BIQU Universal Turbo Kit WS7040 User Manual

1. Introduction

The BIQU Universal Turbo Kit is designed to provide high-quality, high-performance cooling for 3D printers. It features components from Wonsmart Motor, a trusted medical device supplier, combined with a self-developed controller adapter board and custom cables for a seamless, plug-and-play installation experience, similar to connecting a standard DC fan.

Feature Highlights

• Specially designed adapter board and cable for Plug & Play universal compatibility.
• High-quality, high-performance WS7040 blower and driver from Wonsmart Motor.
• Achieves up to 45,000 maximum RPM.
• Provides 6.6 Kpa maximum static pressure.
• Delivers 14.7 CFM maximum flow rate.
• Includes an air filter to prolong turbo lifespan, reduce noise, and filter large filament particles.
• Voron 2.4 exhaust hood mod installation hardware included.
• Voron 2.4 exhaust hood mod model provided.
• Reference 3D model available to aid in designing custom components.
• Printed noise reduction shroud 3D model available.

2. Packaging List

The following items are included in your Universal Turbo Kit package:

Visual representation of all components included in the Universal Turbo Kit, including the blower, driver, adapter board, air filter, cables, potentiometer, and mounting screws.

3. Specifications

3.1 Technical Specifications (Universal Turbo Kit)

Detailed technical specifications for the Universal Turbo Kit.

3.2 Motor Specifications (WS7040-24-V200)

Detailed motor specifications and performance curve for the WS7040-24-V200 blower.

3.3 Driver Specification (WS2403DY01V04)

Detailed specifications for the WS2403DY01V04 brushless driver.

3.4 Dimensions & Pin Layout Diagram

Technical diagrams showing the dimensions of the blower and the pin layout of the adapter board for wiring reference.

4. Installation

4.1 Snappy Installation Overview

The kit is designed for plug-and-play installation. The adapter board features quick-connect terminals, eliminating the need for crimping. It connects directly to 5-24V fan connections, making it easy to replace standard DC fans.

Visual guide for connecting wires to the adapter board using the quick-connect terminals, and showing the pre-crimped terminals for easy setup.

4.2 Wiring Instruction for Speed Control

Using the Potentiometer Knob for Manual Speed Control:

1. Connect the power to 24V.
2. Plug the 3-pin XH2.54 connector into the potentiometer.

The potentiometer knob used for manual speed adjustment.

Using a Mainboard or Pi SBC for Firmware Speed Control:

1. Insert the BLDC driver power cable into the adapter board.
2. Plug the 3-pin XH2.54 connector into the adapter board.
3. Cut the included power and signal cable to your preferred length.
4. Insert the power and signal cable into the adapter board.
5. Connect the power to 24V DC.
6. Connect the signal cable to any fan port (3.3-24V full range compatibility).

Refer to the 'Dimensions & Pin Layout Diagram' in Section 3.4 for visual guidance on connections.

4.3 Air Intake Filter

The kit includes an air intake filter designed to prolong the turbo's lifespan, reduce noise, and effectively filter out large filament particles, ensuring cleaner airflow and better performance.

The included air intake filter, which helps protect the blower and reduce noise.

4.4 Soft Anti-Fold Fan Pipe

The fan pipe is made from a remarkably soft material to minimize resistance during movement. Its specially designed anti-fold shell prevents blockages, ensuring consistent airflow. Please note that this fan pipe requires a separate purchase.

The flexible and anti-fold fan pipe, designed for optimal airflow without blockages.

5. Firmware Setup

5.1 Klipper Configuration

To configure the fan in Klipper, insert your fan port pin into the [fan] section of your "printer.cfg" file. Below are the key parameters and their descriptions:

                
[fan]
pin: # Output pin controlling the fan. This parameter must be provided.
max_power: 0.8
# This should be set to 0.8 on most motherboards to give full range of control to your slicer.
# Anything above 80% duty cycle will be full power on this particular brushless driver.
# To fine-tune the max_power parameter for your particular motherboard, set max_power to 1.0,
# go into the Klipper dashboard, and increase fan speed 1% at a time until the actual fan speed
# stops increasing as you increase the fan speed. Divide the fan speed at this point by 100 and
# enter it into the max_power parameter.
# This parameter defines the maximum power (expressed as a value from 0.0 to 1.0) that the pin
# may be set to.
# The value 1.0 allows the pin to be set fully enabled for extended periods, while a value of 0.5
# would allow the pin to be enabled for no more than half the time.
# This setting may be used to limit the total power output (over extended periods) to the fan.
# If this value is less than 1.0, then fan speed requests will be scaled between zero and
# max_power (for example, if max_power is 0.9 and a fan speed of 80% is requested, then the fan
# power will be set to 72%).
shutdown_speed: 0
# The desired fan speed (expressed as a value from 0.0 to 1.0) if
# The microcontroller software enters an error state.
# The default is 0.
cycle_time: 0.005
# The amount of time (in seconds) for each PWM power cycle to the fan.
# It is recommended this be 10 milliseconds or greater when using software-based PWM.
# The default is 0.010 seconds.
hardware_pwm: False
# Enable this to use hardware PWM instead of software PWM.
# Most fans do not work well with hardware PWM, so it is not recommended to enable this unless
# there is an electrical requirement to switch at very high speeds.
# When using hardware PWM, the actual cycle time is constrained by the implementation and
# may be significantly different than the requested cycle_time.
# The default is False.
kick_start_time: 0.100
# Time (in seconds) to run the fan at full speed when either first enabling or increasing it by more
# than 50% (helps get the fan spinning).
# The default is 0.100 seconds.
off_below: 0.1
# The blower will not spin with the included brushless driver when the duty cycle is below 8%.
# When scaled with Max_power at 0.8, the off_below parameter should be set to 0.1.
                
            

To calibrate the off_below setting, gradually lower the fan speed to determine the lowest input speed that reliably drives the fan without stalls. Set off_below to the duty cycle corresponding to this value (e.g., 8% -> 0.08/Max_power -> 0.08/0.8 -> 0.1) or slightly higher. If a speed lower than off_below is requested, the fan will turn off.

Optional Tachometer parameters:

• Tachometer_pin: Input pin for monitoring fan speed. A pullup is generally required.
• Tachometer_ppr: Number of pulses per revolution of the tachometer signal (default: 1).
• Tachometer_poll_interval: Polling period of the tachometer pin in seconds (default: 0.0005).

5.2 Marlin Configuration

For Marlin firmware, enable "FAN_SOFT_PWM" and set "SOFT_PWM_SCALE" to 5.

5.3 Duet Board Configuration

For Duet Board setup, please refer to the official documentation: Duet3D Fans Connecting Guide.

6. Printed Parts Instruction

To integrate the Universal Turbo Kit with your 3D printer, you may need to print specific parts. Begin by printing everything in the "Stealthburner Parts" folder. Additional parts required for the printhead include: 1x BTT KNOMI V2.0, 1x 15mm CPAP Tube, and 2x Zip Ties. The 15mm CPAP tube needs to be purchased separately to connect the printhead to the Blower.

Next, select one of the following configurations from the "Exhaust parts" folder based on your preference and print all necessary components:

1. Voron-Exhaust-UTK-SFS-without-fan: This is a redesigned Voron exhaust hood with an integrated SFS V2.0 module, utilizing the included Air Filter without a 60mm exhaust fan. This configuration is recommended as it fully encloses the blower, minimizing noise. (Based on a remix from @MichalKelnar_1267496 on Printables. Original design link: Printables Link). Extra parts needed: 1x BIGTREETECH SFS V2.0 module.
2. Voron-Exhaust-UTK-without-fan: A modified Voron design V2.4 exhaust hood without a 60mm exhaust fan. This is recommended for non-SFS users as it completely encloses the blower, keeping noise to a minimum. No extra parts are needed for this configuration.
3. Voron-Exhaust-UTK-SFS-with-fan: This redesigned Voron exhaust hood includes an integrated SFS V2.0 module and a 60mm exhaust fan. A powerful 60mm fan is necessary to maintain negative pressure in the printer enclosure due to the CPAP blower's position. Be aware that this setup will result in higher noise levels as the blower is not enclosed. (Based on a remix from @MichalKelnar_1267496 on Printables. Original design link: Printables Link). Extra parts needed: 1x BIGTREETECH SFS V2.0 module; 1x 60mm Axial Fan.
4. Voron-Exhaust-UTK-with-fan: The original Voron design V2.4 exhaust hood with a 60mm exhaust fan. A powerful 60mm fan is needed to maintain negative pressure in the printer enclosure due to the CPAP blower's position. This configuration will also produce high noise levels as the blower is not enclosed. Extra parts needed: 1x 60mm Axial Fan.

Example of 3D printed parts for Voron 2.4 integration, streamlining the setup process.

7. User Tips

• Ensure all wiring connections are secure and correctly polarized (positive to positive, negative to negative) to prevent damage to the components.
• When using the potentiometer, start at a lower speed and gradually increase to find the optimal cooling for your specific printing needs.
• Regularly check and clean the air intake filter to maintain optimal airflow and prolong the blower's lifespan.
• For firmware control, always back up your printer's configuration files before making changes.
• If experiencing issues with fan speed control, verify your firmware settings match the recommended values for your chosen control method (Klipper, Marlin, etc.).

8. Troubleshooting

• Fan Not Spinning:
  • Check power connections to ensure 24VDC is supplied correctly.
  • Verify signal cable connection to the fan port.
  • If using Klipper, check the off_below parameter; the fan may not spin if the requested speed is below this threshold.
  • Ensure the driver board is correctly connected and receiving power.
• Insufficient Cooling:
  • Increase fan speed via potentiometer or firmware settings.
  • Check for obstructions in the fan pipe or air intake filter. Clean the filter if necessary.
  • Verify that the blower is operating at its rated RPM (check motor specifications).
• Excessive Noise:
  • Ensure the blower is securely mounted and not vibrating against other components.
  • Check if the noise reduction shroud 3D model (if used) is properly installed.
  • Clean the air intake filter, as a clogged filter can cause the fan to work harder and produce more noise.
• Inconsistent Fan Speed:
  • For potentiometer control, ensure the knob is clean and making good contact.
  • For firmware control, check PWM signal stability and configuration parameters (e.g., cycle_time in Klipper).
  • Ensure control wires and hall sensor wires are not twisted with motor phase wires, as this can cause signal interference.

9. Support & Resources

For further assistance or to find more information about the BIQU Universal Turbo Kit, please use the following resources:

• Product Link: https://biqu.equipment/products/universal-turbo-kit
• GitHub Repository: https://github.com/bigtreetech/Universal-Turbo-Kit
• BIQU Official Website: http://biqu3d.com
• BIGTREETECH Official Website: http://bigtree-tech.com
• Online Store: https://biqu.equipment
• Community: https://community.biqu3d.com
• Submit a Support Ticket: If you have any issues with the product, please submit a support ticket via https://biqu3d.com/pages/submit-a-ticket.