105 lines
4.2 KiB
Markdown
105 lines
4.2 KiB
Markdown
# Assembly Overview
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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).
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## Before You Start
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- [ ] All parts printed (see [PRINT_SETTINGS.md](PRINT_SETTINGS.md) for quantities and settings)
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- [ ] All components sourced (see [BOM.csv](BOM.csv))
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- [ ] Heat-set inserts installed in all structural parts (72× M3 inserts)
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- [ ] Soldering iron, hex drivers (M3, M6), and wire tools on hand
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## Assembly Order
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### 1. Install Heat-Set Inserts
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Insert all 72× M3 heat-set inserts into the structural parts using a soldering iron with a heat-set tip. Parts requiring inserts:
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- Base
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- Side plate L / Side plate R
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- Brace
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- Back fan housing
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- Zima support
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### 2. Assemble the Frame
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1. Attach **Side plate L** and **Side plate R** to the **Base** using M3×10-12mm countersunk screws
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2. Install the **Brace** between the side plates
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3. Mount the **Back fan housing** to the rear
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4. Install the **Front grill**
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5. Install the **Zima support** bracket
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6. Install the **PCIe card support**
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Use **M6 threaded rods** with **M6 hex nuts** and **M6 nylon washers** for the drive bay rail system.
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### 3. Mount Electronics
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1. Mount the **ZimaBoard 832** onto the Zima support bracket
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2. Connect the **PCIe SATA expansion card** via the 90° riser cable
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3. Secure the **power adapter PCB** in its designated location
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### 4. Wire Power
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> **Important:** Double-check all connections before powering on. The power adapter PCB handles dual 5V/12V rails at significant current.
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**Power adapter PCB connectors:**
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| Connector | Pins | Function |
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|-----------|------|----------|
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| PSU_IN | 3-pin terminal block | Power supply input (5V, 12V, GND) |
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| ZIMA_PWR | 6-pin header | Power to ZimaBoard |
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| ZIMA_IO | 14-pin header | ZimaBoard IO connection |
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| POWER_SW | 4-pin header | Momentary power button |
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| DRIVES_PWR1 | 4-pin Molex | Drive power rail 1 (drives 1–3) |
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| DRIVES_PWR2 | 4-pin Molex | Drive power rail 2 (drives 4–6) |
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| X1–X4 | 3-pin Molex | Fan headers (12V) |
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**Wiring sequence:**
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1. Connect the **PSU** output to the PCB's **PSU_IN** terminal block
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2. Connect **ZIMA_PWR** and **ZIMA_IO** to the ZimaBoard using the ribbon/header cables
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3. Connect the **power button** to **POWER_SW**
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4. Connect **DRIVES_PWR1** and **DRIVES_PWR2** to SATA power splitters → drive extender cables
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5. Connect fans to **X1–X4** headers
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### 5. Install Drives
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1. Slide each drive into a **Caddy**
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2. Snap on the **Cover**
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3. Insert assembled caddies into the **Slots** separated by **Separators**
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4. Connect SATA data cables from drives to the PCIe SATA card
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5. Connect SATA power via the extender cables
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### 6. Install Covers
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Attach in this order:
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1. **Back IO** panel
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2. **Back plate**
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3. **Side cover**
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4. **Top cover**
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5. **Face plate** (front)
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### 7. Power On and Configure
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1. Connect power cable to the **Power Socket Inlet Module**
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2. Press the **power button**
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3. Access the ZimaBoard via network to configure your NAS OS (CasaOS, TrueNAS, OpenMediaVault, etc.)
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## Safety Notes
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- The power adapter PCB switches up to **40A across dual rails** using P-Channel MOSFETs. Verify all connections before first power-on.
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- Use a multimeter to confirm correct voltage on the 5V and 12V rails before connecting the ZimaBoard.
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- Ensure adequate ventilation — the 4-fan setup is designed for continuous operation.
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- PTC resettable fuses on the PCB provide overcurrent protection, but they are not a substitute for correct wiring.
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## Troubleshooting
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| Issue | Check |
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|-------|-------|
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| No power | PSU_IN terminal connections, power button header, PSU switch |
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| Drives not detected | SATA data cables seated, PCIe card in slot, riser cable connection |
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| Overheating | Fan headers connected (X1–X4), fan direction (intake front, exhaust rear) |
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| Drive caddy too tight/loose | Print tolerance — try ±0.1mm horizontal expansion in slicer instead of scaling |
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## Need More Detail?
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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.
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