QIDI X-Max X-Plus I-Mate (S) Extruder Fan Upgrade

prusaprinters

<p><strong>Update October 9, 2021</strong></p><p>Design updated to fit the newer carriages as well as the old with the small 30 mm fan.</p><p><strong>Description</strong></p><p>This is an alternative to my QIDI X-Max X-Plus I-Mate (S) Advanced Extruder Cover.</p><p>It has similar functions and features an upgraded 40 mm fan, a fan duct and a ribbon cable holder. The reason I wanted to offer this alternative is that the space is quite limited under the Advanced Extruder Cover, meaning it's a bit difficult to remove and install it should you need to do some maintenance on the extruder.</p><p>The main objective is to improve the limited extruder cooling of the stock extruder and lower the noise level. The stock fan is small and noisy and the air isn't directed very good (at all really). The fan duct in this design makes sure the air goes where it is supposed to, limiting the risk of heat creep and other issues related to extruder cooling.</p><p><strong>Installation</strong></p><p>First of all, make sure you have a replacement fan handy. I recommend the Sunon Maglev MF40202V2-1000U-A99 which is a 24V 40x40x20 mm fan that is inexpensive and moves a lot more air (7.70 vs 4.68 CFM) than stock and is considerably quieter (21 dB(A) vs 36.8 dB(A)), it's perfect for the application.</p><p>If you want an even quieter fan you can use a Noctua A4x20 (FLX) with the included low-noise adapter NA-RC12. It's a 12V fan but using the low noise adapter it will effectively bring down the voltage from the printer to the fan so it can be used without issues. You can also use a buck converter.</p><p>If you have a JST crimping tool you can cut off the connector from the new fan and crimp on a JST-XH connector on it. Make sure polarity is correct, the red wire goes where the red wire on the original fan connector goes. Take a look at the stock 30 mm fan if you're unsure. <strong>When the connector is connected to the PCB, the red wire should be on the right side looking in front of the PCB if the extruder was mounted in the printer.</strong>. I have also attached a picture of this. If you're using another fan make and model, make sure you check the polarity so it isn't reversed. If you don't have crimping tool you can just cut off the connector from the original fan and solder/splice it on.</p><p>Print the 3 (4) parts. If you use the parts cooling fan, skip printing of Part 4.</p><p>This design has the following parts:</p><p>Part 1 - "Fan Duct" with friction fit for 40x40x20 mm fan<br>Part 2 - "Ribbon Cable Holder", interlocks with Part 1.<br>Part 3 - "Limit Plate" for the parts cooling fan.<br>Part 4 - "Limit Plate Distances" if you don't use a parts cooling fan.</p><p>First, remove the extruder cover, it is mounted with a single screw on top. Unplug the ribbon cable from the extruder and dismount the extruder, it is mounted with two screws from below. Dismount the small extruder fan and distances.</p><p>Next, remove the two screws holding the parts cooling fan on the right hand side (aka blower fan/turbo fan/radial fan). Mount the Part 3, "Limit Plate" on top of the parts cooling fan, notice that one arm is longer than the other (goes top left). If you don't use the parts cooling fan, use the printed distances in place of the fan and find 2 x 20 mm M3 screws to mount the limit switch plate and distances. The reason we need a limit switch plate is that normally the extruder cover triggers the micro switch when homing so we need a replacement else the printer won't function correctly.</p><p>Next, find 2 x 15 mm M3 screws. Insert the screws into Part 1 - "Fan Duct" and then place it over Part 2 - "Ribbon Cable Holder". It's possible you could use the screws that the original 30 mm fan was mounted with but I haven't tested (they could be too long). Next, mount the fan duct and ribbon cable where the original 30 mm fan and distances were mounted. The end of the ribbon cable holder should rest on the extruder carriage, there is a slot.</p><p>Mount the extruder using the two screws from below. Insert the new fan, it is a friction fit so no screws are needed. The sticker of the fan should face the extruder. Route the ribbon cable over the holder and then insert it into the PCB, not the other way around.</p><p>All done. You may have to do a quick level of the bed depening on how hard the extruder screws were screwed in before/after.</p><p>I recommend printing and using the Draken or Gripen fan duct while you're at it, they improve tthe print quality considerably for parts needing proper cooling.</p><h3>Print Settings</h3><p><strong>Printer:</strong></p><p>QIDI Tech X-Max</p><p><strong>Rafts:</strong></p><p>No</p><p><strong>Supports:</strong></p><p>Yes</p><p><strong>Resolution:</strong></p><p>0.2</p><p><strong>Infill:</strong></p><p>25%</p><p><strong>Filament:</strong> Prusament ASA Jet Black<br><strong>Notes:</strong></p><p>Print the 3 (4) parts in the direction I have placed them. The design consists of the following parts:</p><p>Part 1 - "Fan Duct" with friction fit for 40x40x20 mm fan<br>Part 2 - "Ribbon Cable Holder", interlocks with Part 1.<br>Part 3 - "Limit Plate" for the parts cooling fan.<br>Part 4 - "Limit Plate Distances" if you don't use a parts cooling fan.</p><p>Use supports where needed.</p>