AZERON CYBORG REPLICA

Assembly instructions
Greetings! This manual contains all the information you need to assemble the keypad.
Be careful, take your time and get a great tool for work and play.
 What you need
Fasteners:
Countersunk screws:

М3х6 5 pcs.
М3х8 28 pcs.

М3х10 15 pcs.

М3х12 10 pcs.

М3х16 3 pcs.
Optional:

M2x8 4 pcs.

M3x25 1 pcs.

M3x6 4 pcs.

Pan head screws:

М3х8 10 pcs.
М3х10 4 pcs.

М3х12 5 pcs.

Other details:
Insert nuts 4mm-5mm 64pcs.

Shafts 1.5х10мм 23pcs.

Washers 37mm (1-3pcs.)

M3 nut 1 pcs.

Electronics and more:

1. Teensy++ 2.0 1шт.
2. Omron D2F-01 24pcs.
3. Five way Switch
4. Self-Locking Switch 8mm
5. PCB Screw Terminal Block Connector 10 PIN 5pcs.
 6. Nylon Braided Wire Cable sleeve 4 or 6mm (depending on the wires you will use)
7. Multi-colored wires AWG28 (I just took a cable and divided it into separate wires)
8. Heat shrink
9. Quality Dual-axis XY Joystick Module PS2 (OPTIONAL)
10. 2x Diode
11. 2x resistors 220 Om
12. Tap M3.
13. PS4 joystick
14. XBOX elite stick

Instruments:

1. Knife
2. Drill 1.5, 2, 3.8 (4.2), 2.5мм
3. Soldering iron
4. Solder + flux
5. Diamond files

Preparing for basic printing

Before sending all files to print, I strongly recommend that you print a test case from the
Test.stl file. This will allow you to make sure that the printer settings are correct, the
plastic flow is correctly selected and the parts are well connected to each other. The
entire model is designed for printing with a 0.3 nozzle and a 0.15 layer. Use other
settings at your own risk.

Check:
1. Ball joint and fixation.
2. Fitting the insertion nuts.
3. Microswitch fixation in slots.
4. Connection of parts without gaps and significant modifications with a file.
 Printing
The files for printing are located in the STL folder.

I recommend printing with 0.3 nozzle and 0.15mm layer from PLA.

Files for printing are sorted into groups, if several copies are required, then at the end of the
file name there is a mark “x2, x3….”

Files for printing from TPU located in separate subdirectories (TPU pars may be printed with 0.6
nozzle and 0.2 layer).
All files are numbered in build order.

In the holes marked T, it is necessary to tap the M3 thread, pre-machining with a 2.5mm drill.

Additional options for parts are in the folder “Optional”.

For ease of assembly, the buttons are marked on the back. I recommend printing them on a
photopolymer printer to get a tactilely pleasant surface.

Some parts have overhanging holes, for high quality printing, I added 0.2mm thick plugs to
them. So you may print them with less supports or without it.
- Folder “1. Main Base” contains the details of the keypad base. I recommend printing
them from PLA because of the stiffness that is important to them.

The TPU subdirectory contains the models of the legs, it is better to print them from non-slip
FLEX.

Base assembly diagram:

A 37mm washer with a 4mm drilled hole opposite the RESET button of the controller is used as
the weight number 1.

Insertion nuts must be installed from the opposite side of the screw pull, according to the
diagram. The holes for them can be additionally drilled with a 4 - 4.2mm drill.
-Folder “2. Tower base” contains pivot mounts for fingers and a joystick.
- 3. Folder “Finger tower set” contains all parts for finger stands. Below is a diagram
of the index finger stand, the rest are assembled in the same way.
3.1. Setup the fused nuts in “3.1 Finger Tower (x3)”.

3.2. Setup microswitches in “3.1 Finger Tower (x3)”

3.3. Setup shafts and buttons according schematic below

3.4 Gently file off the adjusting tabs for the most precise fit of the buttons. The buttons must
have full travel and must not have any backlash

3.5 You can choose one of the ways to attach the side buttons. Use glue (if use STL 3.2, 3.4, 3.5,
3.6) or M2х8 screws (if use 3.2.1, 3.4.1, 3.5.1, 3.6.1) and assemble the tower cover according to
the diagram below.
3.6 Connect all parts together with screws and make sure everything is well connected.
3.7 If all is well, you can start wiring
An example of a micro switches connection inside a rack:

Wire colors are conditional. The complete connection scheme is in the file
“Azeron_circuit_layout”. It can also be downloaded from Azeron's official website.
- Folder “ 4. Joystick set” contains the details of the thumbstick.
PS4 version

Use gerber file for order pcb board on services like JLCPCB and ets.

You may use stick from xbox elite controller.

Arduino version
After assembling it and wiring, you can proceed to the final part:

- Folder “5. Controller box” contains controller box parts and wrist rest.
The detail “5.1 Wrist height spacer” is used to adjust the height of the panel under the wrist
(6mm by default) can be changed by scaling along the Z axis in the slicer or just excluded to
achieve the minimum height.
On the side of the box, there is a plane for attaching a plate with your logo in the size of
34x9mm.
As a result, you should get such a wonderful device )))
- Folder “6. Stand” Contains files for assembling a stand for the device allowing it to be
installed at any angle. This is my own modification, the original Azeron does not have this.

Also print with 0.3 nozzle and 0.15 layer so that the protrusions that fix the hinge are pri nted
good.
 The wire connection diagram is in the file
Azeron_circuit_layout.

Upd 2.3 - DXF files have been added for those who want to cut the
base platform and the ground board on the CNC

Firmware
Firmware and software download from the off site installation instructions in the same place

https://www.azeron.eu/downloads/
PS. The original uses a proprietary joystick module with an inverted Y-axis (I decided to unify
the design as much as possible and left the standard Arduino joystick), after assembly it will be
necessary to change the axis in the software settings.

Thank you for supporting my project!

My email for communication: stormds3@gmail.com

VK: https://vk.com/singuras