x1500m table uses 45-degree cross bracing on all sides as shown above.
FORTIS CNC 1500X3000mm Table:
Click on the image(s) to expand
- The 1500x3000m Table uses 6 4080 750mm extrusion legs to provide extra support. See the images above
7.6 FORTIS Router CNC Spoiler Board
The parts required to complete the signage assembly are listed in the table above. Note, the quantities and sizes in the above table are for 1000x1000mm FORTIS Router CNC.
Step 1:
Click on the image(s) to expand
- Slide 7x HARD-40S-TNUT-STEEL-SLID-M5-18-1 (5) into each of the spoiler board extrusions as shown above.
- Using 3x SCREWS-M5-LP-12-1 (3), loosely secure 1x T-TRACK-MS-S-1000 (2) to the spoiler board extrusions as shown above. Repeat the same process for FORTIS Router CNC 1000X1500mm
- For FORTIS Router CNC 1500x1500mm and 1500x3000mm slide in 11x HARD-40S-TNUT-STEEL-SLID-M5-18-1 into each of the spoiler board extrusions.
Step 2:
Click on the image(s) to expand
- Line up the T-TRACK (2) such that it’s 20mm away from the Y-Axis Extrusion.
- Tighten the Low Profile Screws (3).
- Place 3x HARD-40S-TNUT-SPRING-M5-1PC (6), one into each of the spoiler board extrusions as shown above.
Step 3:
Click on the image(s) to expand
- Line up 1x MAT-MDF-16X100-103X1000MM (1) with the already placed Spring Loaded T-Nuts and attach the same using 3x BOLT-M5-CAP-016-1 (4), as shown above.
- Repeat the above steps for the rest of the MDF Sheets and T-Tracks.
- See the complete assembly below
Click on the image(s) to expand
8.0 Signage
The parts required to complete the signage assembly are listed in the table above.
- Using 40 Series Ball Spring T-Nuts – M4 (3) and M4 Cap Head Bolts Stainless Steel -12mm (2), attach PLATE – Signage (1) to the front Linear Rail – 4040 – 944mm as shown above.
Repeat the same process for all different accessories for 160mm clearance configuration.
Congratulations, you have completed the machine assembly.
If you are using E5X MCS T4.1 Controller with this machine, please check the wiring guide below:
Support
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