Raspberry Pi Relay 4040 Extrusion Mount (Ender Switchwire)

Connect to RPI through GPIO. I use it for switching the 230V Line which is connected to the 24V PSU.
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updated July 30, 2023

Description

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I've created this model to mount the RPI relay shield to the 4040 extrusion profile in my Ender Switchwire build. 

The dimensions for the holes on the mount is 49 x 14mm (L x W). If you need other dimensions, leave a comment with your hole dimensions and I'll try to customise it for you.

BOM:
- Raspberry Pi Relay Shield
- 2x M2.5 x 8mm SHCS or BHCS
- 2x M5 x 8 BHCS
- 2x M5 T-nut
- 2x Wire Ferule 
- 3x female jumper cable (1x red, 1x black, 1x any other colour. Use enough length to reach the GPIO pins of the RPI)

Instructions:
01. Unplug the main power from your printer.
02. Use the fasteners and T-nuts to screw the mount to the extrusion profile. 
03. Screw the relay shield to the mount. The terminal side of the relay board has to be on the pins in the 3D model, so no screw can be in the way for the wires.
04. Cut the line wire of your main power line (230V / 110V). It's not recommended to use the 24V line on the relay!*
05. Strip both ends of the line approximately 6mm, and crimp the wire ferules to both wires. Cut the wire ferules to 6mm (make sure the ferule stays as round as possible).**
06. Put one end of the wire in the NO terminal, and the other in the COM terminal. NO is safer then NC, because when your RPI loses power, the relay turns off.
07. Tighten the terminal, but do not over tighten. Tighten it until you can feel it can't move in the terminal. This is because the wire needs to stay as round as possible!**
08. Use the jumpers to connect to the RPI. Red goes to 5V pin, black to ground pin, control wire to i.e. GPIO17.
09. Use your preferable method to control the relay. I.e., in OctoPrint you can install a plugin called OctoRelay.
10. Optional: Hot glue the pins to the board. It's not really necessary but I did it for extra safety.

*: Most relay shields can have a current of maximum 10A. Since most printers have a 24V 350W PSU, the maximum current can be 14.5A (P = U x I so I = P / U. 350W / 24V = 14.5A). Connecting it to the PSU will weld the contacts inside of the relay together, resulting that the relay won't turn off anymore (I can tell you this out of experience ;-)).
**: The wire needs to stay as round as possible, because when you flatten it in the terminal the resistance in the wire goes up. More resistance generates more heat, more heat increases the risk of fire.

If you have never done this before, do your research first. Electricity is dangerous and can lead to serious injury or fires. I am not responsible for your faulty wiring.

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