Wanhao Duplicator 4S - Converted to DuetWifi

StefanG

Hello from snowy Sweden!

I just wanted to tell you that I have now successfully converted my old Wanhao 4S to DuetWifi.

Small description:

Running DuetWifi, currently the 1.19 firmware that was on the board (got it last week).
All running on the 24V PSU from original Wanhao.
Changed from 2 hotends/extruders to one… (https://www.thingiverse.com/thing:2335200). I have never used the dual extruders for something, so hopefully I will not miss it. Also added the extra fan using this setup.
Changed from thermocouples on the hotend to a thermistor. To fit this, I had to drill a small 2 mm hole in the heating block. After that, I used the old thermocouple 4 mm screwhole to fix the thermistor cable.
Using the IR-probe for bed leveling. Made a small mount on the slider for this. Will upload to thingiverse if someone needs it.
Re-used the heated bed and its thermistor.

I just finished the first test-print after some evenings wiring&understanding DuetWifi. I really like the idea with having all in g-code files for easy changing. I am using Simplify3D to slice and I just ran a quick setup of things. I need to walk through a lot here to get everything perfect…but that is just all fun! I need to have a "lift & move away" when print is done for example...after my first print it just sat there on the plastic and almost melted the calibration cube again...hehe.

I am running micro stepping (1/16) right now. What is the recommended for this controller? As I understood it can do far more, but not sure of advantages/disadvantages with other setups.

Still to come:

Have a PanelDue 5 in the box...still not mounted/tested. Will create some holders for this and try to attach it nicely on the front.
Use the LED-strip from the original setup. I think that this is a one-color 24V strip, hence it just needs to go to the PSU.
Need to change/adapt the "single extruder kit" I downloaded from thingiverse, not perfect as it was designed for a FlashForge (very similair however).
Maybe convert to bowden and see how fast it can become.
Update firmware
Calibration...hacking...
...

Anyhow, I just wanted to tell you that you have another happy customer here! Thanks for all hard work with the DuetWifi and its firmware!

dc42

Thanks for the feedback!

StefanG

Small update with some images. This is how far I have come.

LEDs connected. Easy to connect to 24V PSU as this was a one-color-24V-strip.
PanelDue 5" up and running. Need to print a holder for it.
Some rough calibration done. Seems pretty good right now. Love the IR probe for Z-leveling.

Hrm…need to find out how to share images through google photo. Tried the img-tags but did not work, hence added as a link here. Sorry for trouble/inconvenience.
https://photos.app.goo.gl/aFKCqc0p1FHrbeta2

Duetplicator

Its a great project. I've done the same to my Duplicator 4X. I have been trying different speeds for the Z-axis, but ended up with something like 3 mm/s when homing.
What speeds have you achieved on it?
I'm currently printing at 60 mm/s, but contemplating to convert to E3D V6 with bowden setup, maybe dual extrusion… In time.

I'm currently using 256 microstepping withou interpolation on my X, Y and Z axis. And its almost completely silent. Extruder is only at 128 microstepping.

But I'm also looking for a bit of input regarding the selection of steps/microstepping, with or without interpolation.

Good job on your build/customization

StefanG

Glad to see someone else who did the same!
Well…now you caught me with my pants down... I have not thought of testing different homing speeds, but rather used the default that I got from initial research. As I am using the Z-probe (IR version) as home for Z, I understand that this is set by the M558 command in config.g. Anyhow, this is my line:

M558 P1 X0 Y0 Z1 H5 F180 T150000 ; Set Z probe type to unmodulated, the axes for which it is used and the dive height + speeds

```I have not seen any trouble (that I can relate to over speed here…but you got me thinking a lot on this now). I definitely need to evaluate this quite a bit.
I am also printing at 60mm/s (Simplify3D) and that seem to work very nice (rather fast, and yet good quality prints). I have also thought about going down the E3D-route, but I have not yet. Mostly because I upgraded the old hotends to the all-metal MicroSwiss version and I think that one is pretty nice. I am however thinking of changing it to a Bowden setup, but no real plans yet. I am actually rather pleased with speed/quality compromise right now.

For my motor setup:

M350 X16 Y16 Z16 E16 I1 ; Configure microstepping with interpolation

Good luck with yours!

garyd9

StefanG, can you please post your IR probe mount? I've done the conversion on my own FFCP clone (however I've kept both hot ends.) I'm curious if your IR probe mount would work out for me. (So far, the only place I think I'd be able to fit the 18mm tall card is either in front of or behind the extruder carriage.)

Just to chime in on print speeds: I've found that 60mm/sec printing is significantly better with the duet board when compared to the sailfish firmware (and FF board/stepper motors.) I still get a little ripple, but now I really have to look for it (when before I'd see it instantly at even 45mm/sec.)

Thanks
Gary

StefanG

@garyd9:
Sure thing…however I must warn you. I have changed a few times and I currently have it mounted "temporary" right now. I re-used a few bits of plastic (that I had on my desk) to test mount it and I have not yet designed new bits for it.
The story behind this starts with me trying to mount it on the sides of the carriage. First I started on the left side and had it there for a couple of weeks. I even designed a small bracket for that and it worked pretty ok. However, one disadvantage with this was the long distance from the nozzle to the probe. I then decided to mount it on the right side. To do this, I started with just drilling a few holes in the carriage, but that was too high up (compared to the nozzle). With this I got no good readings. I then "broke" my left-side mount bracket, drilled a few holes. This solution lowered lowered the probe to a better height. This new position is actually pretty good, but the disadvantage with using the right side is that I had to place a "calibration cube" (cubic black plastic) on the side of the stepper to have x-home to trigger before the Z-probe smashes into the motor...

So far I am happy with the position, closer to the nozzle and not in the way for viewing the print while printing. The X-axis got "moved" to the left (due to new x-homing) but the nozzle can reach the full build plate without problems. I do have to design a mounting bracket as well as changing/designing some a nice end-stop bracket. At the moment it is not looking nice (but works nice).

Some revealing photos can be found here:
https://photos.app.goo.gl/CLAibO8Zpd7zIHAm1
https://photos.app.goo.gl/qAcHo77tGo8cXMn82

EDIT: Ahh…you wanted the mount. Will post that when I finish it. Sorry for this misunderstanding.