Carbide 3D SHAPEOKO HDZ 4.0 Assembly Manual
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Carbide 3D SHAPEOKO HDZ 4.0 Assembly Manual

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HDZ 4.0
ASSEMBLY GUIDE
support@carbide3d.com
docs.carbide3d.com
1
9/2/2020 Version 4.0

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Summary of Contents for Carbide 3D SHAPEOKO HDZ 4.0

  • Page 1 HDZ 4.0 ASSEMBLY GUIDE support@carbide3d.com docs.carbide3d.com 9/2/2020 Version 4.0...
  • Page 2 support@carbide3d.com docs.carbide3d.com 9/2/2020 Version 4.0...

  • Page 3: Table Of Contents

    Table of Contents INTRODUCTION ........................ 4 BELTED-X/Z TO HDZ ASSEMBLY GUIDE ................5 Prior to Assembly & Installation ........................5 Inventory ................................. 6 Disassemble the Existing X/Z-Carriage......................11 Assemble the HDZ ............................15 Install the Drag Chain Support System ......................20 Insert the Proximity Switch Cables into Drag Chain ..................

  • Page 4: Introduction

    Introduction We’re here to help! If you encounter any issues during assembly, please contact us at: support@carbide3d.com. The HDZ kit includes everything you need to upgrade your existing X/Z-carriage to the HDZ, or heavy-duty X/Z. The HDZ kit also includes new inductive proximity switches to replace the original homing switches on the belted-X/Z machines. How to Use this Assembly Guide For simplicity, we’ve split up this assembly guide to individually address the two existing machine versions: •...

  • Page 5: Belted-X/Z To Hdz Assembly Guide

    Belted-X/Z to HDZ Assembly Guide Prior to Assembly & Installation Disable the BitSetter Machines With BitSetter: Please complete the following steps before moving on to “Gather the Required Tools” section below. Before beginning the HDZ upgrade: 1. Connect your machine to Carbide Motion. a.

  • Page 6: Inventory

    Inventory Belted-X/Z to HDZ Kit Contents The HDZ kit comes with the components listed in the tables on the following pages and shown in Fig. 1 and Fig. 2. Figure 1 support@carbide3d.com docs.carbide3d.com 8/31/2020 Version 4.0...
  • Page 7 HDZ Box The HDZ box components are listed in the tables below and shown in Fig. 1. Item Description HDZ (Heavy-Duty Z/X Carriage) EZ-Tram Plate HDZ Kit Components and Hardware Bag Item Description Motor Mount Baggie (1) M5 × 25mm X-Motor Standoff M5 ×...
  • Page 8 Figure 2 support@carbide3d.com docs.carbide3d.com 8/31/2020 Version 4.0...
  • Page 9 Proximity Switch Kit Baggie The proximity switch kit baggie components are listed in the table below and shown in Fig. 2. Item Description X-Axis Proximity Switch Mount Baggie X-Axis Proximity Switch Mount M5 × 25mm Socket Head Cap Screw M3 × 18mm Socket Head Cap Screw Y-Axis Proximity Switch Mount Baggie Y-Axis Proximity Switch Mount M5 ×...
  • Page 10 Shapeoko Carryover Components The HDZ utilizes several parts from the existing Shapeoko setup. All components and hardware to be carried over are listed in the table below and shown in Fig. 3. NOTE: Please use the replacement screws Throughout this guide, carryover parts will be called out by provided in the HDZ Kit.

  • Page 11: Disassemble The Existing X/Z-Carriage

    Disassemble the Existing X/Z-Carriage NOTE: As you complete the disassembly process, you may find it helpful to keep each carryover component and its associated hardware together and away from the new HDZ parts to avoid any mix ups. Disconnect Cables and the X-Axis Belt 1.
  • Page 12 Remove the Homing Switches, Drag Chain, and Belted-X/Z 1. Remove the Z-Axis homing switch plate from the front of the X/Z-carriage. See Fig. 4. a. Use a 3mm hex key to remove the four (4) M5 ×10mm BHCS securing the plate. (No need to separate any of the switches from their mounting plates.) 2.
  • Page 13 7. Remove the Y-Axis drag chain head bracket from the outside of the Y1-carriage. a. Use an 8mm wrench and a 4mm hex key to remove the two (2) M5 nuts AND the two (2) M5 × 16mm SHCS. 8. Remove the lower two V-wheels from the X/Z-carriage. a.
  • Page 14 4. Remove the Z-motor (upper motor) from the back of the X-carriage plate. a. Use a 4mm hex key to remove the four (4) M5 × 10mm SHCS securing the motor. WARNING: Do not mix up the X- and Z-motors. The orientation of the X motor’s drive pulley on the drive shaft is very important for the HDZ assembly.

  • Page 15: Assemble The Hdz

    Assemble the HDZ NOTE: The application of a blue (i.e. light/medium grade) thread locker is at your discretion. We suggest adding it post-assembly if any screws happen to work their way loose during use. Get Familiar with the HDZ 1. Take a minute to familiarize yourself with the front and back of the HDZ. See Fig. 10. Figure 10 support@carbide3d.com docs.carbide3d.com...
  • Page 16 Install the Idlers, X-Motor Standoffs, and X-Axis Proximity Switch Mount Located in HDZ Kit: Item Description M8 Guide Bearing M8 Spacer M8 Washer M8 × 30mm Button Head Cap Screw X-Motor Standoff X-Axis Proximity Switch Mount M5 × 25mm Socket Head Cap Screw 1.
  • Page 17 Install the X-Axis Drag Chain Head Bracket, Z-Axis Proximity Switch Mount, and V-Wheels HDZ Kit: Item Description X-Axis Drag Chain Head Bracket M5 × 8mm Socket Head Cap Screw Z-Axis Proximity Switch Mount M4 × 6mm Button Head Cap Screw V-Wheel M5 ×...
  • Page 18 Install the Z-Motor HDZ Kit + Carryover Components: Item Description M5 × 10mm Socket Head Cap Screw Z-Motor [CARRYOVER] 1. Install the Z-motor at the top of the HDZ. See Fig. 13 and Fig. 14. a. Insert the Z-motor drive shaft into the motor coupling at the top of the HDZ.
  • Page 19 Install the Router/Spindle Mount and EZ-Tram HDZ Kit + Carryover Components: Item Description EZ-Tram Plate M5 × 18mm Socket Head Cap Screw M5 × 10mm Socket Head Cap Screw HD Eccentric Spacer (Non-Threaded) Router/Spindle Mount [CARRYOVER] M5 × 16mm Button Head Cap Screw [CARRYOVER] 1.

  • Page 20: Install The Drag Chain Support System

    Install the Drag Chain Support System Shapeoko 3 Machines: Skip ahead to the “Install the HDZ” section on page 26. Install the Y-Axis Head Bracket HDZ Kit: Item Description Y-Axis Drag Chain Head Bracket M5 Nut M5 × 16mm Socket Head Cap Screws 1.
  • Page 21 • Post-Dec 2019 extrusion rails. See Fig. 19. o X-Rail: Sixteen M4 threaded screw holes. o Y1-Rail: Two M5 threaded screw holes on the left-side of the rail and four M4 threaded screw holes along the top of the rail. Figure 19 Install Drag Chain Supports Pre-Dec 2019 Rails: You will need to install the four (4) included drag chain support PLATES.
  • Page 22 1. Attach one (1) middle support plate and one (1) tail support plate onto the X-rail. See Fig. 20 (image from rear). a. Measure and mark 5” and 19 ½” from the Y1-carriage. b. Clean the rail, on the far side (Y2-side) of each mark, with an alcohol wipe.
  • Page 23 Install the Drag Chain Support Brackets [Post-Dec 2019 Rails ONLY] HDZ Kit: Item Description X-Axis Drag Chain Supports Drag Chain Middle Support Bracket Drag Chain Tail Support Bracket M4 × 6mm Socket Head Cap Screw Y-Axis Drag Chain Supports Drag Chain Middle Support Bracket Drag Chain Tail Support Bracket M4 ×...

  • Page 24: Insert The Proximity Switch Cables Into Drag Chain

    Insert the Proximity Switch Cables into Drag Chain Install the Proximity Switch Cables HDZ Kit: Item Description X-Axis Proximity Switch Cable (2675mm XXL and 2350mm XL) Y-Axis Proximity Switch Cable (2540mm XXL and 2200mm XL) Z-Axis Proximity Switch Extension Cable (2438mm XXL, 2235mm XL) 1.
  • Page 25 3. Insert the proximity switches and extension cable into the drag chain. See Fig. 24. NOTE: Position the female end of the gray Z-Axis proximity extension cable at the tail of Y-Axis drag chain. a. Insert the X-Axis proximity switch cable and the gray Z-Axis proximity switch extension cable through both the Y-Axis and X-Axis portions of the drag chain.

  • Page 26: Install The Hdz

    Install the HDZ Insert the Eccentric Nuts HDZ Kit: Item Description HD Eccentric Nut (Threaded) 1. Insert the two HD eccentric nuts into the bottom of the HDZ. See Fig. 25. a. Rotate the eccentric nuts into their fully- open position with the dimple facing up. Figure 25 support@carbide3d.com docs.carbide3d.com...
  • Page 27 Install the HDZ onto the X-Rail HDZ Kit: Item Description V-Wheel M5 × 25mm Socket Head Cap Screw M5 Washer (Shim) 1. Assemble the bottom two V-wheels in this order: a. M5 × 25mm SHCS b. V-wheel c. M5 washer (shim) 2.
  • Page 28 Install the X-Motor HDZ Kit + Carryover Components: Item Description M5 × 10mm Socket Head Cap Screw X-Motor [CARRYOVER] 1. Thread the free end of the X-Axis belt under the idlers at the back of the HDZ. 2. Push a large loop of belt up between the idlers. See Fig.
  • Page 29 Install the X-Axis Belt Carryover Components: Item Description [CARRYOVER] X-Axis Belt & Hardware: Belt Clip (1), and M5 × 10mm Socket Head Cap Screw (1) 1. Install and tension the X-Axis belt. See Fig. 30 a. Attach the belt clip to the free end of the belt.

  • Page 30: Install The Drag Chain

    Install the Drag Chain Shapeoko 3 Machines: Skip ahead to the “Install the Proximity Switches” section on page 32. Install the Drag Chain to the X- and Y1-Rails HDZ Kit: Item Description M3 × 6mm Flat Head Screw M3 × 6mm Flat Head Screw 1.
  • Page 31 3. Secure the drag chain to the rails. See Fig. 32. a. Secure the head of the Y-Axis drag chain to the head bracket on the outside of the Y1-carriage. i. Use a 2mm hex key and two (2) M3 × 6mm FHS to secure. b.

  • Page 32: Install The Proximity Switches

    Install the Proximity Switches Install the X- and Z-Axis Proximity Switch to the Mount HDZ Kit: Item Description X-Axis Proximity Switch (2675mm XXL, 2350mm XL, and 712mm Shapeoko 3) M3 × 18mm Socket Head Cap Screw Z-Axis Proximity Switch (200mm XXL and XL, 610mm for Shapeoko 3) M3 ×...
  • Page 33 Install the Y-Axis Proximity Switch HDZ Kit: Item Description Y-Axis Proximity Switch (2540mm XXL, 2200mm XL, 610mm Shapeoko 3) Y-Axis Proximity Switch Mount M5 × 35mm Socket Head Cap Screw M3 × 18mm Socket Head Cap Screw 1. Install the Y-Axis proximity switch mount to the outside of the Y2-carriage.

  • Page 34: Connect The Wiring

    Connect the Wiring Connect the Extension Cables Shapeoko 3 Machines: Skip ahead to the “Connect Cables to the Carbide Motion Board” section below. 1. Connect the X- and Z-motor lead cables to their labeled extension cables at the rear of the HDZ. a.
  • Page 35 Shapeoko 3 Instructions Shapeoko 3 Machines: Your Carbide Motion board should be installed upside down as shown in Fig. 36. Plug the PCB riser board into the Carbide Motion board. See Fig. 36. a. Plug the PCB riser board into the 2 × 8 open bank of pins in the bottom-left of the Carbide Motion board.

  • Page 36: Cleanup The Cables

    Cleanup the Cables Secure Cables at Y1-Carriage and Z-Plus Shapeoko 3 Machines: Skip ahead to the “Secure Cables Along the X-Rail” section on page 37. HDZ Kit: Item Description Several Cable Ties 1. Secure the cables crossing the Y1-carriage plate. See Fig.
  • Page 37 Secure Cables Along the X-Rail Pre-Dec 2019 Rails (see page 20-21): Clean up cables at the rear of the X-rail using the self adhesive cable tie mounts already attached to your X-rail. Complete the instructions in “Cable Cleanup — Pre-Dec 2019 Rails ONLY”...
  • Page 38 Cable Cleanup — Post-Dec 2019 Rails ONLY Shapeoko 3 Machines: You will only use four (4) cable tie mounts and four (4) M4×6mm BHCS. HDZ Kit: Item Description Cable Tie Mounts M4 × 6mm Button Head Cap Screw Cable Ties Several 1.

  • Page 39: Z-Plus To Hdz Assembly Guide

    Z-Plus to HDZ Assembly Guide Prior to Assembly & Installation Disable the BitSetter Machines With BitSetter: Please complete the following steps before moving on to “Gather the Required Tools” section below. Before beginning the HDZ upgrade: 1. Connect your machine to Carbide Motion. a.

  • Page 40: Inventory

    Inventory Z-Plus to HDZ Kit Contents The HDZ kit comes with the components listed in the tables on the following pages and shown in Fig. 1 and Fig. 2. Figure 1 support@carbide3d.com docs.carbide3d.com 8/31/2020 Version 4.0...
  • Page 41 HDZ Box The HDZ box components are listed in the tables below and shown in Fig. 1. Item Description HDZ (Heavy-Duty Z/X Carriage) EZ-Tram Plate HDZ Kit Components and Hardware Bag Item Description Motor Mount Baggie (1) M5 × 25mm X-Motor Standoff M5 ×...
  • Page 42 Figure 2 support@carbide3d.com docs.carbide3d.com 8/31/2020 Version 4.0...
  • Page 43 Proximity Switch Box The proximity switch box components are listed in the table below and shown in Fig. 2. Item Description Z-Motor X-Axis Drag Chain Head Bracket Baggie X-Axis Drag Chain Head Bracket M5 × 8mm Socket Head Cap Screw M3 ×...
  • Page 44 Shapeoko Carryover Components The HDZ utilizes several parts from the existing Shapeoko setup. All components and hardware to be carried over are listed in the table below and shown in Fig. 3. NOTE: Please use the replacement screws Throughout this guide, carryover parts will be called out by provided in the HDZ Kit.

  • Page 45: Disassemble The Existing Z-Plus Carriage

    Disassemble the Existing Z-Plus Carriage NOTE: As you complete the disassembly process, you may find it helpful to keep each carryover component and its associated hardware together and away from the new HDZ parts to avoid any mix ups. Disconnect Cables and the X-Axis Belt 1.
  • Page 46 Disconnect the Proximity Switches and X-Axis Drag Chain Head and Remove the Z-Plus See Fig. 4 (front) and Fig. 5 (back). 1. Remove the Z-Axis proximity switch from the front of the Z-Plus. a. Disconnect the Z-Axis proximity switch from the gray Z-Axis proximity switch extension cable.
  • Page 47 a. Hold the eccentric nuts steady with a 10mm wrench and use a 4mm hex key to remove the V-wheels. 7. Lift the Z-Plus away from the X-rail and lay it on the baseframe. Disassemble the Z-Plus 1. Remove the tramming plate/spindle mount from the front of the Z-Plus. a.

  • Page 48: Assemble The Hdz

    Assemble the HDZ NOTE: The application of a blue (i.e. light/medium grade) thread locker is at your discretion. We suggest adding it post-assembly if any screws happen to work their way loose during use. Get Familiar with the HDZ 1. Take a minute to familiarize yourself with the front and back of the HDZ. See Fig. 6. Figure 6 support@carbide3d.com docs.carbide3d.com...
  • Page 49 Install the X-Motor Idlers, X-Motor Standoffs, and X-Axis Proximity Switch Mount Located in HDZ Kit: Item Description M8 Guide Bearing M8 Spacer M8 Washer M8 × 30mm Button Head Cap Screw X-Motor Standoff X-Axis Proximity Switch Mount M5 × 25mm Socket Head Cap Screw 1.
  • Page 50 Install the X-Axis Drag Chain Head Bracket, Z-Axis Proximity Switch Mount, and V-Wheels HDZ Kit: Item Description X-Axis Drag Chain Head Bracket M5 × 8mm Socket Head Cap Screw Z-Axis Proximity Switch Mount M4 × 6mm Button Head Cap Screw V-Wheel M5 ×...
  • Page 51 Install the Z-Motor HDZ Kit: Item Description M5 × 10mm Socket Head Cap Screw Z-Motor 1. Install the Z-motor at the top of the HDZ. See Fig. 9 and Fig. 10. a. Insert the Z-motor drive shaft into the motor coupling at the top of the HDZ. b.
  • Page 52 Install the Router/Spindle Mount and EZ-Tram HDZ Kit + Carryover Components: Item Description EZ-Tram Plate M5 × 18mm Socket Head Cap Screw M5 × 10mm Socket Head Cap Screw HD Eccentric Spacer (Non-Threaded) Router/Spindle Mount [CARRYOVER] M5 × 16mm Button Head Cap Screw [CARRYOVER] 1.

  • Page 53: Install The Hdz

    Install the HDZ Insert the Eccentric Nuts Located in HDZ Kit: Item Description HD Eccentric Nut (Threaded) 1. Insert the two HD eccentric nuts into the bottom of the HDZ. See Fig. 13. a. Rotate the eccentric nuts into their fully- open position with the dimple facing up.
  • Page 54 Install the HDZ onto the X-Rail HDZ Kit: Item Description V-Wheel M5 × 25mm Socket Head Cap Screw M5 Washer (Shim) 1. Assemble the bottom two V-wheels in this order: a. M5 × 25mm SHCS b. V-wheel c. M5 washer (shim) 2.
  • Page 55 Install the X-Motor HDZ Kit + Carryover Components: Item Description M5 × 10mm Socket Head Cap Screw X-Motor [CARRYOVER] 1. Thread the free end of the X-Axis belt under the idlers at the back of the HDZ. 2. Push a large loop of belt up between the idlers. See Fig.
  • Page 56 Install the X-Axis Belt Carryover Components: Item Description [CARRYOVER] X-Axis Belt & Hardware: Belt Clip (1), and M5 × 10mm Socket Head Cap Screw (1) 1. Install and tension the X-Axis belt. See Fig. 18 (image from back). a. Attach the belt clip to the free end of the belt.

  • Page 57: Install The Proximity Switches

    Install the Proximity Switches Install the X- and Z-Axis Proximity Switches to the Mounts HDZ Kit + Carryover Components: Item Description [CARRYOVER] X-Axis Proximity Switch (Installed in the Drag Chain) M3 × 18mm Socket Head Cap Screw [CARRYOVER] Z-Axis Proximity Switch M3 ×...

  • Page 58: Connect And Cleanup Wiring

    Install the Y-Axis Proximity Switch HDZ Kit + Carryover Components: Item Description [CARRYOVER] Y-Axis Proximity Switch (Installed in the Drag Chain) Y-Axis Proximity Switch Mount M5 × 35mm Socket Head Cap Screw M3 × 18mm Socket Head Cap Screw 1. Install the Y-Axis proximity switch mount to the outside of the Y2-carriage.

  • Page 59: Post Assembly

    Post Assembly Update the Software Settings WARNING: The HDZ is supported by Carbide Motion 4.17 onwards. Do NOT use an older version of Carbide Motion. Update Software 1. Download and install Carbide Motion from: https://carbide3d.com/carbidemotion/download/. 2. Confirm all of the proximity switches and motors are connected correctly, then, ensure that there is nothing restricting the Shapeoko’s movement.

  • Page 60: Re-Calibrate The Bitsetter

    Check Proximity Switches Double check that your proximity switches are installed and functioning correctly. 1. Place a metal object, such as a wrench, in front of each proximity switch target in turn. 2. Check to see if the red LED on the switch lights up. You can also check to see that a blue LED lights up on the Carbide Motion board.

  • Page 61: Maintenance

    2. Position your spindle directly above the BitSetter. a. Click the Position label. This will toggle the view to the machine coordinates. See Fig. 25. b. Click Rapid Position, then click the SE button to move the spindle to the front-right of the machine.

  • Page 62: Tramming Instructions

    Fit the 65mm or 80mm mount directly to the holes on the front of the HDZ using the M6 bolts provided in the 65mm/80mm spindle mount kit. A detailed video on tramming your Shapeoko can be found here: https://www.youtube.com/watch?v=rGOGlNurglE. For additional advice on tramming, check out the Carbide 3D community: community.carbide3d.com. Happy milling! support@carbide3d.com docs.carbide3d.com...

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