ShopBot PRS Assembly Manual Page -1 ShopBot PRS: Assembly Manual These assembly instructions apply to both PRSalpha and PRSstandard models of ShopBot CNC’s. Note that there are different sections for connecting each type of tool to the control box. Make sure that you are using the correct connection section for your ‘alpha’ or ‘standard’...
Contents Assembly Manual ....................1 Table Surface Considerations..........................3 Electrical Precautions ............................4 Overview of Your ShopBot PRS CNC Tool......................5 Assembling Your ShopBot ..........................7 Tools You Will Need ..........................7 Unpacking and Getting Your Work Area Organized: .................8 Connection to Electrical Service ........................9 Overview of the Assembly Process .......................10...
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Connect Cables from the Proximity Switch and Z-zero Plate.................58 Seal the Cable Entry............................59 Ground the ShopBot PRSalpha ........................59 Connect the USB cable from PRSalpha Control Box to computer..............60 Hooking Up Your PRSstandard ................. 61 Plug the Motor Cables into your PRS Standard Control Box .................61 Connect the Cable from the Remote-Stop Switch ..................61...
ShopBot PRS Assembly Manual Page -4 Electrical Precautions MOTOR CONNECTIONS - DO NOT CONNECT OR DISCONECT ANY MOTOR WIRE CONECTORS WHILE YOUR CONTROL BOX IS TURNED ON !! During the process of a ‘hot’ connect or disconnect there is a high load put on the motor driver circuitry which is very likely to damage the motor driver.
(fewer or more legs, different shape, etc.). Before you unpack and start to assemble your ShopBot PRS tool, let's go over the some of the major components and get familiar with the terminology and directions we'll be using: THE TABLE To get us located, refer to the orientation diagram above and imagine looking at the tool from the position of the little man in the drawing.
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THE X-AXIS. The X-axis is the basis for your tool's right and left moves (as seen by you as the little man in the front of the diagram) -- it's the long axis on a standard ShopBot. Note that the distance between the tracks on the X-axis is wide. Because of this span, we power the X-Car movement with 2 motors, one on each side.
ShopBot PRS Assembly Manual Page -7 Assembling Your ShopBot Tools You Will Need • a wrench set with TWO wrenches of the following sizes 7/16”, 1/2”, 9/16”, and 3/4”(the type with box end on one side and open end on the other works well).
You will receive a large shipping crate with the already-assembled X-Car and YZ- Car. One of the large cartons inside the crate holds the ShopBot Control Box. The motors and motor cables are packaged together. The long package with the rails and table sides will usually be strapped to the top of the shipping crate.
By way of giving you a little guidance: It takes one of us about 6 hours to assemble a ShopBot, so we think you should be able to put your ShopBot together over a pleasant weekend if you've already read through this Assembly Manual. Of course, the IRS thinks...
Note there are different sections for the PRSstandard and the PRSalpha. Off and Running… Stopping the ShopBot How to stop the ShopBot with the E-Stop, 3-Button Pendant, Remote Stop Switch and the “S” key. Taking a Test Drive Ok, let’s go for a little spin, then we’ll review a couple of other things you will need to attend to before you get into production.
Measured Drawing (located at the back of this section) specific for the size ShopBot you are assembling. The Measured Drawing plans show the dimensions of the tools, the spacing of the cross supports, and the correct position for the table surface.
ShopBot PRS Assembly Manual Page -14 Assembly Steps Step1.1: Attach a Machine Glide to the Bottom of Each of the Table Legs Screw a Machine Glide through the 5/8” nut in the bottom of each Table Leg. Place a 5/8”...
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ShopBot PRS Assembly Manual Page -15 hold the pieces securely in place. Keep in mind that you will want to tighten all nuts securely at the end of the table assembly when you square the table. If you tighten all fasteners too much now, you won’t be able to square the table later.
ShopBot PRS Assembly Manual Page -16 Step 1.3: Attach the First Upper Table Support Attach the first Upper Table Support to the end of the table. Start it on from the side with the temporary outside leg. Slide the T-nuts for the Upper Table Support into the bottom channel of each Table Side on the far end.
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ShopBot PRS Assembly Manual Page -17 Attach the Lower Table Support to the bottom holes in the Table Legs using ½” Hardware Assemblies. Lower Table Support showing attachment to Table Leg. Your table should now look like this: PRSAssembly080922.doc Copyright 2007,2008 ShopBot Tools, Inc...
ShopBot PRS Assembly Manual Page -18 Step 1.4: Slide the Cross Supports into Position Attach two 5/16” Hardware Assemblies to each end of the Cross Supports. Then slide the T- nuts into the bottom channels of the Table Sides and slide the Cross Supports into position.
ShopBot PRS Assembly Manual Page -19 Step 1.5: Working on the other End of the Table where the Legs are still temporarily attached to the Outside of the Table Sides Install 5/16” Hardware Assemblies on the Upper Table Support and slide it into position.
ShopBot PRS Assembly Manual Page -20 Step 1.6 Square and Level Table Set the table where it will be used. Plan to spend a little time getting it square and adjusted to the exact correct width measurement. [SEE DRAWING & TABLE BELOW] Set the legs perpendicular to the Table Sides with a square and tighten.
ShopBot PRS Assembly Manual Page -21 ========== WORK AREA ========== WIDTH DIMENSION 48” (121.92cm) 60” (12.40cm) 72” (182.88cm) Outside to Outside of Table Sides 64.5” (163.83cm) 76.5”(194.31cm) 88.5”(234.79cm) Gauge between Rail Spacing 61.5”(156.21cm) 73.5”(186.69cm) 85.5”(217.17cm) Table Surface (probably attach later?) The deck surface of your table is created from several sheets of plywood or MDF.
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Supports or center Cross Support and attach with flat washers, lock washers and nuts. If you are putting a vacuum hold-down system on your ShopBot. Please see the documentation for the vacuum hold-down system for more information on installing your plenum and bleeder board.
ShopBot PRS Assembly Manual Page -23 Installing the Gantry Installing the X-Rails and Getting One Rail Straight Slide the X-Rails onto the Table • Mount the X-rails with 5/16 bolts and T-nuts. Slide these nuts into the top track of the table sides as you did with the table legs and cross supports.
ShopBot PRS Assembly Manual Page -24 • With bolts “finger tight,” move along the X-Rail on the front side of your tool, aligning the aluminum bar on the inside exactly flush with the inside of the table side. • Then start at one end further tightening the bolts.
ShopBot PRS Assembly Manual Page -25 Putting the X-Car on the Rails and Using it to Align the Rear X-Rail Lower the X-Car onto the X-Rails The X-Car is fully assembled and ready to be placed on the rails. This is a 2-4 person operation as the car is HEAVY! Note that the car goes on the rails so that the sloping edge of the X-Car faces towards the left when you are at the front of the tool.
ShopBot PRS Assembly Manual Page -26 Detail • Put a C-Clamp across the rails at each end of the table to create a temporary end stop to prevent the X-Car from rolling off the table while you are carrying out the...
ShopBot PRS Assembly Manual Page -27 Mounting the YZ-Car and adjusting its lower wheel bearings Place YZ-Car on the X-Car The YZ-Car is a single piece that is ready to be placed onto the rails that cross the face of the X-Car beam.
ShopBot PRS Assembly Manual Page -28 Attach the Lower Wheel Bearings on the YZ-Car With the YZ-Car in position riding on its upper wheel bearings, you can install the lower bearings. Study the diagram below because the parts in this assembly need to be installed exactly as indicated.
ShopBot PRS Assembly Manual Page -29 Adjust the Lower Wheel Bearings on the YZ-Car The lower bearing is adjusted tight by rotating the eccentric bushing. It has an off-center hole so that rotating the bushing moves the wheel into and out of contact with the rail. The adjustment is done most easily with a 9/16”...
ShopBot PRS Assembly Manual Page -30 Attaching the Motors Put the Pinion Gears on the Motors Locate the X and Y motors. These motors will already be fitted to a blue mounting bracket and have a long cable attached. Also find the bag with your pinion gears.
ShopBot PRS Assembly Manual Page -31 Mount the Motors Since the motor cables (of correct lengths and motor direction orientation) have already been attached to the motors, it is important that the motors and brackets be mounted in the correct location. The mounting hardware for each motor (4 bolts) is already fitted to the tool in the locations where the motors will be mounted.
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ShopBot PRS Assembly Manual Page -32 We recommend applying grease to the rack and pinions. A good quality bearing, lithium, or Teflon grease will work well. The grease will keep the rack motion smooth and reduce gear wear. (Surprisingly little debris actually collects in the grease.) Apply it by squeezing a little into the rack every few inches.
ShopBot PRS Assembly Manual Page -33 Set the Mechanical End Stops for the X Axis The Mechanical End Stops are aluminum blocks that limit the movement of the car on the axis by stopping the pinion motion for the X-axis (The Y stops are already positioned). The blocks are locked into the slotted track just under the gear rack by two set screws.
Run the X-2 Motor Cable through the Aluminum Beam The X-2 cable from the motor on the front side of your ShopBot runs through the X-Car aluminum beam to the back side of your ShopBot before going to the Control Box.
Control Box depending on which cutter you specified at the time you placed your order. They are not interchangeable. Before retro-fitting your tool from a router to a spindle or vice-versa, please call ShopBot to discuss the changes you will need to make to reconfigure your tool.
ShopBot PRS Assembly Manual Page -36 If You Have a High Frequency Spindle: The spindle will come fitted with a custom aluminum backing plate. This plate attaches to the pre-drilled holes at the bottom of the Z axis using 6, 5/16” socket-head bolts. These bolts pass through the beam and into the plate.
ShopBot PRS Assembly Manual Page -37 After Mounting the Router/Spindle Now you will run the wire for motors and accessories and do a little tidying up, then you’ll be ready to plug in your tool, test it out, and put it to use. We will use a lot of wire-ties in this step, so in addition to your other tools, get the wire-tie bag handy and a set of nippers to trim them with.
ShopBot PRS Assembly Manual Page -38 Proximity Switches You’ll find the Proximity/Limit Switches, targets and mounting hardware bagged together. These switches are used to set the zero location for the X- and Y-axes, and also serve to signal the end of the axis to the tool and limit its motion. They switches look like a piece of threaded rod with a wire exiting from one side.
ShopBot PRS Assembly Manual Page -39 • Mount the second Proximity Switch (for the Y Axis) through a hole on the left side of the YZ-Car. • • Y-axis Targets Look at the front side of the Y-Axis Beam on the X Car. You will see t two bolt heads sticking up in the grooves between the two rails.
ShopBot PRS Assembly Manual Page -40 • Push the Proximity Switch over these targets and check the spacing. You want about a 2mm gap (.08”) between the target and the Proximity Switch. After you get your tool connected, you can check and adjust these targets.
This document shows how to install the Energy chain (Echain) on the Y-axis on ShopBot PRS and PRS BT models. Note that the dust collection hose from the ShopBot Dust Skirt must be routed overhead when an Echain is installed; the Y-upper Echain bracket has a fixed attachment point for the dust collection hose.
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ShopBot PRS Assembly Manual Page -42 The Echain comes in the length to match the width of the Y-axis of the ShopBot ordered. These Echains are center mounted so the Echain itself will not physically extend from the end plate to the Y-upper Echain bracket.
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Y-upper Echain bracket will be located on the back left side of the YZ car and the Echain will loop to send the cables toward the back of the ShopBot. Step 1: Installing the Y-upper Echain bracket. •...
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ShopBot PRS Assembly Manual Page -44 Step 2: Mounting the Echain to Y-upper bracket • (1) Echain • (2) 10-32 flat head screws • (2) #10 flat washers • (2) #10 lock washers • (2) 10-32 hex nuts Position the Echain so that it loops towards the right when you are facing the front of the YZ car.
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ShopBot PRS Assembly Manual Page -45 Chart showing distance from End Plate to edge of Y-Lower Bracket Cutting width in Y-axis Distance between end plate and Y-lower (Beam length) bracket 32in (47.992in or 1219mm) 22.50in (572mm) 48in (66.338in or 1685mm) 31.50in (800mm)
ShopBot PRS Assembly Manual Page -46 Secure cables and wiring Use a chained wire tie (link 3 standard wire ties together) and secure the X-2 Motor Cable to the base of the X-2 Motor. Run the cable to the back side of the front End Plate, and secure it with two wire ties behind the back lip of the plate.
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ShopBot PRS Assembly Manual Page -47 Opening the Echain Move the YZ-car to the far end of the Y-axis so that the motor is not over the Echain. This keeps the motor from interfering with the hinged access bars. With a flat head screw driver, insert the tip into either side of the hinged access bar.
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Neither the hose nor the dust collection system is provided by ShopBot. Extend the length of the overhead dust hose to the ShopBot dust skirt and connect the dust skirt. For more information about the installation and use of the dust skirt, please see Installing the PRS Dust Skirt (SBG00326DustSkirtPRS).
You’ve now completed assembly of your PRS CNC Tool and are ready to connect it to the Control Box and try it out. The instructions for hooking up to your Control Box are different for PRSalpha and PRSstandard tools. Make sure to use the correct section that describes the connection process for your specific tool.
Do’s and Don’ts DO contract with a licensed electrician experienced with industrial equipment to wire the power to the PRSalpha control box, a spindle/VFD and for a displacement or regenerative vacuum blower system for hold-down. Documentation provided with spindles and blowers details their power requirements.
Hooking Up Your PRSalpha Powering the PRSalpha Control Box The power to the PRSalpha Control Box should be wired into a fused disconnect by a licensed electrician familiar with industrial equipment. The Power Requirements for the PRSalpha Control Box and Router/Spindle vary according to your configuration.
Mount the PRSalpha Control Box Mount the PRSalpha Control Box in a location so that the operator can reach the front of the Box each time a file is run because it is necessary to hit the start button to engage the safety contactors.
Refer to the labeled picture of the PRSalpha Control Box on the next page. The Contactors, located at the top of PRSalpha Control Box, are the large relays that control power to the equipment. They are controlled by the e-Stop and by software. The size of the contactor may vary with the power requirements of the device it is powering.
ShopBot PRS Assembly Manual Page -54 Inside the PRSalpha Control Box Your box may not be exactly the same as illustrated depending on the model. 1. Disconnect switch 2. Grounding strip 3. Fuses 4. 24v Power Supply 5. 12v Power Supply 6.
Open the Roxtec Fixture You will be routing cables through the Roxtec Wire Management Fixture attached to the side of the PRSalpha Control Box. This device gives all wires a tight entry and will seal your PRSalpha Control Box against dust and debris.
PRSalpha Control Box. Your PRSalpha Control Box may differ slightly from pictures in the manual depending on which model you have. If you have a 3-Button Pendant, your PRSalpha Control Box will not have Start/Reset buttons.
ShopBot PRS Assembly Manual Page -57 Installation Run the cables from the 3-Button Pendant and the separate E-stop switch into the PRSalpha Control Box through the Roxtec opening and plug in the terminal blocks as shown below. Below: The PRSalpha Control Box before the terminal block from the 3-Button Pendant is attached.
Note that the terminal blocks can be removed to make wire insertion easier. When the PRSalpha Control Box is powered up a red LED in the body of the proximity switch out on the tool will stay bright until it is triggered by coming near a target.
USB cable into your computer at this point. Seal the Cable Entry When you have attached all the cables in the PRSalpha Control Box, it’s time to put the gaskets around them and close up the Roxtec fixture. The Roxtec system is designed to keep dust out of the PRSalpha Control Box. Take a moment to fit each of the cables into a gasket so that the cables fit snugly and the two halves of the gasket close well.
On many computers, there are multiple slots for the USB cable. Once you have decided on the one you are going to use, always plug the ShopBot USB cable into the same slot. Plug the USB cable into the USB port on your computer.
The white wire from the Remote-Stop is connected to the Ground connection at the left side of the Input connector. The Black wire is connected to Input terminal #4, which corresponds to Input Switch #4 in your ShopBot Software. Using a tiny screw driver, snug up the wires into the correct location.
Standard Control Box to your computer. It is a short cable that exits on the right side of the Control Board. Plug the longer 10ft cable supplied with your ShopBot into this connector. Do not plug the USB cable into your computer at this point.
On many computers, there are multiple slots for the USB cable. Once you have decided on the one you are going to use, always plug the ShopBot USB cable into the same slot. Plug the USB cable into the USB port on your computer.
ShopBot PRS Assembly Manual Page -64 Mission Accomplished! You might have thought you'd never get here, but: “Mission Accomplished!” PRSAssembly080922.doc Copyright 2007,2008 ShopBot Tools, Inc...
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PRS Assembly Appedix Page -1- Assembly Appendix Stopping the ShopBot Test Spin Surfacing the Table Squaring and Adjusting the X-Car Table Drawings AssemblyAppendixintro.doc Copyright 2008 ShopBot Tools, Inc...
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• Release the red button on the E-Stop by rotating it • Press the RESET button on the PRSalpha Control Box to send power to the spindle/router and motors on your tool. • Clear the message box in the control software by pressing “Quit”.
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The presence of a Remote Stop Switch does not alter the need to good safety procedures for operating your ShopBot. You should always stand clear of the tool when it is in movement, preferably positioning yourself near the computer controlling the operation. A Personal Robotic Tool can be a very safe power tool as long as all safety procedures are followed.
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Run Your ShopBot Now and Check out Some of its Basic Functions. Start the Control Box. If your tool is a PRSalpha, also hit the blue “Reset” button on the box (this activates the relay systems). Your first moves will just be 'air' cuts, so you do not need to have a bit.
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Locations Display for your tool. The second screen is the Control Console which is the place you to enter Commands to tell your ShopBot what you would like it to do. You can use the keyboard or mouse to select commands from the Main Menu bar, or you can enter two letter ShopBot Commands right into the Command Box on the Console.
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• If all has worked well so far, jog back to the starting point using both axes. Use: [J2] 0, 0. Your tool should move rapidly back to where you last zeroed it. TestSpinPRS080916 Copyright 2008 ShopBot Tools, Inc...
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ENTER twice again to start air-cutting the file. • This file cuts the ShopBot logo (normally you would use a 'V' bit), and you can cut it in all different sizes using the proportion feature in the [FP] Command. Note that the underline portion of the logo cuts first, followed by the letters.
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This can be installed on a separate design computer if you wish. Tutorials will be copied to your computer as part of the installation process. Go to Start > All Programs > ShopBot > Tutorials to open them. The accompanying videos are available for download at www.shopbottools.com >...
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Surfacing Table Page -1- Surfacing Your Table One of the first things you'll want to do after getting your ShopBot together and running is to smooth your work surface. Here are a set of general procedures for surfacing your table.
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NOTE: the space after the M2 and the COMMA are very important. Send the router to the lower right corner [M2] 96, 0 to Move 2 Dimensions (the SurfacingTable080916 Copyright 2008 ShopBot Tools, Inc...
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Lower the Z to that point. [K] and PageDown. Read the Z location on the screen on the ShopBot Position screen (red)… it should be a negative number if this point is lower than your original start point.
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Accept [Enter] then [Enter] again to run it. Tools > TS There is also a Table Surfacing Tool in the ShopBot Software under Tools. This is a simplified version of what you’ve just done and will be useful for routine re-surfacings. SurfacingTable080916...
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X axis by moving The X-Car up and down the rails, checking the position of the sheet at the tip of the cutter. SquaringXCar080916 Copyright 2008 ShopBot Tools, Inc...
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Then, when you’ve got it square, turn the power to on to the Control Box, and if a PRSalpha, hit the Reset Button. The motors will power on and lock into position. Your tool is now square in X and Y, and it will remain square whenever it moves until the power is removed.
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Note that as a cutter becomes dull, it will require more force to push through the material and thus will also generate more side force. SquaringXCar080916 Copyright 2008 ShopBot Tools, Inc...
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Making an Adjustment for Wheel Bearing Alignment or Square The X-Car of your PRS ShopBot is the primary structural component of the tool. We build the X-Car in a precision fixture that exactly spaces the wheel bearings and that assures a perfectly square and true gantry.
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