The wasteboard shown in the image above is the previous wasteboard, it is not included with the post-November 2021 X-Carve Kit.
Welcome to the X-Controller assembly instructions! The images shown at the beginning of each step show the finished results of that step. This provides context for what you're about to start working on, and offer those eager and willing to figure things out on their own a way to skim through more quickly. Click on the thumbnails to see more details.
Each step also begins with a bill of materials (BOM) that details the necessary components to complete the step. Please review the full bill of materials, listed below, before getting started. Few things are more frustrating than being partway through a build and suddenly discovering something is missing.
Click the black bar below to reveal the BOM and make sure you received everything. Note that the FRONT AND BACK PANELS are located in the styrofoam inserts. If any parts are missing, please contact us at help @ inventables.com for replacements.
Unscrew the Phillips head screw from the power supply. Attach the power supply interface PCB using the power supply Phillips Head screws.
Using the M4 x 8mm button head cap screws, attach the power supply through the mounting holes on the underside of the chassis. The threaded holes on the base of the power supply are delicate, so try not to overtighten the screws when assembling. The two remaining M4 x 8mm button head cap screws can be installed in the threaded holes on the sides of the chassis.
Note: The chassis is not symmetrical. The power supply interface PCB will be flush with the end of the chassis when installed correctly.
Attach the ribbon cables and the e-stop connectors to the power supply interface PCB. The cables can only be connected in one orientation. Make sure the ribbon clamps are in the open position. If the cables don't attach well, double-check them and try again. Try orienting the cables so that the wires easily travel from board to board.
Note: Make sure to tuck the e-stop cable along the edge of the enclosed power supply to prevent snagging or pinching.
For your X-Controller to work correctly with your X-Carve, you must check the current potentiometers and microstepping switches for each axis. You shouldn't need to make any adjustments, just confirm your board looks like the configuration shown below:
Note that the 'dial' of the potentiometer is the notch with the two small dots on either side. This should be tuned to roughly the 2 o'clock position to give roughly 2.6A-2.8A. The X and Y dip switches are set to 8x microstepping with switches 1, 3, and 4 in the 'ON' position. For the Z axis, you'll set the driver to 2x microstepping with only switches 2 and 4 'ON'.
Slide the controller board into the channels of the chassis, making sure you route the wires through the cutout on the board to prevent snagging or pinching. The two remaining M4 x 8mm button head cap screws can be installed in the threaded holes on the sides of the chassis. The screws act as stoppers, preventing the controller board from moving around within the chassis.
Note: The wires might be stiff. If you're having trouble, don't force the wires. Try shaping the wire into place. Double-check all of your connections before moving forward, in case the wires snag and become loose when sliding into position. If your main controller board does not slide in, pull the chassis sides open.
Connect the ribbon cable and e-stop button cable from the power supply interface PCB to the main controller PCB as shown below:
Remove the button from the screw terminals by gently pulling on the yellow tab. With the button upside down (as pictured), pull the tab towards you and then to the right to disengage the two parts. Unscrew the black nut attached to the base of the button. This nut will be used to secure the button to the top cover.
In this next step, you will attach the e-stop button to the top cover as pictured above.
Insert the button through the hole on the top panel and secure using the nut.
Make sure the side of the button marked "TOP" is facing the center of the top panel. Set aside.
Note: When wiring the e-stop in subsequent steps, make sure the "TOP" marking on the button lines up with the "TOP" marking on the screw terminals.
In these next steps, you will assemble the front panel as pictured above.
First, install the nylon threaded standoffs to the buttons PCB board. Insert the male end of the standoff through the buttons PCB from the front, securing each standoff in the back using a nylon hex nut on the back side. The standoff should be on the front side of the board to act as a spacer between the board and front cover (see 2nd image below).
Align the buttons PCB with the button holes in the front panel and attach the PCB with the M3 x 6mm button head screws. Next, secure the standoffs to each corner of the board.
Then, remove the silver Phillips head screws from the USB cable terminal. Attach the USB cable terminal to the front panel from the backside of the panel. Secure it in place using the Phillips head screws.
Don't attach the front panel to the chassis until the rest of the e-stop is installed in the next step.
Loosen the Phillips head screws on the e-stop screw terminals and attach one end of the e-stop cable to each side of the NC screw terminal. Both cables are red; it does not matter which cable goes into which side. Tighten the screws on the screw terminals to hold the cable in place.
Next, connect the remaining ribbon cable to the main controller board, and the other end on the back of the buttons PCB board on the front panel. Additionally, attach the other end of the USB cable to the main controller board.
Slide the top panel into the channels of the chassis. Attach the Emergency Stop wired screw terminal to the button, line up the "TOP" marking on the button with the "TOP" marking on the screw terminal. Once in position, move the yellow tab towards the back of the assembly to lock in place.
Attach the front panel using the included M4 socket head cap screws.
Using the included M3 socket head cap screws, nuts, and finger guard, attach the fan to the front panel with the wires pointed down. Make sure the fan label faces the inside of the X-Controller.
Attach the fan cable to the power supply interface PCB. The cable can only be connected in one orientation. If it doesn't attach well, double-check it and try again. Ensure the ribbon cable connector at the power supply interface PCB and attach the back panel using the included M4 x6mm socket head cap screws. You may need to wiggle the lower PCB in place when installing it, in order for the back panel to align flush with the chassis.
Wire the cables into the green terminal block plugs by inserting the exposed metal ends of each wire and tightening the screws until the wire is held firmly in place. Plug the block plugs into the corresponding spots on the X-Controller. The screws on the terminal blocks will face upward, and you should feel the blocks click into place. Make sure the colors on the wires match the colors in the diagrams.
With two motors on the y axis facing each other, you'll need to flip one of the Y-Axis pairs for the motors to move in the same direction. The diagram above shows the black and green wires flipped on Y2 AXIS.
Note: The stepper motors will act as generators when moved manually and will feed current back into the X-Controller, potentially damaging the stepper drivers and other components. If you want to move the gantry manually, make sure the stepper motor cables are disconnected from the X-Controller.
Wire the homing switches to their respective terminals on the X-Controller. Make sure that the red wire is connected to the limit switch pin and the black wire is connected to the 'GND' pin on the connector.
Note: NEVER hook a spindle directly up to the X-Controller. These are only control signals, NOT power.
If you have a Z-Probe on your machine, wire the red wire into the 'Probe' Port on the same terminal block as the limit switches and the black wire to the adjacent 'GND' connection.
The remaining terminal block plug is used for more advanced spindle options, such as a relay or VFD controlled spindle, and will not be used in a stock X-Carve configuration.
Use the M5 x 14 button head cap screws from the Sideboard Kit to attach the X-Controller to the sideboard. If you do not want to mount the X-Controller to the sideboard, use the rubber feet.
The X-Controller Has 4 buttons on it. The red button is the e-stop (emergency-stop) which cuts the power to the machine. Press down on it to activate it and twist it clockwise while pulling up to deactivate it. Do not use it as a regular off switch.
The grey buttons on the front of the X-Controller are used during carving. The first button pauses the carve and raises the bit. The second resumes the carve. The last button stops the carve and cancels the project.
This video is intended to help those with opening back up their X-Controllers for troubleshooting.
Check to make sure your e-stop button is pulled out and not engaged.
Check that the ribbon connectors are fully pushed into the mating connectors.