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ShopBot PRSalpha, Assembly Manual

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ShopBot PRSalpha Assembly Manual Download Page 91

Section 11: Secure Table and Spoil Board • May 2, 2016

© Copyright 2016 ShopBot Tools, Inc.  

 page 11-1

Section 11. Secure Table and Spoil Board

Introduction

These instructions are based on a ShopBot PRSalpha 96-48. Larger or smaller table sizes will require 
additional baseboards and/or cutting material to fit.

Hardware

Part Name

Quantity

ShopBot Part Number

Notes

3/8 x1 1/2” carriage bolts

000953

ShopBot supplied

3/8” Lock washer

000092

ShopBot supplied

3/8” Flat washer

000444

ShopBot supplied

3/8-16 Hex nut

000452

ShopBot supplied

3/4” cabinet grade plywood
3/4” Medium-Density Fiberboard (MDF)
Wood glue

1 Gallon

NOTE: 

If table size is greater than 96x48”, it will be necessary to tile multiple sheets to cover the full 

working area.

Refer to the table drawing for specs and measurements specific to machine.

Base Layer

The base layer should be a sheet of 3/4” cabinet-grade plywood. This is the foundation of the work-
bed, and will likely last the life of the tool. When choosing plywood, keep in mind that a higher number 
of plies typically creates a more stable board that is less likely to warp.

Summary of Contents for PRSalpha

Page 1: ... Copyright 2016 ShopBot Tools Inc page 1 ShopBotTools com 888 680 4466 Assembly Guide For PRSalpha and PRSstandard Tools ...

Page 2: ...Assembly Guide for PRS Alpha and Standard Tools May 2 2016 Copyright 2016 ShopBot Tools Inc page 2 ...

Page 3: ...nstall Middle Lower Cross Support 2 8 Insert T Nuts in Bottom Slot 2 8 Mount Table Supports and Gussets to Table Legs 2 9 Mount Table Supports and Cross Supports to Rails 2 11 Install Cross Supports 2 11 Level and Square the Table 2 12 Level the Front Table Side 2 12 Level the Rear Table Side 2 13 Square the Rear Table Side 2 14 Install the Rails 2 15 Adjust the Front Rails 2 16 Section 3 Gantry I...

Page 4: ...Carrier Configurations 4 10 Section 5 Control Box Installation 5 1 Introduction 5 1 Hardware 5 2 Installation 5 4 Alternate Mounting for 12 and 24 Z Axis Models 5 5 Section 6 VFD Installation and Spindle 6 1 Introduction 6 1 VFD Installation 6 1 Hardware 6 2 Determining the VFD Model 6 2 Voltage Amperage 6 3 Mounting the 10 VFD 6 3 Mounting the 16 VFD 6 4 Spindle Installation 6 5 Hardware 6 5 Lowe...

Page 5: ... Checklist 8 7 Y Cable Carrier 8 7 Through Center of Gantry Beam 8 7 X Cable Carrier 8 7 Section 9 Control Box Installation 9 1 Introduction 9 1 Section 10 Software Installation 10 1 Introduction 10 1 Hardware 10 1 Computer Recommendations 10 2 Computer Configuration 10 2 Install ShopBot 3 Control Software and VCarve Pro Software 10 2 Software Overview 10 2 Engage Pinions with Rack 10 3 Connect Sh...

Page 6: ...entation 12 2 Optional Axes 12 2 Setting Up RPM Control 12 3 System Check 12 4 Check Movement 12 4 Check Stops and Targets 12 4 Check Limit Switches 12 4 Check Movement Distance 12 5 Test X Axis Distance 12 5 Test Y Axis Distance 12 5 Test Z Zero Function 12 5 Proximity Switch Targets 12 5 ShopBot Setup 12 6 Z Zero Plate 12 6 XY Zeroing Point 12 6 Fine Tune Setup 12 7 Square the Spindle 12 7 Secur...

Page 7: ... cutting and be aware of any small parts that may come loose after being cut If a small part catches the edge of a spinning bit it can be thrown forcefully in any direction causing injury or damage Never place your hands on the rails of the ShopBot Be aware that the machine may move unexpectedly in any direction which can cause serious injury if your hands are in the path of movement Never wear gl...

Page 8: ...e Assembly Section 2 Gantry Installation Section 3 Cable Carrier Installation Section 4 Control Box Installation Section 5 VFD and Spindle Installation Section 6 Mounting X and Y Axis Motors Section 7 Wire and Cable Routing Section 8 Control Box Installation Section 9 Software Installation Section 10 Secure Table and Spoil Board Section 11 Setup and Fine Tuning Section 12 ...

Page 9: ...Assembly Guide for PRS Alpha and Standard Tools May 2 2016 Copyright 2016 ShopBot Tools Inc page 9 Main Parts of PRSalpha ...

Page 10: ...Assembly Guide for PRS Alpha and Standard Tools May 2 2016 Copyright 2016 ShopBot Tools Inc page 10 ...

Page 11: ...hen the control box is powered off If you must push pull an axis by hand do so very slowly Spinning the motors can generate an electric charge and damage the drivers or other electronic components Static Discharges Follow all wiring and grounding instructions electronic circuits are very sensitive to static and power surges Avoid doing any vacuuming around your machine before it is properly ground...

Page 12: ... and a Phillips head screwdriver to uncrate the components It will require two people to lift out some of the heavier pieces Take a few moments to read through the assembly directions and sort the components by their function to help organize the assembly process Sort hardware by size to reduce the amount of time searching for the correct bolts nuts and washers for a given stage of the assembly Ma...

Page 13: ...es are the rails which create the path of travel for the X axis The table sides and rails are included in the long cardboard package secured to the top of the crate The assembly that rides along the table sides is called the gantry The gantry consists of an extruded aluminum beam which has been fitted with V rails for wheel bearings and gear rack This forms the path of travel for the Y axis The bl...

Page 14: ...o the PC through a single USB cable The variable frequency device VFD is used on machines that contain a spindle only not a router It controls speed and power for the spindle The control box provides the VFD with on off signals but speed is controlled through an RPM controller unit which connects to the PC through a separate USB cable In most cases the X Y and Z axes will be referred to in respect...

Page 15: ...changer bar etc depending on the size shape and accessories but the same basic steps will be followed The table drawings provided will detail the specific measurements Note It is critical to follow the table drawing carefully to ensure correct assembly of the table and accessories The table leveling and squaring steps should be completed with the table is in its final location Moving the table aft...

Page 16: ... included in the small box marked table hard ware Part Name Quantity ShopBot P N Notes 1 2 13x1 1 2 Hex bolt Varies 001956 Used for components to leg 1 2 Lock washer Varies 000588 Used for components to leg 1 2 Flat washer Varies 000029 Used for components to leg 1 2 13 Hex nut Varies 000440 Used for components to leg 5 16 18x3 4 Hex bolt Varies 000529 Used for cross supports leg 5 16 Schnorr wash...

Page 17: ... Varies 000452 Used to secure base board Specific quantities can be found on the packing list enclosed with the hardware Marking the rails Remove table sides from packaging and lay them on the floor side by side Locate where the Home Posi tion X 0 will be Locate the machine specific table drawing at the back of this assembly manual This drawing provides dimensions for the placement of the table le...

Page 18: ...ace that the tool will occupy Mount Table Levelers to Legs Screw a leg leveler into the bottom of each table leg to its approximate half way point Thread a 5 8 hex nut onto the leg leveler Leave this nut loose until the table is leveled Thread the middle leg levelers all the way up to ensure that the feet do not interfere during the leveling procedure Install Table Legs Insert eight T nuts per tab...

Page 19: ...cated with curve towards the bolt head They can make threading the bolts into the T nuts difficult If necessary use a zip tie or other shim behind the T nut to force it clos er to the surface of the slot so it is easier to catch the threads with the bolt assembly Hold a framing square against the leg and the table side while bolts are tightened to ensure leg is installed at a 90 degree angle Hand ...

Page 20: ...nfigured for 12 and 24 axes have extra table side extrusions and table legs with added mounting holes Assembly of these table configurations is identical with the exception of these unique parts and extra mounting hardware The table supports and gussets will go under the bottom table side extrusion and the rails will mount to the top extrusion To turn the spindle off click the output 1 switch agai...

Page 21: ...ssembly Raise each table side If performing the assembly alone use safety straps to secure the sides in place to prevent injury or dam age to the frame Note If the rubber foot of a leveler pops off while lifting the sides in place simply place the rubber foot under the ball of the hard ware and press down on the table side to reseat it Connect Side Assemblies Attach lower table supports to opposit...

Page 22: ...hex nut on the back side to secure the lower support to the middle set of table legs Snug the bolts enough to preload the lock washers If the middle table levelers touch the floor raise them until they no longer make contact Insert T Nuts in Bottom Slot The table and cross supports are fastened to the side rail using threaded T nuts Insert T nuts so the solid face is to the outside face down of th...

Page 23: ... the gusset as in the illustration the flange faces the table leg Use the same 1 2 hard ware hex bolt and flat washer on one side flat washer lock washer and hex nut on the back side to secure the bottom corner of each gusset When a gusset is properly oriented the gusset flange will rest against the table leg hold ing it in position Tighten bottom bolt but not the top one If performing this step w...

Page 24: ...f the leg Only one side uses gussets The second middle table support is installed facing the opposite direction as the first one The middle leg will be sand wiched between two upper supports If working alone use clamps or a sling to hold the table support in place until the appropriate hardware is attached Install the remaining gussets and table supports using 1 2 hardware hex bolt lock washer fla...

Page 25: ... NOTE Do not use lock washers with the table sup port assembly Do not fully tighten the table supports yet Install Cross Supports Use an assistant or sling s to hold the cross supports in place for installation Line up T nuts that were installed earlier with the mount ing holes using a zip tie Attach each end of the cross support with 5 16 Hex bolt lock washer and flat washer into the T nuts Line ...

Page 26: ...s Note When referring to the front side of the table it is as sumed that this will be closest to the 0 0 point as indicated on your table drawing Starting with the front side of the table place a level on the outside of each leg to ensure that it is perpendicular to the floor Pull the table into square side to side and tighten the hardware on the gussets and table supports to hold the table square...

Page 27: ...d and adjust the leveling feet on the back table side Once this is level move down to the next set of legs TIP When checking a long span a lon ger level will give a more accurate read ing If possible use a level that spans the entire width of the table If this is not possible place a shorter level on top of a straightedge What ever method used make sure that the straightedge is actually straight w...

Page 28: ...d Previewing a file with an offset There are several ways to perform a test run without actually cutting the material First enter Move Cut mode and click on the Cut Part button or File and Part File Load Select part file and the following screen will appear Locate the line marked Offset in 2D or 3D A 2D offset will cut the file at normal depth in a different X Y location on the table Once the X Y ...

Page 29: ...re all table leg and table support bolts are tight Install Rails Lay the rail on top of the side with the rack on the outside of the table side Mark on the inside of the rail where the T nuts go un der each counter bored hole in the top of the rail Set the rail aside and slide the T nuts into position smooth side up Set the rail on top of the sides to make sure the T nuts are visible under the cou...

Page 30: ... of the rail with the end of the table side at the 0 position Start at one end of the table and tighten the bolts down the length of the rail While performing this step check each side of the rail with a level or straight edge to be sure that the rail is perfectly straight Do not tighten the second rail at this time ...

Page 31: ... 2016 Copyright 2016 ShopBot Tools Inc page 3 1 Section 3 Gantry Installation Introduction The gantry will come mostly assembled in the crate Assistance will be required to safely lift the main assembly and place it on the table assembly ...

Page 32: ...002407 1 4 lock washer 8 000031 48 push bar kit 1 001996 Push bar 2 001898 1 4 20x5 8 8 002407 1 4 lock washer 8 000031 60 push bar kit 1 001997 Push bar 2 001919 1 4 20x5 8 8 002407 1 4 lock washer 8 000031 72 push bar kit 1 001998 Push bar 2 001920 1 4 20x5 8 8 002407 1 4 lock washer 8 000031 108 push bar kit 1 Push bar 2 002012 1 4 20x5 8 8 002407 1 4 lock washer 8 000031 Zip tie A R 003100 Har...

Page 33: ... Ensure front rails are already tightened With the help of another person lift the gantry onto the rails The dual V wheels should ride on each rail as shown Adjust the Rails Align the back rail by running the gantry up and down the length of the rail while watching from above to make sure rail is centered in the wheel Starting at one end of the gantry adjust then tighten the rail as the gantry is ...

Page 34: ...erial over the cross supports at this time to serve as a temporary workbench Install the YZ Car The YZ car comes with the Z motor already mounted The two pairs of V wheels mount to the gantry rails The top two wheels near the motor are concentric and should remain snug Remove the lower wheels marked with a paint dot using the 5 8 wrench and the provided gantry wheel wrench Place the YZ car on the ...

Page 35: ...he wrench in place while snugging the nut with an adjustable wrench Repeat for the other wheel Test and adjust wheel tension Test each wheel by holding it firmly while moving the YZ car be mindful not to pinch fingers When it s possible to just stop the wheel tighten the nut an additional 1 16th of a turn Test again to ensure each wheel stays snug along the entire rail Note Do not over tighten the...

Page 36: ...t the end of the rails to prevent the gantry from rolling off the end of the tool The X axis mechanical stop blocks prevent the gantry from leaving the rails One goes at each end of both side plates They must hit on both sides of the gantry at the same time Orient the bolts vertically in the top two slots on the side rail The stop block should just clear the geared track below the rails Leave stop...

Page 37: ... to be adjusted Adjust the stop blocks to the measurements shown using a 3 16 Allen wrench Adjust proximity switch targets using a 1 2 wrench They should be the specified distance away from the stop blocks Note Measurements are to the edge of the stop blocks and the center of the target bolts Targets should be installed with the nuts and head aligned with one of their flat surfaces vertical for be...

Page 38: ...Section 3 Gantry Installation May 2 2016 Copyright 2016 ShopBot Tools Inc page 3 8 ...

Page 39: ...ure a Y axis cable carrier going from the top of the gantry to the YZ car X axis cable carriers are included with PRSalpha and PRSstandard machines 96 and above 48 or 72 X axis machines use the included cable carrier kit to keep the cables organized along the X axis Instructions for these should be included in the shipment If not they can be accessed under the E Chain section at http www shopbotto...

Page 40: ...4 flat head screws 4 002246 10 flat washers 4 000629 10 lock washers 2 000539 10 32 hex nuts 2 002247 E chain trough bracket 1 002155 5 16 18 x 3 4 Button head screws 2 002033 5 16 Lock washer T Nut 2 T Nut 2 000728 64 E chain trough or 74 E chain trough 2 002158 002159 1 4 20 x 3 4 Flat head screws 4 001600 1 4 Lock washer 4 000031 1 4 Flat washer 4 000030 1 4 Nylock nut 4 000454 Alternate parts ...

Page 41: ...into the installed position Check end link orientation Both end links should face down as shown Reversing the End Links If the end links are not in the correct orientation insert a screw driver blade into the slot at the end of the link and twist until the flange pops off the side lugs Reverse the end link as needed Push the end link until the flang es snap into the side lugs ...

Page 42: ... chain bracket and loosely secure with 3 16 flat head screws Start a few of the threads of the twist in T nut onto the screws Use the chart below to position the lower bracket and then tighten the 3 16 flathead screws Y axis cutting length Beam length Distance between end plate and Y lower bracket 32 in 47 992 in or 1219 mm 22 50 in 572 mm 48 in 66 338 in or 1685 mm 31 50 in 800 mm 60 in 78 346 in...

Page 43: ... Align the counter sunk holes in the cable carrier with the holes in the top of the lower Y bracket Loosely start the 10 32 x screws into the lower Y chain bracket Mount Cable Carrier to Upper Y Bracket Align the counter sunk holes in the cable carrier with the holes in the top tab of the upper Y bracket Use screws flat washers lock washers and hex nuts to secure the end link to the Y upper bracke...

Page 44: ...ough Brackets for ShopBots with 6 Z s Depending on the length of the machine the number of trough brackets needed can vary from 2 4 The hardware called for here will reflect the mounting of a single trough bracket for a tool with a 6 Z Note Tools configured for 12 and 24 Z s have dual side plates and require different mounting brack ets Place ball and spring pivot inserts into slot on bottom of th...

Page 45: ...e trough sets together Machines with 12 and 24 Z Axis Machines with two side rails require alternate mounting brackets for the X axis trough brackets The brackets are attached to the outside of the lower frame rail with T nuts Slide a 5 16 18 T nut into each of the top three grooves on the lower table side extrusion with the flanged face of the nuts facing towards the inside of the table Loosely t...

Page 46: ... point for one end of the carrier Mount the X upper cable carrier bracket to the 1 4 20 holes located in the side of the endplate Use the button head screw and lock washer to secure the X upper cable carrier bracket to the endplate Cable Carrier to Upper X Bracket Attach one end of the cable carrier to the tab that extends from the X upper cable carrier bracket Use flat head 10 32 screws flat wash...

Page 47: ...he machine Use flat head 10 32 screws flat washer lock washer and nuts to attach the lower portion of the cable carrier to the trough Test Cable Carrier Mobility on Both Axes Place the open access gates close to their clasps to keep them from snagging and breaking off while testing the carrier mobility Move the X axis back and forth the full extent of travel The cable carrier should not feel as th...

Page 48: ...Section 4 Cable Carrier Installation May 2 2016 Copyright 2016 ShopBot Tools Inc page 4 10 X Axis Cable Carrier Configurations ...

Page 49: ...Section 4 Cable Carrier Installation May 2 2016 Copyright 2016 ShopBot Tools Inc page 4 11 ...

Page 50: ...Section 4 Cable Carrier Installation May 2 2016 Copyright 2016 ShopBot Tools Inc page 4 12 ...

Page 51: ... control box In this section the control box will be mounted to the table Note This section shows a conventional table with a 6 Z axis Tables configured for 12 and 24 axes have an extra side rail on each side and require an alternate mounting bracket Refer to the last page of this manual for the alternate orientation Control box mounting for 18 Z axis tables is identical to the 6 table ...

Page 52: ... axis Lower control box bracket 1 003137 for tools with 12 and 24 Z axis Upper control box bracket 2 002579 HSCS 5 16 18x1 3 002415 BHSCS 5 16 18x3 4 4 002033 Washer flat 5 16 Z USS 10 000848 T nut standard 5 16 18 ball and spring pivot insert 4 000728 Nylock Hex Nut 5 16 18 3 002264 Nut 1 2 13 Z 1 000440 Flat Washer 1 2 SAE Z 2 000442 Lock Washer 1 2 Z 1 000588 Hex Cap Screw 1 2 13x1 1 2 Z5 1 000...

Page 53: ...e brackets for the control box are attached to the INSIDE of the table Notice that the control box flanges are in front of brackets at both the top and bottom If the place ment of the flanges against the brackets is not consistent the control box will sit at an angle and not open or close easily ...

Page 54: ...ith the existing cross sup ports Mount the lower control box bracket to the lower left tab of the control box using flat a 1 button head screw flat washer con trol box tab through the bracket washer and a nylock nut Note it is important that the control box tabs sit on the same side of the blue brackets at both the top and the bottom of the control box Space the upper control box brackets to the a...

Page 55: ...ount the lower control box bracket to the side of the leg with bolt flat washers lock washer and nut Once the lower bracket is firmly in place tighten the button head screws holding the upper brackets to the table sides Alternate Mounting for 12 and 24 Z Axis Models 12 and 24 Z axis tools are configured with two side plates on each side The second side rail requires a different lower mounting brac...

Page 56: ...Section 5 Control Box Installation May 2 2016 Copyright 2016 ShopBot Tools Inc page 5 6 ...

Page 57: ...n also be accessed at http www shopbottools com Shop BotDocs files RouterRemovalInstall pdf If attaching Automatic Tool Changer ATC refer to ATC Installation Manual This document was pro vided with the tool and can also be accessed at http www shopbottools com ShopBotDocs files ATCCombinedManual pdf VFD Installation ShopBot Tools with spindles use a VFD to regulate input power and control rotation...

Page 58: ... 003036 Determining the VFD Model There are two main types of VFDs a 10 model and a 16 model These can be easily differentiated by their size and model numbers Model numbers are found on the front of the VFD underneath the RUN and STOP buttons as shown on left There are five different amperage configurations These will not impact installation but it may be beneficial information for tech support V...

Page 59: ...ole of the VFD to the left hole in the strap Using the 1 4 flat washer and 1 4 nylock nut se curely fasten the VFD to the strap Repeat the above step for the other strap on the bottom of the VFD Use a 1 4 20x3 4 button head screw to attach the right upper hole of the VFD to the middle hole in the strap and upper left hole of the leg Securely fasten the VFD and strap to the leg with 1 4 flat washer...

Page 60: ...e front middle leg of the ShopBot Attach securely with 1 4 flat washer and 1 4 nylock nut Repeat this step on the lowest set of holes on the leg with the second strap Install two 1 4 20x3 4 button head screws button head screws 1 4 flat washers and 1 4 nylock nuts on the bottom bracket Install the VFD Slide the VFD onto the bottom bracket screws and install two 1 4 20x3 4 button head screws throug...

Page 61: ... 380 460V 3PH 5 9A 12584 PRS Alpha Colombo 3HP 380 460V 3PH 5 9A 12585 PRS Standard Colombo 5HP 220 230V 1PH 34A 12592 PRS Alpha Colombo 5HP 220 230V 1PH 34A 12593 PRS Standard Colombo 5HP 230V 3PH 20 6A 12511 PRS Alpha Colombo 5HP 230V 3PH 20 6A 12594 PRS Alpha Colombo 5HP 230V 1PH 20 6A 12595 PRS Standard Colombo 5HP 380 460V 3PH 11 2A 12596 PRS Alpha HSD 2 2HP 220V 1PH 12569 PRS Standard HSD 2 ...

Page 62: ...removed to complete this step Raise the Z axis above YZ car until a screw that is not recessed into the rack is visible on the backside as shown Be careful to support the Z axis and ensure it does not move down enough to disengage the rack from the pinion gear Note Do not remove any low profile screws as they se cure the rack and removal may cause misalignment Spindle Mounting Plate The spindle wi...

Page 63: ...on and loosely attach the six 5 16 18 x 1 1 2 bolts to hold the spindle in place Use shims or an assistant to hold the spindle plate threads level with the Z axis through holes Replace Stop Screw If the Z axis stop screw was removed reinstall it Install it snug and test the Z travel to ensure the screw stops travel before the pinion leaves the rack ...

Page 64: ...Section 6 Spindle and VFD Installation May 2 2016 Copyright 2016 ShopBot Tools Inc page 6 8 Section 6 Appendix Table Leg Drawings 6 Table Leg ...

Page 65: ...ion 6 Spindle and VFD Installation May 2 2016 Copyright 2016 ShopBot Tools Inc page 6 9 Section 6 Appendix Table Leg Drawings cont d 12 Table Leg Top mounting hole Middle mounting hole Bottom mounting hole ...

Page 66: ...Section 6 Spindle and VFD Installation May 2 2016 Copyright 2016 ShopBot Tools Inc page 6 10 ...

Page 67: ...d Y Axis Motors Introduction The motors providing movement along the X Y and Z axes use a geared pinion that engages a rack mounted to the side rails and gantry In this section the motors to power the X and Y axes will be installed The Z axis motor comes preinstalled on the YZ car and will only need minor adjustment ...

Page 68: ...ed on tool 1 4 lock washer 12 000031 Preinstalled on tool 1 4 flat washer 12 000849 Preinstalled on tool Motors Standard AR AS Part Number 110v 002259 003347 x Part Number 220v x x 001959 Domestic Domestic International Mount Pinions to Motors Pinions can be found in a bag that includes hex keys lithium grease and the eccentric bearing wrench Motors for PRS machines come with the cable attached In...

Page 69: ...s with 1 8 hex key Secure set screws with the 1 8 hex key Check Alignment of Pinions with Rack Check Pinion Rack Alignment To ensure full engagement and even wear the outside edge of the rack should line up with the edge of the pinion The pinion should never rub on the face of the aluminum side plate extrusion This image shows the pinion in correct alignment Adjust Pinions If Required Remove any m...

Page 70: ... they are mounted onto the tool Mounting hardware 1 4 20 x 3 4 button head screw 1 4 lock washer 1 4 flat washer is already fitted to the gantry end plates and YZ car where the motors will be mounted Place each motor in proper location and loosely secure the motor with the mounting hardware and the 3 16 hex key After all hardware is installed snug all hardware Note Do not engage the pinion teeth w...

Page 71: ...r Remain on opposite side of signal and motor wires Arch cable over top of YZ car and install on spindle Take up slack in cable moving from Y to X cable carriers and secure cable with zip ties Motors and Signal Cables Install the source if it is not already installed Unroll cable to ensure even feeding and minimize coiling Secure cable with zip ties along the route to the proper location Route to ...

Page 72: ...ect plug and tighten screw locking it into place Zip tie the cable to the spindle power cable up to the point where it would enter the Y carrier Proximity Switch Installation Locate the proximity switches and the corresponding cables The cables are marked with colored tape at both ends for ease of identification Blue indicates Y axis Red indicates X axis Note The tape at the far end of the cable m...

Page 73: ...t side of the YZ car and through the YZ plate Secure cable to the YZ plate flange using zip ties in the pre drilled holes Z Zero Plate Assembly The Z zero plate assembly allows for accurately calibrating the height of the Z axis before cutting All of the Z zero plate components are packed in a plastic bag inside the box of accessories Locate 30 gray cable and the two black 3mm screws in the Z zero...

Page 74: ...hain Ensure no zip ties are in the e chain as they will get hung up and make sure cables are not too tight in the E chain Zip tie cables to first and last e chain links Zip tie cables to tie brackets see picture on left Note Spindle power cable is the orange cable in picture This is not installed until p 8 7 Mount Auxiliary Emergency Stop Switch There are pre threaded holes available on both gantr...

Page 75: ...h is mounted in a threaded hole near the X1 motor on the gantry end plate Roll the gantry until it is against the stop blocks The proximity switch hole should be centered over the target bolt Adjust the proximity target if needed Note The powder coating process sometimes leaves residue on the threads of the end plate and YZ car If installation of the threaded prox imity switch is difficult an M8 x...

Page 76: ...th ends of e chain Continue using zip ties along the rest of the cables approxi mately 3 6 apart Note Spindle power cable is the orange cable in picture This is not installed until p 8 7 Pneumatic Air Hoses Certain applications such as the automatic tool changer ATC pneumatic assist and air drill have one or more air hoses that will route through the cable carrier To install an air drill refer to ...

Page 77: ...that may cause connection problems during use All wires and cables from the gantry will be carried in the X and Y axis cable carriers Use this checklist to inspect cables before closing the cable carrier Y Cable Carrier _____ Spindle or router power cord _____ Spindle fan cable if applicable _____ Y motor cable _____ Z motor cable _____ Y axis proximity switch _____ Z axis proximity switch optiona...

Page 78: ...Section 8 Wire and Cable Routing May 2 2016 Copyright 2016 ShopBot Tools Inc page 8 8 ...

Page 79: ...power according to local code and the wiring and power diagrams included with the tool The specific instruction for this section should follow this introduction If the instruction is missing or otherwise not available please see http www shopbottools com ShopBotDocs gantry htm then Control box mounting and wiring standard models or Control box mounting and wiring alpha models depending on the tool...

Page 80: ...Section 9 PRS Alpha Control Box Wiring May 2 2016 Copyright 2016 ShopBot Tools Inc page 9 2 ...

Page 81: ...tion and training can be found in the control software Help menu as well as ShopBottools com and Vectric com The following software will be installed during this section ShopBot 3 Control software used to operate the ShopBot tool and run part files ShopBot Editor Enhanced text editing software used to view and edit ShopBot part files VCarve Pro ShopBot Edition CAD CAM software used to create and e...

Page 82: ...t recommends performing the following actions before installation _____ Install program using administrative account _____ Set User Account Control UAC not applicable to Windows XP to Never Notify _____ Disable network connection _____ Disable security and antivirus software _____ Make sure the USB cable from the ShopBot is not plugged in Install ShopBot 3 Control Software and VCarve Pro Software ...

Page 83: ...a USB hub It pre vents older operating systems from spontaneously reducing the USB communication rate Use only the ShopBot commu nication cord with this hub Locate the control box USB port The control box ships with a sticker partially covering the port that reads Stop Install Software First Remove this sticker only after installing the ShopBot control software Plug the cable into the control box ...

Page 84: ...me by clicking on Utilities and Reset Default Settings Double click on PRS ShopBots then select PRS_alpha Tools Select the proper file corresponding to the ShopBot tool size Default settings will load and the main ShopBot screen opens Although it looks like no changes have been made the correct settings have been loaded Install Control Box Firmware The ShopBot control box is programmed with firmwa...

Page 85: ...ollow the prompts in the window that appears checking the box as each step is completed After the control box is turned on the progress bar below should pop up It will take about 10 seconds to complete Once this progress bar completes the firmware has been loaded on the control box If progress bar does not appear conduct the firmware downloader operation again ...

Page 86: ...e To access all features needed for setup switch to the Full mode by pressing the blue question mark button Select Switch to FULL Once setup is complete return to the Easy display by pressing the EASY button at the top right of the command console win dow Full Display Overview The Command Console window left side allows for adjusting settings loading part files and enter ing commands The Position ...

Page 87: ...er a command click the command box in the main window and type the command followed by any parameters if applicable Movement Testing Connect the USB cable from the control box to the computer Note Windows 7 computers can have both USB 2 0 and 3 0 ports The control software works best if the control cable is plugged in to a USB 2 0 port USB 3 0 ports can be unsat isfactory and are identified by blu...

Page 88: ... target clearance is still 1 32 1 16 1 2mm and snug both nuts with a 1 2 wrench Set Stop Block Positions Ensure stop blocks are loosened Move gantry to one end of rail and back off gantry to access stop blocks Tighten stop block screws securely ensuring stop blocks do not move during tightening Repeat process at other end of rail Check Y Axis Proximity Switches Run YZ car to the complete right and...

Page 89: ... connector is also used for optional accessories such as the 3D optical probe The Z zero plate kit includes two rubberized tabs which act as insu lators Place one or both on the V wheel bolt below the Z zero plate This prevents erroneous signals to the control software The Z zero clip can be placed on the Wago connector or other conve nient location until needed Secure Cables Tie up cables underne...

Page 90: ...Section 10 PRS Alpha Control Box Wiring May 2 2016 Copyright 2016 ShopBot Tools Inc page 10 10 ...

Page 91: ...plied 3 8 Flat washer 000444 ShopBot supplied 3 8 16 Hex nut 000452 ShopBot supplied 3 4 cabinet grade plywood 3 4 Medium Density Fiberboard MDF Wood glue 1 Gallon NOTE If table size is greater than 96x48 it will be necessary to tile multiple sheets to cover the full working area Refer to the table drawing for specs and measurements specific to machine Base Layer The base layer should be a sheet o...

Page 92: ...he head of the carriage bolt to sit below the surface of the plywood Drill pilot holes with a 3 8 bit and press the car riage bolts into the clearance holes and through the cross supports Use a mallet to tap bolts through if necessary Measure the spacing and location of the sheet one last time to make sure that it is positioned according to the table drawing Use the included 3 8 flat washer and he...

Page 93: ...s feature will be used for homing the X and Y positions and for limiting the safe table cutting boundaries and other techniques that you may develop to help your productivity and accuracy Input 4 This input is connected to the stop switch When inactivated the switch allows for use of the tool and when depressed the connection is severed and the tool comes to a stop Input 5 The Z axis proximity swi...

Page 94: ...software the X axis goes from left to right on the screen The Y axis moves across the gantry beam The model shown has a 48 Y axis In the design software the Y axis goes from bottom to top on the screen The Z axis moves up and down over the table bed The model shown has an 8 Z axis In the design software the Z axis is represented by the depth of cut Optional Axes Some models feature two cutting hea...

Page 95: ...hopbot USB it should go straight into an empty port on your computer Click on RPM in the left corner of the Spindle Control window and a settings window appears Change the following parame ters Start when SB3 starts 1 Opens the Spindle Control window every time ShopBot 3 starts Start when SB3 Starts 1 Hertz 60 US Canada Mexico and Japan or 50 Europe and most other regions Hertz Scale Same as Hertz...

Page 96: ...e sensor The LED light should turn off and then turn back on when the object is pulled away Test the function of the limit switch and target setup When set up properly the sensors should see the targets and cause the tool to stop approximately 1 4 before the pinions hit the physical stop blocks Open the keypad and hold down the left arrow key to move the gantry in the negative X direction The gant...

Page 97: ...Look at the red position window to check the X value This is the total available X movement distance This value should be at least 1 larger than the nominal X movement distance Record this value The X axis typically has extra movement available at this end for use with the Automatic Tool Changer option For example a 96 48 table might have an X movement distance of 102 824 Move the X axis off the p...

Page 98: ...oing Point By default the XY zeroing point will be the corner of the table near est the control box There is a program that will repeatedly and ac curately find this point using the X and Y proximity switches The XY zeroing program can be run by clicking on the XY button in the red position window This is sometimes called a C3 routine as entering C3 into the command line also runs this program Mak...

Page 99: ...cebar or emergen cy stop button if the machine travels further than expected Use the keypad controller to move the tool near the 0 0 location Mark the current position on the table with a pencil or pen Click on the zero axes button in the keypad control and check the boxes for the X and Y axes The X and Y position values should change to 0 000 in the keypad and position windows Move the axis a set...

Page 100: ...s provided with tool delivery and can be found at www shopbottools com ShopBotDocs gantry ShopBot Quick Start Guide For maintenance and troubleshooting information refer to http www shopbottools com ShopBotDocs maintenance htm Resources To the best of our knowledge these links are current If you find that any of them are no longer work ing please contact us so that we can update them accordingly D...

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