65mm VFD Spindle (ER-16)

Note: On May 2025, the 65mm VFD Spindle Kit was updated to include an ER16 spindle, which allows the use of larger collets and endmills on a Shapeoko. This manual is specific to the ER16-equipped 65mm VFD Spindle Kit. For the previous version (ER11), click here.

Contents

• 65mm Air-Cooled Spindle
• Enclosed 110v Variable Frequency Drive (VFD) Unit
• Power Cable for VFD (NEMA 5-15P to C13)
• Communications Cable
• Spindle Cable, 6m
• ER16 Collets
  • 1/8" Collet
  • 1/4" Collet
  • 3/8" Collet
• ER-16 Collet Nut (M19 Thread)
• 22mm Wrench, for collet nut
• 16mm Wrench, for spindle shaft

About the VFD Spindle Kit

The VFD Spindle Kit control unit includes custom electronics to suppress electrical interference and a make the system plug-and-play with all Shapeokos. Spindle activation and RPM is controlled by your G-code or cutting program.

This spindle uses ER collets, which allow the spindle to hold endmills of various diameters. For a detailed explanation about how ER collets work, please read our primer here.

A six-month warranty is provided on the spindle and VFD control unit.

VFD Spindle Kit Specs:

• Collet Nut Size: ER16M
• Collet Type: ER16
• Electrical Requirements: 110V, 12A
• Rated Power: 1200W
• RPM Range: 8-24k RPM ±5%
• Cooling: Air-Cooled

To prevent accidental changes to critical settings, the VFD controller comes pre-programmed and with operational parameters locked.

Shop Requirements

• Shapeoko CNC Router
  • Note: The illustrations in this manual show the installation process on a Shapeoko 5 Pro, but the overall process will be similar for all other Shapeokos.
  • Advisories for Shapeoko 3 owners:
    • Because of the increased weight of the VFD spindle, we do not recommend installing it on a Shapeoko 3 with a belt-driven Z-axis.
    • If you have Shapeoko 3 with a V2.3 controller or older (shipped prior to November 2019), you will also need to purchase an updated Carbide Motion PCB w/ enclosure, which includes a new controller with the Spindle data connector installed.
• A computer running the latest version of Carbide Motion 6.
• 110v outlet for VFD (15A minimum)
• The spindle kit should be operated when the ambient temperature is between 15°C/59°F and 30°C/86°F.

Tools and Consumables Required

• Carbide 3D Shapeoko tool kit (metric hex wrenches ranging from 1.5 to 5mm)
• Flathead screwdriver for opening the drag chain link

Step 1 - Remove Old Spindle & Wiring

• Bring the gantry to the front of the machine for easier access. On a Shapeoko 5 Pro this requires the machine to be powered on.
  • Power on the Shapeoko and connect to it through Carbide Motion.
  • Initialize the machine.
  • Jog the machine gantry to the front of the table and center the Z-axis.
  • Turn off the machine.
• Unplug the current router/spindle from the power outlet.
• Using a 5mm hex key, loosen the two M6x20 bolts on the spindle mount's right side.

• Remove the old router or spindle by lifting it up through the top of the spindle mount.
• Remove the Left Gantry End Cap by loosening and removing two M6 socket head screws. (Shapeoko 5 Pro Only)

• Remove the drag chains that guide the spindle power cable. These are the left side Y-axis drag chain and rearmost X-axis drag chains on the machine.
  • Using a 2.5mm hex key, remove the eight M3x6 socket head screws that secure the left-side Y-axis and rear-most X-axis drag chain. The bolts are located on the left Y carrier plate, left Y rail/limit switch mount, left X extrusion, and rear X/Z drag chain bracket.

• Open all drag chain links using a flathead screwdriver.
  • Insert the screwdriver tip underneath one end of the link cover, approximately 1/16" or 1.5mm deep, and twist gently to pop the cover open.

• Remove the spindle/router cable from the drag chains.

Step 2 - Raise Spindle Mount (5 Pro Only)

• Using a 5mm hex key, remove the four M6x35 bolts securing the spindle mount to the Z-axis.
  • Note: The Z-Plus on the Shapeoko 3/4/Pro does not have an alternate installation position for the spindle mount. Skip this step.

• Raise the mount to utilize the middle set of M6 mounting holes. Using a 5mm hex key, remove the four M6x35 bolts securing the spindle mount to the Z-axis.

Step 3 - Install New Spindle

• Lower the ER16 Spindle through the top of the spindle mount and re-tighten the two M6x20 bolts that clamp the spindle mount shut.
  • Make sure you support the spindle from below so it doesn't fall through the mount and hit the table.
• The VFD spindle should be installed at a height such that the shortest endmill in your arsenal is able to reach your work surface.
  • For most people, the nose of the spindle should be between 4 to 5 inches below the bottom of the mount.

Step 4a - Install Wiring (Gantry Drag Chain)

• With the drag chain removed from the Shapeoko and individual linkages open, lay the spindle cable in the drag chain.
  • Ensure the threaded spindle connector is on the side of the drag chain that terminates on the Z-axis.
• Leave approximately 65cm (~2 ft) of spindle cable free on the Z-axis side of the drag chains.
• Snap the drag chain links closed.

Step 4b - Install Wiring (Y-Axis Drag Chain)

• With the drag chain removed from the Shapeoko and individual linkages open, lay the spindle cable in the drag chain.
• Leave approximately 15cm (~6") of spindle cable free on the side closest to the gantry drag chain.
• Snap the drag chain links closed.

Step 5 - Re-Mount Drag Chains onto Shapeoko

• Reinstall the rear X-axis drag chain to the gantry in the reverse of the process performed in Step 1
• Ensure the spindle cable has enough slack to reach the spindle.
• Reinstall the rear left Y-axis drag chain in the reverse of the process performed in Step 1. Feed cable through the drag chain as needed to create slack as required.
• Reinstall the Left Gantry End Cap, capturing the spindle cable against the gantry extrusion. (Shapeoko 5 Pro Only)

• Check for any pinching, kinks, or strain on the cable.
• Plug the spindle cable into the threaded connector on the top of the spindle.

Step 6 - VFD Control Box Setup

• The VFD unit should be placed in a location sheltered from dust and debris.
• The VFD unit should be easily accessible. You must be able to operate the spindle lockout button on the enclosure.
• The area around the VFD enclosure must be kept clear of anything that could hamper ventilation, specifically on the vented sides of the enclosure (left). We recommend maintaining a 30 cm (about 1 foot) separation between the VFD and any obstructions.
• The VFD enclosure can optionally be wall-mounted. There are two slotted holes spaced 85mm apart that can be used to hang the unit.

Step 7 - Connecting the VFD Control Unit

• Connect the Shapeoko controller to the VFD Control Unit

  • With the Shapeoko powered off, plug the appropriate end of the communication cable into the Spindle port on the Shapeoko controller.

• On Shapeoko 5 Pro, there is an adapter cable that needs to be used between the communications cable and the controller.

• Plug the other end of the communications cable into the 6-pin port on the left side of the VFD enclosure.

• Plug the 4-pin spindle power cable into the connector on the right side of the VFD Control Unit.

• Connect the VFD Control Unit to wall power.

  • Plug the C13 end of the power cable into the receptacle on the VFD enclosure's right side.
  • Plug the other end of the power cable into an NEMA 5-15/20 receptacle.

• Flip the power switch on the VFD Enclosure next to where you plugged in the power cable.

Step 8 - Configuring Carbide Motion

• For your Shapeoko to communicate with the VFD correctly, you will need to run the New Machine Setup Wizard.
• When prompted for the type of spindle being used on your CNC, select VFD Spindle

Step 9 - Operating & Testing Your VFD Spindle

Before performing any cuts with the VFD Spindle, you should test and run a warm-up cycle. This is also recommended if the machine has been sitting idle for more than 2 days and/or if the ambient temperature is below 15°C/59°F.

• You can run a built-in warm-up cycle through Carbide Motion's Quick Actions menu.

• The Spindle Enable button on the front of the VFD controller disables the spindle. This can provide an additional layer of safety when you are interacting with the spindle (ex. changing and endmill), or be used to ensure the spindle does not run when using tools like drag engraving tools or drag knives.
  • If the Spindle Enable button is on (illuminated), the VFD is ready to run. If it is off, the spindle will not activate, even if commanded to in a program.

Proper Collet Usage

For a detailed explanation about how ER collets work, please read our primer here. The short version is as follows:

1. A collet needs to be installed in the collet nut before a tool is inserted. The collet should loosely snap into a retaining groove in the collet nut.
2. Likewise, you must remove an endmill from the collet before the collet can be separated from the collet nut.
3. At a minimum an endmill should be inserted to the same depth as the back of the collet. An endmill should also not bottom out against the inside of the spindle shaft, otherwise it may not self-center properly when the collet is tightened.
4. You may see a drilled divot(s) on the side of the collet, that is normal. It is for balancing.
5. There is an off-center ring on the inside of the collet nut, that is by design. It is meant to capture the collet, and pull it out of the spindle when you loosen the collet nut.
6. Periodically clean the collet, collet nut, and inside of the spindle shaft to remove dust build-up.

Caring for Your VFD Spindle

Please refer to the VFD Spindle Care & Maintenance guide

MISSING

FAQ

What do these VFD error codes mean?
Below are common codes and errors. Support periodically updates this list. If any of these error codes cannot be resolved, please email support@carbide3d.com.

• Err01 - Over-current detection. Check cables for proper connection and verify wall outlet voltage is 110V +/- 10%
• Err04 - High voltage. Ensure wall outlet voltage is 110V +/- 10%
• Err08 - Low voltage. Ensure wall outlet voltage is 110V +/- 10%
• Err31 - Current fault detected. Check the wiring between the spindle and VFD