Ormerod 2 Upgrade doc

[Marri]

I have no idea where to put this, so it's posted here!

If I find a different/better web site to post this to, I'll link to it.
Ormerod 2 upgrade!

As RepRapPro has closed it's doors, and I can't read Chineese, I'm writing up this list to try to provide some documentation on how to upgrade existing Ormerod 2's into Ormerod 2 dual-color.

The Short list of what's needed:
Printed parts
1 additional Extruder.
1.5 additional Hot-ends. (Or 2 hot-ends, if you don't reuse parts from the existing one.)
Upgraded electronics.


Here's what you need for the Nozzle Assembly (x2):
PTFE Heatshrink 4:1 -- This wraps the thermister, I don't have a source for this yet.
100k Thermistor -- https://emaker.io/product/axial-thermistor-100k/
Quick-Set Nozzle -- https://emaker.io/product/quickset-nozzle-0-3mm/ They only have the 0.3mm, there's discussion on the forum about finding a 0.5, but at this point, I don't know where to get one.
Heater Block -- https://emaker.io/product/quick-set-heater-block/
Heater -- https://emaker.io/product/cartridge-heater-60w/
Molex Plug -- https://www.digikey.com/product-deta...2772-ND/323611 - Note, need 1 more for the Fan for the vanilla version (3 total)
Small 24~26 guage thermistor wire - No online source, just about any source will do.
Tapered Nut -- https://emaker.io/product/quick-set-tapered-nut/
Molex plug pins x4: https://www.digikey.com/product-deta...2772-ND/323611
Housing contacts (For the thermistor connections) x2: https://www.digikey.com/product-deta...37CT-ND/467810
Bowden fitting: https://emaker.io/product/bowden-start-fitting/
PTFE Bowden Tube: https://emaker.io/product/ptfe-bowden-tube/

Should probably get a few extra Molex terminals if you are inexperienced with crimping them. They are quite easy to destroy.

Only need 1 of these:
Quick-set cooling block: https://emaker.io/product/quick-set-cooling-block/

Electronics:
If you want to use your existing Duet, you'll need an upgraded regulator, new wiring connectors, and the Duet shield. It's an awful lot of work and added complexity.
New shield: https://emaker.io/product/duet-shield-pcb/
New Regulator:https://emaker.io/product/5v-regulator-pcb/
I don't have a link for new wires, however, I reccomend simplifying things by replacing all of that with just a new upgraded Duet: https://www.think3dprint3d.com/Elect...cs-boards/Duet




Wire Looms:
The dual-color has different wire looms than the mono Ormerod. The Ormerod Mono gets by with a single 6-lead loom to handle the fan/hot end/thermister, but the dual color uses 3 4-wire looms. One pair for each thermistor/heater, and 1 4-lead for the 2 fans. (Always on cooling fan, and optional work-cooling fan, which is left unconnected.)
Thermistor/Heater Loom:
4-conductor wire (1m): http://www.digikey.com/product-detai...8-5-ND/5270263 They have lots to choose from, may want to shop around.
3-connector plug: *Needed for 0.6 Duet ONLY, 0.8.5 uses screw-terminals* https://www.digikey.com/product-deta...868-ND/2508637
2-connector plug: (Needed for thermistors) https://www.digikey.com/product-deta...867-ND/2508636
Pins for plug: https://www.digikey.com/product-deta...871-ND/2508640
4-connector housing: https://www.digikey.com/product-deta...1784-ND/252497
Pins for housing: https://www.digikey.com/product-deta...37CT-ND/467810


If you use the Duet 0.8.5, the Z-Probe loom needs to be adjusted, as the 0.8.5 Duet has it's own Z-Probe sensor port.
Plug: https://www.digikey.com/product-deta...869-ND/2508638
You can use a small blade screwdriver on the existing 2/3 ports to remove the pins and place them in the new plug.


Hardware:
I have not kept up with hardware (screws/nuts/etc.) at all. No clue if any extra are needed, I've had everything I needed to hand. Except for the few screws/hobbed insert for the extruder.

[EduardLuc]

Great stuff Marri. Very detailed, much appreciated.