Shapeoko HDM 3.0 Manual

Welcome and Congratulations

The Shapeoko HDM 3.0 is a high-end, professional-grade CNC resulting from five years of prototyping and testing. It cuts wood, plastic, and non-ferrous metals (like aluminum and brass) quickly and accurately, and will run all day without breaking a sweat. The machine comes fully assembled, wired, and ready to go.

Support

If you encounter any issues setting up your machine, contact our support team at support@carbide3d.com. We will open a ticket for you and respond within 24 hours.

Important Safety Instructions

The Shapeoko HDM 3.0 is a machine tool that requires the same care and attention as any power tool. Please keep this manual in a safe place for reference.

Please read the following warnings carefully to reduce the risk of burns, fire, electric shock, injury, death, or damage to equipment or property.

Eye Protection: Always wear safety glasses or goggles that are suitably impact-resistant.

Hearing Protection: Always wear earplugs or ear muffs. For long jobs, it may be desirable to wear both. Hearing damage is cumulative and irreversible, so one should always err on the side of caution.

Respiratory Protection: Always wear a filter or respiratory mask suitable for the dust generated by the cut material. If necessary, arrange for dust collection and proper ventilation.

Clothing, Hair, and Jewelry: Always ensure that clothing, hair, and jewelry are not caught in the machine. Always wear appropriate clothing, such as long-sleeved shirts, pants, and suitable footwear. When metalworking, gloves and an apron are also recommended.

Machine Safety

• Never reach into the machine’s working envelope while it is running.
• Always engage the spindle lock-out before performing tool changes.
• Always disable the machine's power and turn on the spindle lock-out (disable the spindle) before adjusting the machine or performing maintenance.
• Never leave the machine running unattended.
• Never move the machine during operation.
• Always inform someone before operating the machine and check in with them after completing work.
• Never allow children to use the machine unsupervised.

Operating the Chiller

• The chiller must be turned on when operating the spindle.
• Operating the spindle without the chiller could cause fire and/or catastrophic damage to the spindle, VFD, or machine.
• Always leave the chiller on for an additional 5–10 minutes after turning off the spindle to allow it to cool completely.
• Never run the chiller when the coolant tank is empty.
• Ensure there is plenty of clear space on all sides of the chiller (approximately 1 foot/3 cm) for adequate air circulation.

Shut Off the Machine When Not in Use

After each use, always power down the machine: enable the spindle lock-out, disable the machine's power, and then turn off the power switch on the electronics cabinet.

Fire Prevention

Never run the spindle with the chiller turned off. Consider the possibility of a fire caused by friction from the spindle and take suitable fire prevention precautions (e.g., keeping a fire extinguisher handy and other appropriate precautions).

Power Requirements

A 20A circuit is recommended to run the HDM 3.0. Two separate outlets are required: one for the electronics cabinet and one for the chiller.

End Mill Safety

Use care when handling end mills—both to avoid being cut and to avoid damaging them. It is recommended that you handle end mills with suitable gloves or a cloth to avoid contaminating them. Inspect end mills carefully before each use and ensure that they are securely held by the collet.

Debris Disposal

Recycle or safely dispose of milling debris and dust, keeping in mind flammability, (potential) spontaneous combustion, and chemical considerations. Even natural materials can have disposal implications. For example, walnut wood dust is allelopathic (it inhibits plant growth), irritates the skin and respiratory tract, and is potentially poisonous to some animals. These possible disposal implications are in addition to the spontaneous combustion hazard posed by all types of sawdust.

Software Requirements

The HDM requires a computer running Windows or Mac OS. Our control software, Carbide Motion version 6.49 or higher, must also be installed on the computer to run the machine.

Carbide Motion can be found here:
carbide3d.com/carbidemotion/download/
https://carbide3d.com/carbidemotion/beta/

Warranty

Our standard Shapeoko warranty covers the Shapeoko HDM 3.0.

Details of this can be found here:

carbide3d.com/policy/warranty

Note: The solid hybrid table does not come under the 60-day mistakes on us warranty due to its expendable nature.

carbide3d.com/policy/mistakes/

Join the Carbide 3D Community

Join the Carbide 3D Community:
community.carbide3d.com

Join the Carbide 3D Facebook group:
facebook.com/groups/officialshapeoko

Find or start a discussion on machine troubleshooting, product announcements, software issues (Carbide Create, Carbide Motion, MeshCAM, Carbide Copper, Fusion 360), problems with tutorials, community contests, project galleries, and more.

For getting started videos, please see our YouTube:
youtube.com/carbide3d

Machine Operating Checklist

• Practice Safe Machining. Always follow the safety guidelines listed at the beginning of this document and wear appropriate safety equipment, especially safety glasses/goggles and hearing protection.
• Check the Machine's Condition. Check that all screws are tight; ballscrews, linear rails, guides, spindle, VFD, chiller, and extrusions are in good condition with no nicks or other damage; wiring and coolant tubing is in good condition with continuity and securely fastened; and nothing is frayed or broken, and everything is clear and safe.
• Examine the End Mill(s). Ensure each end mill used is sharp, in good condition, and not chipped.
• Secure the Workpiece. Secure the workpiece right-side up and in the desired orientation to the work surface using a technique appropriate to the material.
• Clear the Work Area. Ensure the work area is clear, and the spindle can move without interference.

What’s new

• New solid all-aluminum Hybrid Table
• New base frame with vertical work holding
• A more powerful 4-pole spindle
• New upgraded electronics
• Power Pendant
• BitSetter 5
• New over-molded harnesses
• Re-designed Y axis
• New sheet metal and brackets

The Shapeoko HDM 3.0 features:

• 80mm water-cooled spindle - 110v 1.5kw or 220v 2.2kw with VFD control and chiller.
• Carbide 3D Warthog electronics with integrated VFD.
• Solid Hybrid Table with T-slot work holding.
• HG15 linear bearings on every axis.
• Billet Y axis
• Heavy-duty X extrusion
• 16mm ballscrews on every axis with custom ballscrew wipers on the X and Y axes.
• Gas Strut
• Power Pendant
• CW3000 Chiller

Assembly Diagram

The Shapeoko HDM 3.0

• A - Z-axis
• B - X-Axis
• C - Y-Axis
• Stepper Motors - at the end of each axis
• D - Spindle
• E - Spindle Mount
• F - Gas Strut
• G - Drag Chains X and Y
• Linear Rails - located on each axis
• Ballscrews - located centrally on each axis
• H - Y Axis Covers - on both Y-axis
• I - Hybrid Table x 7
• J - Vertical Mounting (M6 holes)
• K - BitSetter

The Shapeoko HDM 3.0 Electronics Diagram

• A - Power Switch
• B - Power Input
• C - Spindle Output
• D - VFD Display
• E - Spindle Lockout
• F - USB Port
• G - Power Pendant Port
• I - HDM-W2 Port
• H - HDM-W1 Port

Shipment Contents

• HDM 3.0
• Electronics Cabinet

CW3000 - Chiller Box

• CW-3000 Chiller
• Power Cord
• User Manual

Accessories Boxes

• Sweepy 80mm V2 Dust Boot with Hose Adapters
• #201 ¼” Square End Mill
• Precision ER20 Collets:
  • ¼”
  • 1/8”
  • 1/2"
• Precision ER20 Nut
• Spindle Wrenches: 30mm and 22mm
• Maintenance Kit
• Essential Clamps - Injection-Molded Clamps
• Nutz 'n Bolts Kit
• Tool Kit: 1.5, 2, 2.5, 3, 4, 5mm Ball-Nose Hex Keys; 8, 10, 13mm Wrenches
• 1x Power Pendant
• 1x Power Pendant Cable
• Electronics Cabinet Power Cord
• USB Cable

Setting up the machine

Unpack & Move the Machine

• Open the crate from the top and remove the top and all side panels, giving clear access from all sides.
• Remove the accessory boxes from the crate and put them to one side.
• Lift from below the Y rails between the base frame members
  • Never lift the machine from the ball screws, motors, or drag chains.
  • Keep the machine level when lifting.
• Set the machine on a clean, sturdy, level work surface, supporting all base frame members.
  • It's recommended that you use a forklift, or hoist where available but can be moved by 2-3 able people.
• Please note that cables come from the machine, and the Y drag chain is unsupported. These should remain secured before lifting—ensure they do not get caught or trapped under the machine when placing them down.
  • When placed on a workbench - these should be supported.

The Controller

The electronics cabinet contains the Warthog controller, power supply, and variable-frequency drive (VFD), which controls the water-cooled spindle. The Warthog controller uses a 36-volt power supply to power the motors. Warthog combines optical isolation and a USB connection to the computer for increased immunity from electrical noise and static discharge.

• Always turn off the power switch on the electronics cabinet after using the machine.
• Before opening the electronics cabinet, turn off the power switch AND unplug the power cable from the outlet.
• Connectivity should only be done through USB.

Controller Setup

• The controller can be wall-mounted using the key slots on the rear. These are spaced at 215mm.
  • The controller should be placed within 1m of the machine.
• Alternatively, the controller can be placed on a flat surface.
  • Ensure the two air vents on the left side of the electronics cabinet are not obstructed to permit free airflow.
  • The controller's location should be sheltered from dust and moisture.

Plug in the cables

• Refer to the HDM 3.0 Electronics Diagram
• Plug in HDM-W1 into the controller.
• Plug in HDM-W2 into the controller.
• Plug the spindle cable into the controller on the right side.
• Connect the power pendant to the controller using the provided 6-pin cable.
• Insert the power cable into the jack on the side of the electronics cabinet.
• Plug in the USB cable and connect it to the computer.

The Chiller (CW3000)

The CW3000 chiller is a non-refrigerated industrial chiller. It continually circulates coolant through the spindle to prevent overheating and maintain consistent, high-quality cutting. In the event of a malfunction, the chiller displays an error code on the LED screen.

The chiller has a built-in coolant flow sensor built in, there is no need to install an independent one in-line with the spindle. If the flow of coolant is restricted, you will see an error code.

Setting Up the Chiller

• Place the chiller at the base of the workbench or on the floor beneath it.
  • The CW3000 is a recirculating chiller. It's function is to reduce the coolant temperature to ambient levels.
  • It should be placed away from dust and debris.
  • Approximately 30cm (1 foot) of clearance should be maintained around the unit for best performance.

• Locate the two 8mm coolant tubes exiting the Y-Axis drag chain (at the back-right corner).
• Push the two 8mm tubes into the two 8mm push-fittings on the rear of the chiller. The tubes are interchangeable.
• Gently pull on the tubes to check the secure connection.
• Plug the power cord into the jack on the back of the chiller and a power outlet.
• To fill, remove the cap on the top of the CW3000.
• This unit can accept 9L of coolant.
• Fill the CW3000 with either:
  • Fresh distilled water and general-purpose automotive mono-ethylene glycol-based coolant.
  • Wiper fluid can also be used but should be diluted to spec.
  • Note: Coolant must be diluted according to the manufacturer's specifications. Failure to dilute the coolant with distilled water will lead to a low flow alarm on the CW3000.
• Replace the reservoir cap.
• Run the CW3000 for several minutes to purge air from the system and check for any leaks at the connections between the machine, hoses, and spindle.

Notes

• The chiller MUST be turned on when operating the spindle. Operating the spindle without the chiller could cause fire and/or catastrophic damage to the spindle, VFD, or machine.
• Always leave the chiller on for an additional 5–10 minutes after turning off the spindle/VFD to allow the spindle to cool completely.
• Never run the chiller when the coolant tank is empty.
• Ensure plenty of clear space on all sides of the chiller to allow for adequate air circulation.
• Always use distilled water, windshield wiper fluid, or antifreeze in the chiller. Using non-distilled water will lead to bacterial growth inside the tank.
• Antifreeze is recommended when operating in a cold environment.

CW3000 Specification

• 49 x 27 x 38 cm (L X W X H)
• Power draw 1A @ 110V.
• Flow rate - 10L per min
• Reservoir capacity - 9L

Error Codes

• E0 - Poor flow detected.
  • Ensure the coolant hoses are free of blockages or kinks and that the coolant is appropriately diluted. An incorrect concentration may not register on the built-in flow sensor.
• E1 - Coolant Temperature High
  • Ensure ambient temperatures are within recommended bounds (below 30°C/86°F) and allow the CW3000 some time to reduce the coolant temperature.

The Spindle

The 80mm spindle has an 8–24k RPM range and is fully water-cooled for minimal maintenance.

It has an ER20 collet nut. Collets are available in imperial and metric sizes. We provide a set of AA-rated collets as standard.

The spindle is controlled by the variable-frequency drive (VFD) and cooled by the closed-loop chiller. The VFD’s custom interface board turns the spindle on and off and sets the RPM based on the project G-code. The display screen on the VFD shows the spindle RPM during operation and error codes in the event of a malfunction.

• The chiller MUST be turned on when operating the spindle. Operating the spindle without the chiller could cause fire and/or catastrophic damage to the spindle, VFD, or machine.
• Always engage the spindle lock-out before performing tool changes.

ER Collet Basics

Please refer to our guide found here:

carbide3d.com/hub/docs/er-collet-basics/

Adjusting the Height of the Spindle

Depending on the job, it's possible to raise or lower the height of the spindle.

Always support the spindle when loosening any screws on the spindle mount. Loosening the screws will allow the spindle to slide within the mount.

• Loosen the top and bottom M6×30mm screws on the right side of the spindle mount.
  • As the mounts are machined to a high tolerance, there is a chance the mount needs to be opened slightly - to do this, insert an M6 x 30mm screw in the middle hole of the mount and slowly tighten. Tighten until the spindle can move.
• Once the spindle is at the desired height, remove the M6 screw from the middle hole.
• Fully tighten the top and bottom M6×30mm screws to secure the spindle to 10nm.

The BitSetter

The BitSetter is a pre-installed automatic tool offset probe. It is in a fixed position and on at all times. It tracks the length of every tool installed in the spindle and updates the Z-zero position based on changes to the length of the tool.

BitSetter function and workflow are detailed here:

carbide3d.com/blog/bitsetter-changes-carbide-motion/

Machine-Control Buttons

The HDM 3.0 doesn't have any physical buttons. Control for the machine is done via the computer and the Power Pendant and Controller.

• e-Stop - Press to e-Stop. This will cut the power of the machine. Twist to turn the power back on.
  • This should not be treated as a power button.
• Feed Hold - Press and hold the button for feed hold. To continue, press Resume in Carbide Motion.

• Power switch - Always turn off the power switch on the electronics cabinet after using the machine.
• Spindle lockout—Press to enable/disable the spindle lockout. When the red LED is lit, the spindle is enabled. When the button LED is off, the spindle is disabled.

Refer to the electronics diagram for these switches/buttons

Shapeoko HDM Maintenance

The HDM features dust covers on the left and right of each Y axis. These are designed to be removable. Always check for dust build-up and clean out as needed.

Refer to our maintenance documentation found here:

carbide3d.com/hub/docs/maintenance/

Tramming the HDM

As standard, the HDM is trammed when it leaves the factory.

If desired, it may be re-trammed after setup.

Troubleshooting Guide

The machine will not turn on.

• The power switch on the control cabinet is not turned on.
• The Power pendant is e-Stop is triggered.
• The cables are not correctly plugged in. Ensure all cables are correctly connected.
• The fuse in the electronics cabinet may have blown if the machine stops suddenly.

The spindle will not turn on.

• The spindle lock-out is enabled (the spindle is disabled).
• G-code not loaded or project not started. Load the project and tool in Carbide Motion, then start the project.

Glossary

• BitSetter is an automatic tool offset probe that makes it easy to run jobs using multiple tools without stopping and re-zeroing manually. BitSetter measures the length of the cutter in the spindle and, combined with Carbide Motion, automatically resets the Z-axis zero point to reflect the new length.
• CAD (Computer-Aided Design): CAD is where you turn your idea into a digital design. CAD is software that allows you to draw on your computer. This can be anything from a full-blown parametric 3D modeling package like Solidworks to something as simple as Carbide Create. Don't let the word CAD scare you. All it means is 'a program to draw in'.
• CAM (Computer Aided Manufacturing): CAM is where you turn your CAD design into something your CNC machine can understand. CAM software lets you specify HOW your CNC machine will make your design. Your CAM program will output G-Code. Like most terminology around CNC, CAM sounds scarier than it is.
• Chiller: The closed-loop chiller constantly circulates coolant (distilled water, antifreeze, or windshield wiper fluid) through the water-cooled spindle during operation
• Collet: A collet is a cone-shaped sleeve that holds an end mill in the spindle.
• End Mill / Cutter / Bit / Tool: The Shapeoko HDM uses end mills, which are cutting tools. They come in several varieties, such as square, ball nose, and V-bit, and many sizes.
• G-code: G-code (general or geometric code) is a CNC programming language that controls when, where, and how the machine moves across the workpiece (for example, when to turn the spindle on or off, how fast to travel to a particular location, what paths to take, etc.).
• Home: Homing the machine is sending it to a known, fixed, repeatable location. This means that every time you go home, the machine will move to exactly the same position, allowing you to move the machine to positions relative to the home position with great precision. On the Shapeoko HDM, the home is positioned in the back-right corner.
• Hybrid Table: The Hybrid Table is a system of T-tracks and support surface. In most machines it consists of custom aluminum extrusions with sacrificial MDF inserts. The HDM features a solid aluminum Hybrid table without the MDF. It makes the machine base square and extremely rigid, while still providing a variety of work-holding options.
• Job Zero / Job Origin /Toolpath Zero / Program Zero: It may have many names, but job zero tells the machine where to begin running the job. Job zero is a point in your design where all of the toolpaths will be based on (the X, Y, and Z coordinates). Job zero is most commonly set in the lower-left corner of your stock.
• Jog: Move the spindle to a specific position (a set of X, Y, Z coordinates) in the work area.
• Spindle: The spindle is the part of the Shapeoko HDM that turns the end mills. The 80mm water-cooled spindle has an 8–24k RPM motor. It is controlled by the variable-frequency drive (VFD) and cooled by the closed-loop chiller.
• Stock / Workpiece / Material: The sheet of material (wood, plastic, composite/synthetic, metal) being machined.
• Toolpath: A toolpath is the “route” the cutting tool will follow as it shapes the workpiece. We use Carbide Create or MeshCAM to define the tool paths for a project.
• Tool change: Carbide Motion will prompt you each time you need to change tools when running a job requiring multiple tools. After each tool change, the machine will use the BitSetter HDM to measure the length of the new tool.
• Variable Frequency Drive (VFD): The VFD controls the spindle. The custom VFD interface board turns the spindle on and off and automatically sets the RPM based on the project G-code. It also filters the AC power lines to reduce the electrical noise that can leave the VFD, spindle, and get into the AC supply lines.
• Warthog: Warthog is the fourth major version of our GRBL-based motion control. It uses a 36-volt power supply for better performance with the larger motors used on the HDM. The Warthog also uses a combination of optical isolation and an RS-422 serial connection to the computer for additional immunity from electrical noise and static discharge.
• Work Envelope: A working envelope is the CNC machine’s range of movement across its three axes: X, Y, Z.