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WWW.VORONDESIGN.COM

VERSION 2021-05-23

SWITCHWIRE ASSEMBLY MANUAL

We build space shuttles with gardening tools

so anyone can have a space shuttle of their own.

VORON

Summary of Contents for SWITCHWIRE

Page 1: ...1 WWW VORONDESIGN COM VERSION 2021 05 23 SWITCHWIRE ASSEMBLY MANUAL We build space shuttles with gardening tools so anyone can have a space shuttle of their own VORON ...

Page 2: ... machine can maim burn and electrocute you if you are not careful Please do not become the first VORON fatality There is no special Reddit flair for that Please read the entire manual before you start assembly As you begin wrenching please check our Discord channels for any tips and questions that may halt your progress Most of all good luck THE VORON TEAM ...

Page 3: ...3 WWW VORONDESIGN COM TABLE OF CONTENTS Introduction Hardware Frame Y Axis Skirts X Z Axis X Carriage AfterBurner Electronics Panels Final Touches 04 06 08 18 32 38 52 68 84 100 ...

Page 4: ...LAYER HEIGHT Recommended 0 2mm EXTRUSION WIDTH Recommended Forced 0 4mm INFILL TYPE Grid Gyroid Honeycomb Triangle or Cubic INFILL PERCENTAGE Recommended 40 WALL COUNT Recommended 4 SOLID TOP BOTTOM LAYERS Recommended 5 PRINT IT FORWARD PIF Often times our community members have issues printing ABS will bootstrap themselves into a VORON using our Print It Forward program This is a service where ap...

Page 5: ... that can help you out if you get stuck https discord gg voron THIS IS JUST A REFERENCE This manual is designed to be a simple reference manual Building a Voron can be a complex endeavour and for that reason we recommend downloading the CAD files off our Github repository if there are sections you need clarification on It can be sometimes be easier to follow along when you have the whole assembly ...

Page 6: ... common fastener used on the Voron ISO 4762 HEX NUT Hex nuts couple with bolts to create a tight secure joint You ll see these used in both M3 and M5 variants throughout this guide ISO 4032 SHIM Not to be confused with stamped washers These are used in all M5 call out locations in this manual DIN 988 FLAT HEAD COUNTERSUNK SCREW FHCS Metric fastener with a cone shaped head and a flat top ISO 10642 ...

Page 7: ...dges on the insert for excellent resistance to both torque and pull out F695 BEARING A ball bearing with a flange used in various gantry locations POST INSTALL T SLOT NUT Nut that can be inserted into the slot of an aluminium profile Used in both M3 and M5 variants throughout this guide SELF TAPPING SCREW Fastener with a pronounced thread profile that is screwed directly into plastic ...

Page 8: ...8 WWW VORONDESIGN COM FRAME ...

Page 9: ...TTING EXTRUSIONS TOGETHER Separate the extrusions you re going to need for this section of the build We ve laid out all the parts you should have and highlighted the ones that will be used in the following sections EXTRUSIONS ...

Page 10: ...8x16 BHCS BLIND JOINT BASICS Blind Joints provide a cost effective and rigid assembly method The head of the BHCS is slid into the channel of another extrusion and securely fastened through a small access hole in the other extrusion ...

Page 11: ...ranite surface to ensure you can get it as square as possible UPSIDE DOWN ASSEMBLY For ease of assembly we often recommend to assemble components upside down Assemble on a flat surface to ensure that the base is square BLIND JOINT ACCESS HOLES Use the access holes to fasten the screws ...

Page 12: ...12 WWW VORONDESIGN COM M5x10 BHCS FRAME T NUTS We don t show the insertion of T Nuts in our assembly manuals The Post Install T Nut s we recommend can be inserted at any point during the installation ...

Page 13: ...y before moving on Check the 90 angles with a machinist square 90 140mm 90 90 90mm 90mm MIND ACCESS HOLE POSITION We do our best to call out things that may bite you later in the assembly process but may skip things that seem obvious to us If in doubt please refer to the CAD model it might save you some considerable time down the road 90 ...

Page 14: ...s section of the frame on a glass or granite surface to ensure you can get it as square as possible TILT FRAME 90 The access holes for the Blind Joints are at the bottom Lay the frame flat on it s side to access them This also helps in mounting the uprights flush to the base ...

Page 15: ... the corners and make sure that they are at 90 angles Use a small machinist square If you have the measuring equipment verify that both uprights are dead on parallel Correct the angle is required Failure in doing so may result in a sticky Z Axis 90 165mm ...

Page 16: ...o prevent the carriage from sliding of the rail Some rails come with little plastic stop pins you can leave the bottom one in place If your rail does not have these stop pins leave the last screw slightly loose to act as a stopper Tip Mark the location with some tape to draw your attention to it later MIND THE CARRIAGE The carriages are designed to slide along the rail easily This unfortunately al...

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Page 18: ...18 WWW VORONDESIGN COM Y AXIS ...

Page 19: ...N COM M3x8 SHCS BED CARRIAGE CARRIAGE MODIFICATION Temporarily mount the drill template to the carriage Drill the 6 holes marked on the right with a 3mm or 3 2mm drill bit Remove the template after you drilled the holes ...

Page 20: ...20 WWW VORONDESIGN COM M5x30 BHCS M5 Shim F695 Bearing Y IDLER UPSIDE DOWN ASSEMBLY Why fight gravity if it can work for us ...

Page 21: ...21 WWW VORONDESIGN COM M5x10 BHCS Y IDLER ...

Page 22: ...e thread locker on all grub screws after you set their position Loose grub screws account for the majority of issues that our users report Save yourself hours of troubleshooting and apply thread locker to all grub screws during the build See the products application notes for instructions ...

Page 23: ...23 WWW VORONDESIGN COM M3x30 SHCS M5x10 BHCS Y MOTOR ...

Page 24: ...24 WWW VORONDESIGN COM M3x8 SHCS Y AXIS DECK PANELS You can install the deck panels at this point if you like We didn t show them to make some captures easier ...

Page 25: ...W VORONDESIGN COM Heat Set Insert M5x10 BHCS Y CABLE CHAIN MOUNT HEAT SET INSERTS You will need to install heat set inserts into the cable chain mount If you need help on the correct procedure ask in Discord ...

Page 26: ...26 WWW VORONDESIGN COM M3x8 SHCS Prusa Style Bed Carriage BED CARRIAGE INSTALLATION ...

Page 27: ...7 WWW VORONDESIGN COM Heat Set Insert Microswitch M2x10 Self Tapping M3x12 SHCS Y BELT HOLDER SOLDER WIRES Solder approx 100mm of wire to the mircoswitch before installing it See setup guide for details ...

Page 28: ...28 WWW VORONDESIGN COM M3x30 SHCS Y BELT HOLDER ...

Page 29: ...29 WWW VORONDESIGN COM Y BELT PATH BELT POSITION Adjust the position of the pulley if required Heavy contact with the flanges will introduce artifacts into your prints ...

Page 30: ...N COM Heat Set Insert M3x8 SHCS Y CABLE CHAIN HOLE PATTERN Cable chains with a variety of mounting hole pattern We offer mounts for both the in line pattern found on IGUS chains and the triangle pattern on budget chains ...

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Page 32: ...32 WWW VORONDESIGN COM SKIRTS ...

Page 33: ...33 WWW VORONDESIGN COM Heat Set Insert M3x8 SHCS FRONT SKIRTS DON T TIGHTEN Leave the screws slightly loose for the next step ...

Page 34: ...34 WWW VORONDESIGN COM M3x8 SHCS M3x8 SHCS M5x10 BHCS FRONT SKIRT TIGHTEN SCREWS Tighten the screws that connect the centre piece once installed on the frame ...

Page 35: ...35 WWW VORONDESIGN COM M3x8 SHCS Heat Set Insert BACK SKIRT DON T TIGHTEN Leave the screws slightly loose for the next step ...

Page 36: ...36 WWW VORONDESIGN COM M5x10 BHCS M3x8 SHCS M3x8 BHCS BACK SKIRT TIGHTEN SCREWS Tighten the screws that connect the centre piece once installed on the frame ...

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Page 38: ...38 WWW VORONDESIGN COM X Z AXIS ...

Page 39: ...39 WWW VORONDESIGN COM GT2 20T Pulley Heat Set Insert M3x40 SHCS M3x30 SHCS Z MOTOR MOUNT ...

Page 40: ...40 WWW VORONDESIGN COM M5x16 BHCS Z MOTOR MOUNT ...

Page 41: ...41 WWW VORONDESIGN COM GT2 20T Pulley Heat Set Insert M3x40 SHCS M3x30 SHCS X MOTOR MOUNT ...

Page 42: ...42 WWW VORONDESIGN COM M5x16 BHCS X MOTOR MOUNT ...

Page 43: ...43 WWW VORONDESIGN COM M5x40 SHCS M5 Shim F695 Bearing M5x10 BHCS LEFT IDLER ...

Page 44: ...44 WWW VORONDESIGN COM M5x40 SHCS M5 Shim F695 Bearing M5x10 BHCS RIGHT IDLER ...

Page 45: ...45 WWW VORONDESIGN COM TOP IDLERS CHECK ORIENTATION Make sure the cut out is facing down ...

Page 46: ...46 WWW VORONDESIGN COM M5x30 BHCS M5 Shim F695 Bearing XZ BLOCKS UPSIDE DOWN ASSEMBLY We ll flip these components a few times Pay attention to their final orientation ...

Page 47: ...47 WWW VORONDESIGN COM M3x8 SHCS M5x10 BHCS MGN12 Linear Rail X AXIS CENTERED RAIL INSTALLATION GUIDE Use the guides to position the rail in the center of the extrusion prior to fastening the screws ...

Page 48: ...48 WWW VORONDESIGN COM X AXIS CHECK ORIENTATION Make sure the XZ joints are oriented correctly The relieved cutout section points towards the front The idlers towards the bottom ...

Page 49: ...49 WWW VORONDESIGN COM Heat Set Insert M3x30 SHCS Z BEARING BLOCK ...

Page 50: ...IS X AXIS INSTALLATION Lightly tighten the M5x40 screws and align the X axis horizontally by moving it all the way to the top Hold the X axis against the stoppers and fully tighten the screws Move the axis up and down and check for binding ...

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Page 52: ...52 WWW VORONDESIGN COM X CARRIAGE ...

Page 53: ...53 WWW VORONDESIGN COM Heat Set Insert HEAT SETS ...

Page 54: ...54 WWW VORONDESIGN COM Heat Set Insert M3 Nut Microswitch M2x10 Self Tapping X CARRIAGE SOLDER WIRES NOW Solder approx 150mm of wire to the mircoswitch before installing it See setup guide for details ...

Page 55: ...55 WWW VORONDESIGN COM M3x16 SHCS M3x40 SHCS M3x12 SHCS X CARRIAGE SCREW DEPTH Don t tighten the screws all the way Leave 3 4mm of exposed thread ...

Page 56: ...obes wires to about 15cm Don t cut them flush with the carriage frame OTHER PROBE TYPES The picture shows a PL 08 probe The recommended Omron TL Q5MC probe will fit in the same space but require M3x25 SHCS Other probes with a similar form factor and characteristics might work as well ...

Page 57: ...57 WWW VORONDESIGN COM M3x8 SHCS X CARRIAGE PLATE ...

Page 58: ...58 WWW VORONDESIGN COM M3x12 SHCS X CARRIAGE ...

Page 59: ...PATH Take your time and make sure your belt routing is as intended Belts should never rub on plastic parts BELT POSITION Adjust the position of the pulley if required Heavy contact with the flanges will introduce artefacts into your prints ...

Page 60: ...60 WWW VORONDESIGN COM Z BELT ...

Page 61: ...61 WWW VORONDESIGN COM X BELT ...

Page 62: ... M5x10 SHCS COUNTERWEIGHT MOUNT WEAR EYE PROTECTION The Key Bak will violently retract if you loose grip of the end piece Wear eye protection or a face shield until it is securely mounted RAIL CARRIAGE The rail carriage is now secure Fully fasten the bottom most screw ...

Page 63: ...N COM M5x16 BHCS F695 Bearing M5 Shim M3x12 SHCS COUNTERWEIGHT IDLER MOUNTING THE KEYBACK END PIECE Pull the end piece of the Key Bak and mount it as shown Extend more of the cord and hook it in the idler mounted above ...

Page 64: ...64 WWW VORONDESIGN COM AFTERBURNER ...

Page 65: ...TRIDGE Heat Set Insert E3D V6 Style Hotend M3x16 SHCS AVAILABLE MOUNTS We also provide mounts for the Slice Engineering Mosquito and TriangleLab Phaetus Dragon Hotend They are assembled in a similar manner M3x16 SHCS Heat Set Insert ...

Page 66: ...66 WWW VORONDESIGN COM TOOL CARTRIDGE M3x40 SHCS PTFE Tube PTFE STICKOUT The PTFE tube should end 10mm above the surface of the printed part PTFE Tube ...

Page 67: ...67 WWW VORONDESIGN COM TOOL CARTRIDGE M3x40 SHCS ...

Page 68: ...SERTS You will need to install heat set inserts into various plastic parts If you need help on the correct procedure ask in Discord GENERIC CABLE CHAIN The 3 hole pattern is usually found on generic cable chains IGUS CABLE CHAIN IGUS chain have 2 mounting holes ...

Page 69: ...69 WWW VORONDESIGN COM CLOCKWORK Het Set Insert ...

Page 70: ...on ALL UNITS ARE METRIC If a unit is not specified assume it s metric MOTOR ORIENTATION Rotate the motor in such a way that the connector wires are on the left side when looking at it from the back This side will be covered by the cable cover later ...

Page 71: ...71 WWW VORONDESIGN COM CLOCKWORK M3x8 SHCS ADJUSTABLE MOTOR POSITION The motor position is adjustable to allow for a proper meshing of the drive gears Start in the top most position of the slot ...

Page 72: ...earings must slip on and off the shaft easily to allow the gear to self centre Do not shim into position Pressing the bearings on the shaft will damage them Lightly sand the shaft if required CHECK PLACEMENT Make sure the filament drive gear is fully seated against the drive shaft gear ...

Page 73: ...73 WWW VORONDESIGN COM CLOCKWORK M3x30 SHCS CHECK CLEARANCE The drive shaft must not touch the motor housing You can sand the face of shaft if required ...

Page 74: ...74 WWW VORONDESIGN COM CLOCKWORK CHECK GEAR PLAY The gear should have a slight play and should should turn without any tight spots or binding Adjust the position of the motor if required See page 71 ...

Page 75: ...75 WWW VORONDESIGN COM BMG Idler Assembly LUBRICATE BEARINGS A lubrication film is required to ensure smooth operation and longevity Refer to the BOM for lubricant options CLOCKWORK ...

Page 76: ...76 WWW VORONDESIGN COM CLOCKWORK CHECK GEAR PLAY The gear should have a slight play and should not be fully tight against the pinion Adjust the position of the motor until you have a faint play ...

Page 77: ...77 WWW VORONDESIGN COM CLOCKWORK BMG Idler Assembly LUBRICATE BEARINGS A lubrication film is required to ensure smooth operation and longevity Refer to the BOM for lubricant options ...

Page 78: ...78 WWW VORONDESIGN COM CLOCKWORK M3x20 SHCS M3x8 SHCS ...

Page 79: ...79 WWW VORONDESIGN COM CLOCKWORK M3x30 SHCS M3x20 SHCS ...

Page 80: ...80 WWW VORONDESIGN COM FAN ASSEMBLY DON T OVER TIGHTEN The screws are screwed directly into plastic REMOVE TOP COVER Split the fan open by bending the taps on the side M3x16 SHCS ...

Page 81: ...81 WWW VORONDESIGN COM FAN ASSEMBLY Piece of Filament ...

Page 82: ...82 WWW VORONDESIGN COM FAN ASSEMBLY M3x12 SHCS M3x30 SHCS ...

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Page 84: ...84 WWW VORONDESIGN COM ELECTRONICS AND PANELS ...

Page 85: ...85 WWW VORONDESIGN COM Mains Inlet MAINS INLET ...

Page 86: ...86 WWW VORONDESIGN COM M4x8 BHCS M4x8 BHCS MAIN PSU Meanwell LRS350 24 ...

Page 87: ...87 WWW VORONDESIGN COM M2x10 Self Tapping M3x8 SHCS M3x8 SHCS PI SECONDARY PSU CONTROL BOARD RS25 05 PSU SKR Mini E3 1 2 Dunar s Cursor ...

Page 88: ...88 WWW VORONDESIGN COM M5x10 BHCS PSU INSTALLATION ...

Page 89: ...89 WWW VORONDESIGN COM M5x10 BHCS M5x10 BHCS SECONDARY PSU PI INSTALLATION ...

Page 90: ...90 WWW VORONDESIGN COM M5x10 BHCS 6020 Fan CONTROL BOARD FAN INSTALLATION APPLY VHB TAPE 3M VHB tape is a double sided adhesive tape Other vendors have similar products that you can use as a substitute ...

Page 91: ...91 WWW VORONDESIGN COM M5x10 BHCS DECK PANEL DECK PANELS Unless you installed the panels earlier undo the 6 screws on the bed carriage and remove the bed carriage to install the panels ...

Page 92: ...92 WWW VORONDESIGN COM Heat Set Insert M5x16 BHCS Z CHAIN MOUNT ...

Page 93: ...93 WWW VORONDESIGN COM M3x6 FHCS 10x11 Cable Chain Z CABLE CHAIN ...

Page 94: ...94 WWW VORONDESIGN COM 10x11 Cable Chain M3x6 FHCS X CABLE CHAIN ...

Page 95: ...95 WWW VORONDESIGN COM M3x6 FHCS 10x11 Cable Chain M3x6 FHCS Y CABLE CHAIN ...

Page 96: ...96 WWW VORONDESIGN COM Heat Set Insert M3x12 SHCS Mini12864 Display LCD THING ...

Page 97: ...97 WWW VORONDESIGN COM LCD THING ...

Page 98: ...98 WWW VORONDESIGN COM M5x16 BHCS BOTTOM PANEL ...

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Page 100: ...100 WWW VORONDESIGN COM FINAL TOUCHES ...

Page 101: ...101 WWW VORONDESIGN COM Piece of PTFE Tube M5x16 BHCS SPOOL HOLDER ...

Page 102: ...102 WWW VORONDESIGN COM 6x6x3 Spacer Prusa MK52 Style Heated Bed M3x12 FHCS HEATED BED ...

Page 103: ...103 WWW VORONDESIGN COM Flex Sheet HEATED BED ...

Page 104: ...104 WWW VORONDESIGN COM M3x8 SHCS CABLE COVER ...

Page 105: ...you get stuck https discord gg voron MECHANICAL ASSEMBLY COMPLETED NEXT STEP WIRING ELECTRICAL This manual is designed to be a simple reference manual for the build process Wiring and the initial setup of your printer is not included For details on wiring setup of the electronics and other initial steps of your new printer please visit our documentation available on github https github com VoronDe...

Page 106: ...106 WWW VORONDESIGN COM Github https github com vorondesign Website www vorondesign com Discord https discord gg voron VORON ...

Page 107: ...107 WWW VORONDESIGN COM ...

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