The Carbide 3D VFD Spindle Kit is a powerful and quiet upgrade for Shapeoko CNC machines, designed for improved performance and ease of use. This kit offers a plug-and-play solution for users looking to enhance their machine's capabilities with a more robust and precisely controlled spindle.

Function Description:

The VFD Spindle Kit replaces a standard trim router, providing a more powerful and quieter cutting experience. The Variable Frequency Drive (VFD) controller manages the spindle's speed, allowing for precise RPM control directly from G-code commands within Carbide Motion software. This integration ensures that the spindle operates at optimal speeds for various materials and cutting operations, leading to cleaner cuts, reduced noise, and extended tool life. The kit is designed to be user-friendly, with pre-programmed VFD parameters to ensure proper functionality and support. The system includes built-in AC filtering and a custom adapter board for seamless compatibility with Shapeoko machines.

Important Technical Specifications:

Spindle Type: 65mm Air-cooled 1200W spindle.
Collet System: Uses ER-11 collets, with ¼" and 1/8" precision collets included.
Power Requirements: 110V, 12A draw.
RPM Range: 8,000 to 24,000 RPM, fully controlled by G-code.
VFD Controller Features: Built-in AC filtering and an adapter board for speed control from Carbide Motion.
Compatibility: Requires Carbide Motion version 551 or higher. Compatible with Shapeoko 3, 4, and Pro machines. Recommended for use with HDZ (Z-Plus also works well), but not recommended for original Shapeoko 3 belt-drive Z-Axis due to weight.
Dust Collection Compatibility: Compatible with Sweepy 65 for dust collection.
Shapeoko 3 (V2.3 board and below) Requirement: May require purchasing a Carbide Motion PCB with enclosure, which includes a new circuit board with the BitRunner connector installed.
Warranty: 6-month warranty on the spindle and VFD.

Usage Features:

The VFD Spindle Kit is designed for straightforward installation and operation.

Installation: The installation process involves removing the old router, routing the spindle power cable through the drag chains, and installing the VFD spindle in the spindle mount. The kit includes all necessary components, such as the VFD controller, spindle, collets, logic cable, power cable, and spindle wrenches. An installation video is also available for guidance.
Spindle Mounting: The spindle is installed in the existing spindle mount, with guidance on positioning it to match the previous router's setup.
Cable Connections: The spindle power cable connects to the top of the spindle, and the VFD controller power cable plugs into a wall outlet. A 6-pin logic cable connects the VFD controller to the Shapeoko controller, ensuring G-code based speed control. A critical warning is provided regarding the correct orientation of the logic cable's triangular peg to prevent damage and ensure operation.
Carbide Motion Integration: Enabling the VFD spindle in Carbide Motion is a simple process, involving selecting "VFD Spindle" in the settings dropdown and confirming the Shapeoko configuration.
Testing: A test procedure is outlined to verify proper spindle operation, including flipping the power switch, enabling the spindle via its button, and sending an M3S10000 command in Carbide Motion's MDI screen to observe clockwise rotation and RPM display.
Collet Installation: Instructions are provided for installing and removing ER11 collets, emphasizing the importance of not fully tightening the collet nut without an end mill inserted to prevent damage.
Spindle Control: The VFD controller features a "Spindle Enable" button that allows users to quickly enable or disable the spindle, useful for tool changes or when using tools that don't require spindle rotation (e.g., drag bits). The button's LED indicates the spindle's status (ON/OFF).
Project Execution: Running a project is streamlined: connect and home the machine, load the tool and material, zero the machine, flip the VFD controller power switch to ON, enable the spindle, load the G-code file in Carbide Motion, and start the job. The spindle automatically starts and stops according to the G-code.
Tool Changes: A safety warning emphasizes disabling the spindle before tool changes. Carbide Motion pauses the job for tool changes, and users are guided to disable the spindle, change the tool, re-enable the spindle, and resume cutting.

Maintenance Features:

Tramming: The manual provides detailed information on "tramming" the VFD spindle, which is crucial for achieving flat and consistent cuts. Tramming addresses issues like small tool marks or changes in audible pitch during cutting, which indicate that the end mill is not perfectly parallel to the machine bed.
Identifying Tram Issues: Visual guides illustrate how different tram errors (nodding backward/forward, yaw clockwise/counterclockwise) manifest in surface finish, helping users identify the specific adjustment needed. The deepest cutting edge is highlighted to aid diagnosis.
Adjusting Nod: Nod (front-to-back tilt) is adjusted first using metal shims placed between the Z-Axis carriage and the spindle mount. The process involves loosening spindle mount bolts, inserting shims, re-tightening, and checking the tram. Kitchen foil (0.024mm thick) is suggested as a readily available shim material.
Adjusting Yaw: Yaw (side-to-side tilt) is adjusted by gently tapping the spindle mount after loosening the bolts, then re-tightening and checking the tram.
Tramming Tools: The manual recommends specialized gauges like the Edge Technology Mini Pro Tram System for high-precision calibration, advising users to consult the manufacturer's manual for tool-specific instructions.
VFD Controller Placement: Users are advised to set up or mount the VFD controller in a location safe from chips and dust, with clear space for unobstructed ventilation, to ensure longevity and proper operation.
Cable Management: Instructions include securing the spindle power cable to prevent it from getting caught on machine parts, such as the Z-Axis motor or dust collection system.

Carbide 3D VFD Spindle Kit - Page 10

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