# Assembly Overview

This document provides a high-level assembly reference for the 3D Printed NAS. For detailed step-by-step instructions with photos, see the [Instructables guide](https://www.instructables.com/3D-Printed-Home-Server-6-Bay-ZimaBoard-NAS/) or the [build video](https://youtu.be/NXIu-B52WPU).

## Before You Start

- [ ] All parts printed (see [PRINT_SETTINGS.md](PRINT_SETTINGS.md) for quantities and settings)
- [ ] All components sourced (see [BOM.csv](BOM.csv))
- [ ] Heat-set inserts installed in all structural parts (72× M3 inserts)
- [ ] Soldering iron, hex drivers (M3, M6), and wire tools on hand

## Assembly Order

### 1. Install Heat-Set Inserts

Insert all 72× M3 heat-set inserts into the structural parts using a soldering iron with a heat-set tip. Parts requiring inserts:
- Base
- Side plate L / Side plate R
- Brace
- Back fan housing
- Zima support

### 2. Assemble the Frame

1. Attach **Side plate L** and **Side plate R** to the **Base** using M3×10-12mm countersunk screws
2. Install the **Brace** between the side plates
3. Mount the **Back fan housing** to the rear
4. Install the **Front grill**
5. Install the **Zima support** bracket
6. Install the **PCIe card support**

Use **M6 threaded rods** with **M6 hex nuts** and **M6 nylon washers** for the drive bay rail system.

### 3. Mount Electronics

1. Mount the **ZimaBoard 832** onto the Zima support bracket
2. Connect the **PCIe SATA expansion card** via the 90° riser cable
3. Secure the **power adapter PCB** in its designated location

### 4. Wire Power

> **Important:** Double-check all connections before powering on. The power adapter PCB handles dual 5V/12V rails at significant current.

**Power adapter PCB connectors:**

| Connector | Pins | Function |
|-----------|------|----------|
| PSU_IN | 3-pin terminal block | Power supply input (5V, 12V, GND) |
| ZIMA_PWR | 6-pin header | Power to ZimaBoard |
| ZIMA_IO | 14-pin header | ZimaBoard IO connection |
| POWER_SW | 4-pin header | Momentary power button |
| DRIVES_PWR1 | 4-pin Molex | Drive power rail 1 (drives 1–3) |
| DRIVES_PWR2 | 4-pin Molex | Drive power rail 2 (drives 4–6) |
| X1–X4 | 3-pin Molex | Fan headers (12V) |

**Wiring sequence:**
1. Connect the **PSU** output to the PCB's **PSU_IN** terminal block
2. Connect **ZIMA_PWR** and **ZIMA_IO** to the ZimaBoard using the ribbon/header cables
3. Connect the **power button** to **POWER_SW**
4. Connect **DRIVES_PWR1** and **DRIVES_PWR2** to SATA power splitters → drive extender cables
5. Connect fans to **X1–X4** headers

### 5. Install Drives

1. Slide each drive into a **Caddy**
2. Snap on the **Cover**
3. Insert assembled caddies into the **Slots** separated by **Separators**
4. Connect SATA data cables from drives to the PCIe SATA card
5. Connect SATA power via the extender cables

### 6. Install Covers

Attach in this order:
1. **Back IO** panel
2. **Back plate**
3. **Side cover**
4. **Top cover**
5. **Face plate** (front)

### 7. Power On and Configure

1. Connect power cable to the **Power Socket Inlet Module**
2. Press the **power button**
3. Access the ZimaBoard via network to configure your NAS OS (CasaOS, TrueNAS, OpenMediaVault, etc.)

## Safety Notes

- The power adapter PCB switches up to **40A across dual rails** using P-Channel MOSFETs. Verify all connections before first power-on.
- Use a multimeter to confirm correct voltage on the 5V and 12V rails before connecting the ZimaBoard.
- Ensure adequate ventilation — the 4-fan setup is designed for continuous operation.
- PTC resettable fuses on the PCB provide overcurrent protection, but they are not a substitute for correct wiring.

## Troubleshooting

| Issue | Check |
|-------|-------|
| No power | PSU_IN terminal connections, power button header, PSU switch |
| Drives not detected | SATA data cables seated, PCIe card in slot, riser cable connection |
| Overheating | Fan headers connected (X1–X4), fan direction (intake front, exhaust rear) |
| Drive caddy too tight/loose | Print tolerance — try ±0.1mm horizontal expansion in slicer instead of scaling |

## Need More Detail?

The full photo-illustrated build guide is on [Instructables](https://www.instructables.com/3D-Printed-Home-Server-6-Bay-ZimaBoard-NAS/). The [build video](https://youtu.be/NXIu-B52WPU) walks through the entire process.