Carbide 3D VFD Spindle Kit User manual

VFD Spindle Kit
INSTALLATION GUIDE

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Table of Contents
Welcome and Congratulations ...........................................................................2
Step 1: Remove the Old Router..........................................................................4
Step 2: Install the VFD Spindle..........................................................................10
Step 3: Enable the Spindle in Carbide Motion .................................................13
Step 4: Test the VFD Spindle.............................................................................14
Step 5: Install a Collet .......................................................................................15
Controlling the VFD Spindle..............................................................................16
Tramming the VFD Spindle ...............................................................................18
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Welcome and Congratulations
The long-awaited VFD spindle kit has arrived. It’s more powerful and has quieter, smoother operation than a
standard trim router, and it’s plug-and-play to boot. We've handled all of the testing, integration, and wiring for
you. All you have to do is set it up.
In this guide we’ll walk you through the super-simple installation and setup of your new VFD Spindle kit.
Additionally, you’re also welcome to check out the VFD Spindle Kit Installation video at youtu.be/lf23E374dAU.
If you encounter any issues during installation or setup, contact our tech support team at
[e-mail] and we’ll get you up and running ASAP.
Details & Specs
The VFD controller includes custom electronics to reduce electrical noise and a custom controller board to make
the system plug-in compatible with a Shapeoko so that your spindle RPM is controlled by your G-code. In
addition, we provide a 6-month warranty on the spindle and VFD.
VFD Spindle Specs:
•65mm Air-cooled 1200W spindle.
•Uses ER-11 collets.
•110V, 12A draw.
•8k–24k RPM.
•RPM is fully controlled by your G-code.
•VFD controller has built-in AC filtering.
•VFD controller has built-in adapter board for speed control from Carbide Motion.
NOTE: In an attempt to make the VFD spindle kit as plug and play as possible, and to ensure that we can
support it properly, the VFD controller comes preprogrammed with the parameters locked. This protects
against accidental changes to the configuration.
Compatibility & Software Requirements
Carbide Motion version 551 or higher is required for the VFD spindle.
The VFD spindle is 65mm in diameter, so it should fit any Shapeoko 3, 4, or Pro. That said, it is significantly
heavier than a standard trim router, so we prefer to pair it up with an HDZ—although the Z-Plus works well too.
We do not recommend adding the VFD spindle to the original Shapeoko 3 belt-drive Z-Axis.
NOTES:
•The 65mm VFD spindle is compatible with Sweepy 65 for dust collection.
•If you have Shapeoko 3 with a V2.3 board and below (Shapeoko 3 machines purchased before Black
Friday 2019), you will also need to purchase a Carbide Motion PCB with enclosure, which includes a
new circuit board with the BitRunner connector installed.

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VFD Spindle Kit Contents
Item
Description
Qty
A
VFD Controller (with Built-in Speed-control Board and AC Filter)
1
B
65mm Air-cooled 1200W Spindle (with Collet and Collet Nut)
1
C
ER11 Precision Collets (¼” and 1/8”)
2
D
6-pin Logic Cable
1
E
VFD Controller Power Cable
1
F
Spindle Wrenches
2
NOTE:
•If any items are missing or damaged in shipping, contact us at [e-mail] and we’ll ship
you a replacement ASAP.
Figure 1

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Step 1: Remove the Old Router
1. Power off and unplug the machine and the router.
2. Clip any zip ties securing the router power cable to the machine.
3. Measure (approximate is okay) how much of the router is showing below the spindle mount. (You will
need this measurement in order to install the VFD spindle in the spindle mount.)
Shapeoko 3 Machines ONLY
4. Use a 4mm hex key to loosen the two M5 screws securing the old router, and remove it from the
spindle mount.
5. Go ahead and skip ahead to Step 2: Installing the VFD Spindle on page 10.
Shapeoko Pro & Shapeoko 4 Machines ONLY
4. Use a 5mm hex key to loosen the two M6 screws securing the old router, and remove it from the
spindle mount. See Fig. 2.
5. Follow the steps on the next pages to remove and reinstall the router drag chains.
Figure 2

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6. Remove the X-Axis router drag chain. See Fig. 3.
a. Use a 2mm hex key to remove the two M3 screws securing the X-Axis head to the bracket on
the back of your Z-Axis.
b. Use a 2mm hex key to remove the two M3 screws securing the tail to the drag chain support
panel.
c. Set all of the screws aside for reinstallation.
Figure 3

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7. Remove the Y-Axis router drag chain. See Fig. 4.
a. Use a 3mm hex key to remove the two M5 screws securing the X/Y transition bracket to the
Y-left gantry plate.
b. Use a 2mm hex key to remove the two M3 screws securing the Y-Axis tail to the drag chain
support panel.
c. Set all of the screws aside for reinstallation.
Figure 4

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8. Open the both drag chains, remove the router power cable, and set the router aside. See Fig. 5.
a. Be sure to note which way the drag chains attach to the gantry to you can reinstall them
correctly.
b. Use a medium size hex key to pry open the drag chain links from one side.
c. You may need to remove the tail links from both axes to be able to remove the power cord.
See Fig. 5. Make sure to note their orientation so you can re-install them correctly. Use a small
screwdriver to pry off the tail links.
Figure 5

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9. Route the gray spindle power cable exiting the side of the VFD controller through the drag chains.
See Fig. 6.
a. The spindle power cable’s screw-on connector and about 14 inches of cable should extend
beyond the head of the X-Axis drag chain.
b. The VFD controller will be at the tail of the Y-Axis drag chain.
Figure 6

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10. Reinstall the drag chains. See Fig. 7 (Y-Axis) and Fig. 8 (X-Axis).
Figure 7
Figure 8

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Step 2: Install the VFD Spindle
All Machines
1. Install the spindle in the spindle mount. See Fig. 9.
a. Position the VFD spindle in the spindle mount so that the amount of the spindle showing below
the spindle mount is close to the setup of your old router (use your measurement from
Step 1: Remove the Old Router).
Figure 9

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2. Plug the spindle power cable’s screw-on connector into the top of the spindle and tighten the
threaded ring. See Fig. 10.
a. The screw-on connector is keyed and will only connect one way.
b. Don’t secure the spindle power cable to the machine just yet.
3. Plug the black VFD controller power cable into the jack on the side of the controller and then plug it
into a wall outlet.
a. Make sure to insert the plug in firmly to seat it completely in the jack.
4. Plug in the male end of the 6-pin logic cable into the 6-pin jack on the other side of the VFD controller.
a. Make sure the small latch on the side of the connector fits properly into the notch in the 6-pin
jack.
Figure 10

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WARNING: The small triangular-shaped peg on the female connector must face OUT. The logic cable has
reverse-voltage protection to prevent damage to the controller and VFD spindle in the event it is incorrectly
plugged in. However, if the cable is plugged in incorrectly, the VFD spindle will not operate.
5. Connect the female end of the logic cable to the 6-pin male accessory connector protruding from the
front-end of the Shapeoko controller. See Fig. 11.
a. Remove the Shapeoko controller cover.
b. Use your thumb and index finger to firmly support the accessory connector so it doesn’t pull
away from the Carbide Motion board as you connect the logic cable.
c. The logic cable’s small triangular peg faces OUT (away from the rail). Make sure the cable is
properly oriented to avoid damaging it, the VFD controller, or the Shapeoko controller.
d. The connector fits tightly. Press in and down firmly to get it to fully seat.
6. Set the VFD controller off to the side of the machine or mount it to the wall.
a. Make sure to set up where it will be safe from chips and dust.
b. Make sure there is plenty of clear space around the VFD controller to allow for unobstructed
ventilation.
7. Clean up the cables as needed.
a. Before securing the spindle power cable to the machine, make sure it won’t get caught on
anything, including the Z-Axis motor, your dust collection system, or other parts of the machine.
Figure 11

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Step 3: Enable the Spindle in Carbide Motion
All Machines
1. In Carbide Motion, connect to and home the machine.
2. Click Settings in the menu bar.
3. Select VFD Spindle in the Spindle dropdown list. See Fig. 12.
4. Carbide Motion will prompt you to select your Shapeoko configuration (machine type and Z-Axis).
5. Click OK to exit the settings window.
Figure 12

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Step 4: Test the VFD Spindle
To check to see that the VFD spindle is working properly with Carbide Motion:
1. Flip the power switch on the side of VFD controller to the ON position.
2. Press the Spindle Enable button on front of VFD controller to enable the spindle. The spindle is enabled
when the button is depressed and the button LED is on. The spindle is disabled when the LED is off.
3. Tighten or remove the collet nut to make sure it won’t fly off.
4. In Carbide Motion, click MDI in the menu bar to open the MDI screen.
5. Type “M3S10000” in the command line and click the Send button. See Fig. 13.
The VFD should turn on after a few seconds. When viewed from above, you should see the spindle
spinning clockwise. You can check the RPM on the VFD controller display for the commanded RPM,
10000 (the RPM shown on the display may fluctuate by up to 5% due to the resolution of the control
signal and voltage variances).
6. Type “M5” in the command line and click the Send button to turn off the spindle.
7. Press the Spindle Enable button again to disable the spindle.
Figure 13

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Step 5: Install a Collet
All Machines
1. Turn the collet nut counterclockwise to remove it from the VFD spindle shaft.
2. Place the collet nut and one of the ER11 collets right-side up on a flat surface. See Fig. 14.
3. Place the grooved base of the collet into the nut and use your thumb to press the top of the collet
down. You will hear a “click” as the base snaps into the eccentric ring inside the nut. See Fig. 14.
4. Re-install the collet nut onto the spindle shaft. Never fully tighten the collet nut without first inserting
a tool or you can damage the collet.
To remove an ER11 collet from the collet nut:
1. Use your thumb to apply sideways pressure in several places around the top of the collet to loosen it.
2. Remove it from the nut.
Figure 14

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Controlling the VFD Spindle
Enable / Disable the VFD Spindle
The Spindle Enable button on the front of the VFD controller allows you to disable the spindle during tool
changes and when using tools, such as drag bits, where the spindle stays off.
1. Press the Spindle Enable button to supply power to the VFD spindle. The red button LED will turn ON.
2. Press the Spindle Enable button again to cut power to the VFD spindle. The button LED will turn OFF.
Install an End Mill
1. Press the Spindle Enable button to disable the VFD spindle. The button LED will turn OFF.
2. Install the end mill.
Run a Project
The VFD spindle is about as plug-and-play as it gets. To run a project:
1. Connect to and home the machine.
2. Load the tool and your material, and zero the machine.
3. Flip the VFD controller power switch to the ON position.
4. Press the Spindle Enable button on the front of the controller. The button LED is ON when the spindle is
enabled.
5. Click Run in the menu bar.
6. Click the Load New File button to load the project G-code file.
7. Press the Start Job button, then click Start.
8. The spindle will automatically start up at the RPM designated by the G-code. You can check the RPM on
the display window at the top of the VFD controller. The G-code (or absence thereof) determines when
the VFD controller cuts or supplies power to the spindle. If there is no G-code/.nc file being executed in
Carbide Motion, then no power is supplied to the spindle.
9. When the project finishes, the spindle will turn off automatically.
10. Always press the Spindle Enable button to disable the spindle and flip the power switch on the side of
the VFD controller to turn it off when done cutting.

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Perform a Tool Change
WARNING: For safety, it is best practice to press the Spindle Enable button to disable the VFD spindle
BEFORE installing an end mill or performing a tool change. The button LED is OFF when the spindle is
disabled.
1. When the G-code reaches a tool-change command, Carbide Motion will pause the job, direct the VFD
controller to cut power to the VFD spindle, and alert you that it’s time to change the tool.
2. Press the Spindle Enable button on the front of the VFD controller to disable the spindle. The button LED
will turn OFF.
3. Change the tool.
4. Press the Spindle Enable button again to enable the spindle. The button LED will turn ON.
5. In Carbide Motion, click the Resume button to resume cutting. The VFD controller will continue supplying
power to the spindle until it’s time to perform another tool change, load the next G-code file, or until the
project is done.

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Tramming the VFD Spindle
What is Tramming and Why Is it Important?
Have you ever seen small tool marks on your projects or found that the audible pitch of the router/spindle
changes significantly when cutting in a certain direction? If you are nodding to either of these, then you may
need to tram your machine.
As the end mill travels along the X/Y axis, the actual tip
of the end mill should be parallel to the machine bed.
When the bottom of the end mill is not parallel, the
lowest edge of the end mill becomes the deepest part of
the cut (Fig. 15 shows an exaggerated view of this).
When this happens, you get the issues described above.
These tool marks are more prevalent in harder materials
like metals or composites than in wood because wood is
softer. They will also be more prominent when using a
larger stepover or a larger end mill.
Tramming isn’t a new ‘thing’, every single CNC
machine—even a $150,000 VMC—will have been
trammed upon setup and regularly thereafter as part of
its maintenance cycle.
Identifying and Defining Tram
Below we will define the two types of tram and look at how you can correct them. To help visualize this, imagine
the end mill is your head.
•Nod: Nod is where the spindle tram is out front-to-back. The spindle is nodding forwards or backwards.
•Yaw: This is where the tram is tilted from side-to-side. The spindle is tilted in a clockwise or
counterclockwise direction.
On the next page is a quick guide to help you identify in which direction the tram is out. The guide shows a birds-
eye view of the surface finish. The red line indicates where the cutter is cutting deepest.
Figure 15

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Spindle is nodding backward.
The rear edge is cutting deepest.
Spindle is nodding forward.
The front edge is cutting deepest.
Spindle yaw is counterclockwise.
The left edge is cutting deepest.
Spindle yaw is clockwise.
The right edge is cutting deepest.