ShopBot PRSalpha Assembly Manual

Hide thumbs Also See for PRSalpha:

Assembly manual (93 pages)

Quick start manual (26 pages)

Assembly manual (74 pages)

Table Of Contents

100

page of 100

/ 100
Contents
Table of Contents
Bookmarks

Table of Contents

Quick Links

Download this manual

888-680-4466 •

ShopBotTools.com

Assembly Guide

For PRSalpha and PRSstandard Tools

page 1

Table of Contents

Need help?

Do you have a question about the PRSalpha and is the answer not in the manual?

Questions and answers

Summary of Contents for ShopBot PRSalpha

Page 3: Table Of Contents
Assembly Guide for PRS Alpha and Standard Tools • May 2, 2016 Table of Contents General Safety and Precautions ......................7 PRS Quick-Start Process Flow .......................8 Main Parts of PRSalpha ..........................9 Section 1. Setup and Assembly Overview ..................1-1 Electrical Precautions ......................... 1-1 Safety............................1-1 Unpacking the Crate........................
Page 4 Mount Pinions to Motors ......................7-2 Identify Motors..........................7-3 Check Alignment of Pinions with Rack ..................7-3 Check Pinion/Rack Alignment ....................7-3 Adjust Pinions (If Required) ......................7-3 Mounting Locations ........................7-4 © Copyright 2016 ShopBot Tools, Inc. page 4...
Page 5 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 ShopBot to Computer....................10-3 USB Communication Cable ....................
Page 6 Fine Tune Setup ........................12-7 Square the Spindle ......................12-7 Secure Mounting Screws....................12-7 Test Movement Distance ....................12-7 Install Push Bars ........................12-7 Install Dust Foot........................12-7 Install End Caps........................12-7 Resources ............................12-7 © Copyright 2016 ShopBot Tools, Inc. page 6...
Page 7: General Safety And Precautions
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.
Page 8 Motors (Section 7) (Section 5) Installation (Section 6) Routing (Section 8) Control Box Software Installation Secure Table and Spoil Setup and Fine Installation (Section 9) (Section 10) Board (Section 11) Tuning(Section 12) © Copyright 2016 ShopBot Tools, Inc. page 8...
Page 11: Section 1. Setup And Assembly Overview
Schedule the services of a licensed electrician to complete the ShopBot setup. Connecting power to the control box can be done before or after assembly of the machine, but it is easiest to wait until the tool is set up in its final position.
Page 12: Unpacking The Crate
Section 1: Setup and Assembly Overview • May 2, 2016 Unpacking the Crate The ShopBot components arrive in two packages: a large wooden crate and a long box. The crate and box leave ShopBot banded together. Contact the shipping company if a piece is missing, or if they do not arrive together.
Page 13: Terms To Know
The blue plates on either side of the gantry are referred to as end plates. The YZ car moves across the gantry, and controls the height of the cutter head (either a router or high-speed spindle, depending on the tool). © Copyright 2016 ShopBot Tools, Inc. page 1-3...
Page 14 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 to the machine. Another frequent- ly-used term is the XY home position, as indicated here. © Copyright 2016 ShopBot Tools, Inc. page 1-4...
Page 15: Section 2. Table Assembly
The diagrams in this manual depict a 96” x 48” table, the most common ShopBot table size. The table layout may look a little different (fewer or more legs, tool changer bar, etc.) depending on the size, shape, and accessories, but the same basic steps will be followed.
Page 16: Hardware
Cross supports, leg, control box 5/16-18 T-nut Varies 002498 Used for control box 5/16-18x3/4 Button head Varies 002033 Used for control box cap screw 5/16-18x3/8 T-nut Varies 001569 Used for cross supports, leg © Copyright 2016 ShopBot Tools, Inc. page 2-2...
Page 17: Marking The Rails
Note for international customers: The location of the table legs and cross supports along the X-rails can be adjusted slightly to reflect metric units. © Copyright 2016 ShopBot Tools, Inc. page 2-3...
Page 18: Mount Table Levelers To Legs
The T-nuts slide in with the rough side down. Note the line marked for alignment. Do not forget to insert the T-nuts for the middle legs in the T-slots prior to assembling the end legs. © Copyright 2016 ShopBot Tools, Inc. page 2-4...
Page 20 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 again or close the keypad window. © Copyright 2016 ShopBot Tools, Inc. page 2-6...
Page 21: Stabilize With Lower Table Supports
Note: Do not install upper bolt on lower front right side - this is where the control box will be attached. Square sides with the lower supports and snug the bolts enough to preload the lock washers. © Copyright 2016 ShopBot Tools, Inc. page 2-7...
Page 22: Install Middle Lower Cross Support
T-nuts. Insert T-nuts so the solid face is to the outside (face down) of the slot and move them to their approximate locations before mounting any components. Note: Failure to perform this step will require disassembly to fix. © Copyright 2016 ShopBot Tools, Inc. page 2-8...
Page 23: Mount Table Supports And Gussets To Table Legs
Note: This image shows the approximate T-nut locations for the upper table supports and cross sup- ports for the PRSalpha 96-48 table set up. A table configuration with more table legs or cross supports will require additional T-nuts as indicated on table drawing. Two are needed for every component.
Page 24 Install the remaining gussets and table supports using 1/2” hardware (hex bolt, lock washer, flat washer on one side… flat washer and hex nut on other side). © Copyright 2016 ShopBot Tools, Inc. page 2-10...
Page 25: Mount Table Supports And Cross Supports To Rails
T-nuts. Line up the leading edge of each cross support with mark and snug the bolts enough to compress the lock washers. Do not fully tighten the cross supports. © Copyright 2016 ShopBot Tools, Inc. page 2-11...
Page 26: Level And Square The Table
Do the main adjust- ments with the end legs, as the middle leg is primarily for support. Do not lower the middle leg levelers until the gantry is installed, the table is level and square. © Copyright 2016 ShopBot Tools, Inc. page 2-12...
Page 27: Level The Rear Table Side
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 with parallel sides. © Copyright 2016 ShopBot Tools, Inc. page 2-13...
Page 28: Square The Rear Table Side
To avoid cutting into the workpiece, make sure that the starting distance between the bit and the material is greater than the maximum cut depth. Click “START” or Enter on your keyboard to proceed. © Copyright 2016 ShopBot Tools, Inc. page 2-14...
Page 29: Install The Rails
Using a 5/16” allen wrench, loosely install the bolts into the T-nuts to prevent any rocking, while still allowing some side to side play. Do not fully tighten the bolts on either rail. © Copyright 2016 ShopBot Tools, Inc. page 2-15...
Page 30: Adjust The Front Rails
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. © Copyright 2016 ShopBot Tools, Inc. page 2-16...
Page 31: Section 3. Gantry Installation
Section 3: Gantry Installation • May 2, 2016 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. © Copyright 2016 ShopBot Tools, Inc. page 3-1...
Page 32: Hardware
108” push bar kit Push bar 002012 1/4-20x5/8 002407 1/4” lock washer 000031 Zip tie 003100 Hard stops X mechanical stop 000660 1/4-20x1/2 Hex Cap Screw 001006 1/4-20x3/8 Socket Head Set Screw 001288 © Copyright 2016 ShopBot Tools, Inc. page 3-2...
Page 34: Fine Tune The Rail Level
Place the YZ car on the gantry. Ensure the wheels rest on the hard- ened rail on the front of the gantry. Loosely snug the bottom wheels and nuts so the V groove captures the bottom rail. © Copyright 2016 ShopBot Tools, Inc. page 3-4...
Page 35: Test And Adjust Wheel Tension
Note: Do not over tighten the wheels. This will stress the bearings, creating binding, and reducing component life. Install wheel covers for YZ car and gantry. © Copyright 2016 ShopBot Tools, Inc. page 3-5...
Page 36: Mount The X-Axis Stop Blocks And Proximity Targets
1-2 mm (approximately 1/16”). They should be placed at each end of the back rail (opposite from the control box side). The targets will be centered under the proximity switch when the pinion is butted against the stop block. © Copyright 2016 ShopBot Tools, Inc. page 3-6...
Page 37: Adjust The Y-Axis Stop Blocks And Sensor Targets
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 best performance. © Copyright 2016 ShopBot Tools, Inc. page 3-7...
Page 39: Section 4. Cable Carrier Installation
All tools feature 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”...
Page 40: Hardware
Alternate parts: 12” E-chain trough bracket 003293 5/16-18 T-nuts 002498 X upper E-chain bracket 002156 Parts for Y-Axis carrier Parts for X-Axis carrier 6” Z Parts for X-Axis carrier 12” or 24” Z © Copyright 2016 ShopBot Tools, Inc. page 4-2...
Page 42: Y-Axis Cable Carrier
60 in (78.346 in or 1990 mm) 37.50 in (953 mm) 72 in (90.354 in or 2295 mm) 43.50 in (1105 mm) 108 in (126.456 in or 3212 mm) 61.50 in (1562 mm) © Copyright 2016 ShopBot Tools, Inc. page 4-4...
Page 43: Install Upper Y-Chain Bracket
Drop T-section into gantry slot at desired position. Twist T-section 90 degrees to lock in place. Position cable tie brackets evenly between cable carriers and end plate. © Copyright 2016 ShopBot Tools, Inc. page 4-5...
Page 44: X-Axis Cable Carrier
Section 4: Cable Carrier Installation • May 2, 2016 X-Axis Cable Carrier X-axis cable carriers are included with PRSalpha and PRSstandard tools with table sides 96” and up. Table configurations with 48” and 60” are not shipped with X-axis cable carrier kits.
Page 46: Install The Upper X Cable Carrier Bracket
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 washer, lock washer and nut. © Copyright 2016 ShopBot Tools, Inc. page 4-8...
Page 47: Cable Carrier To Lower X Bracket
(X-axis.) Finishing by tightening the 5/16 button head screws holding the brackets to the table. The lower end plate on the Y-axis can also be adjusted slightly if the Y-axis binds. © Copyright 2016 ShopBot Tools, Inc. page 4-9...
Page 51: Section 5. Control Box Installation
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. © Copyright 2016 ShopBot Tools, Inc. page 5-1...
Page 52: Hardware
T-nut standard 5/16-18 ball and 000728 spring pivot insert Nylock Hex Nut 5/16-18 002264 Nut 1/2-13 Z 000440 Flat Washer 1/2" SAE Z 000442 Lock Washer 1/2" Z 000588 Hex Cap Screw 1/2-13x1 1/2" Z5 000589 © Copyright 2016 ShopBot Tools, Inc. page 5-2...
Page 53 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. © Copyright 2016 ShopBot Tools, Inc. page 5-3...
Page 54: Installation
Lift the control box into place and mount with a button head screw, flat washer, control box flange, through the bracket, flat washer, and a nylock nut for each bracket. © Copyright 2016 ShopBot Tools, Inc. page 5-4...
Page 55: Alternate Mounting For 12" And 24" Z-Axis Models
The second side rail requires a different lower mounting bracket. This bracket will be installed over the lower cross sup- port with the control box mounting tab pointing down. © Copyright 2016 ShopBot Tools, Inc. page 5-5...
Page 57: Introduction
ATCCombinedManual.pdf VFD Installation ShopBot Tools with spindles use a VFD to regulate input power and control rotation speed. There are two major body sizes, 10” and 16”, which are used depending on specific voltage and phases require- ments. The supplied bracket will work for each size.
Page 58: Hardware
An example model number is shown below. The model number is CIMR–VU2A0040GAA. The first bold and underlined number in the written example is the voltage. 2 = 200-240 Vac, 3-phase 4 = 380-480 Vac, 3-phase © Copyright 2016 ShopBot Tools, Inc. page 6-2...
Page 59: Mounting The 10" Vfd
Section 6: Spindle and VFD Installation • May 2, 2016 Mounting the 10” VFD The 10” VFD mounts to the top and middle set of holes in the middle leg of the ShopBot gantry tools with the VFD 1000 mounting kit.
Page 60: Mounting The 16" Vfd
Use a 1/4-20x3/4 flat head screw in the middle hole of the VFD mount- ing strap and the upper left hole on the 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.
Page 61: Spindle Installation
HSD 4HP 380/460V 3PH 12574 HSD 4HP 380/460V 3PH 12575 Standard PO957 HSD 9HP 230V 3PH 12619 HSD 9HP 380/460V 3PH 12621 HSD 4HP 220V 1PH 12562 5/16”-18 x 1-1/2” Socket Cap Screw 001326 © Copyright 2016 ShopBot Tools, Inc. page 6-5...
Page 62: Lower The Z-Axis Extrusion
Removing the four countersunk screws allows the plate to be rotated 180 degrees. Mounting plate in this orientation shifts the spindle up 1.5” (38mm) in relation to the Z-axis. This allows clearance of taller work stock at the expense of maximum cut depth. © Copyright 2016 ShopBot Tools, Inc. page 6-6...
Page 63: Attach Spindle
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. © Copyright 2016 ShopBot Tools, Inc. page 6-7...
Page 64: Section 6 Appendix: Table Leg Drawings
Section 6: Spindle and VFD Installation • May 2, 2016 Section 6 Appendix: Table Leg Drawings 6” Table Leg © Copyright 2016 ShopBot Tools, Inc. page 6-8...
Page 65: 12" Table Leg
Section 6: Spindle and VFD Installation • May 2, 2016 Section 6 Appendix: Table Leg Drawings (cont’d) 12” Table Leg Top mounting hole Middle mounting hole Bottom mounting hole © Copyright 2016 ShopBot Tools, Inc. page 6-9...
Page 67: Section 7. Mounting X- And Y-Axis Motors
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. © Copyright 2016 ShopBot Tools, Inc. page 7-1...
Page 69: Identify Motors
Ensure that the pinion gear set screws are really tight against the shaft Apply a small amount of Lithium grease to each pinion. This will ensure smooth movement and pre- vent corrosion. © Copyright 2016 ShopBot Tools, Inc. page 7-3...
Page 70: Mounting Locations
3/16” hex key. After all hardware is installed, snug all hardware. Note: Do not engage the pinion teeth with the rack. This will be done in Section 11. © Copyright 2016 ShopBot Tools, Inc. page 7-4...
Page 71: Section 8. Wire And Cable Routing
Route other cables into X cable carrier (X motor cables, X prox switch, and emergency stop). • Secure cables between cable carriers with zip ties. • Organize and relieve tension on cables in X cable carrier and secure with zip ties. • Route cables under table. © Copyright 2016 ShopBot Tools, Inc. page 8-1...
Page 72: Spindle Fan Cable Installation
Note: The tape at the far end of the cable may be loose. If so, secure it with scotch tape or similar to prevent it from falling off during cable routing. Y Proximity Switch Locate 8mm threaded hole to the left of the spindle/router © Copyright 2016 ShopBot Tools, Inc. page 8-2...
Page 73: Z Zero Plate Assembly
Note: The white plastic hooked piece indicated by the arrow is known as a Wago tool. It’s used as a fulcrum to release wires from Wago connector terminals. Store it in a safe place. © Copyright 2016 ShopBot Tools, Inc. page 8-3...
Page 74: Route Wiring
There are pre-threaded holes available on both gantry endplates. The auxiliary emergency stop switch can be mounted on either location. The example shown will be mounted on the control box side gantry plate. © Copyright 2016 ShopBot Tools, Inc. page 8-4...
Page 75: Route Wiring (Cont'd)
The screws come through the back of the endplate. Note: Pressing the emergency stop button will cause input #4 to flash red on the computer screen and the ShopBot control software will not allow the ShopBot to move. Route Wiring (cont’d) Run X2 motor cable along inside lip of gantry and secure with zip ties.
Page 76: Route Wiring (Cont'd)
To install an air drill, refer to PRS alpha Air Drill manual located at http://www.shopbottools.com/Shop- BotDocs/files/PRSalphaAirDrillDV.pdf. To install an ATC, refer to ATC Installation manual located at http://www.shopbottools.com/ShopBot- Docs/files/ATCCombinedManual.pdf. To install a pneumatic assist, refer to Installing a Z-axis pneumatic assist manual located at http:// www.shopbottools.com/ShopBotDocs/files/PneumaticAssistInstall.pdf.
Page 77: Route Spindle Cable
X Cable Carrier: All of the above, plus _____ X1 motor cable (routed above the upper X cable carrier bracket) _____ X-axis proximity switch _____ Pneumatic air hoses (for ATC tools and optional air drills or pneumatic assists) © Copyright 2016 ShopBot Tools, Inc. page 8-7...
Page 79: Introduction
Section 9. Control Box Wiring Introduction ShopBot highly recommends that a licensed electrician hook up the source 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...
Page 81: Section 10. Software Installation
ShopBot tools are shipped with three software programs that can program, edit, and run part files. This section covers the installation of all software and provides a basic overview of the ShopBot con- trol software. Additional information and training can be found in the control software “Help” menu as well as ShopBottools.com and Vectric.com.
Page 82: Computer Recommendations
Refer to “Installing ShopBot Applications” section in “Uninstalling and Reinstalling ShopBot and VCarve Software” document found at http://www.shopbottools.com/ShopBotDocs/files/SBG%20 00441%20Uninstalling%20and%20Reinstalling%20ShopBot%20and%20VCarve%20Software.pdf. Software Overview All programs included with the ShopBot are now installed. The icons below represent how they will appear on the computer desktop. © Copyright 2016 ShopBot Tools, Inc. page 10-2...
Page 83: Engage Pinions With Rack
Load the Settings File ShopBot control software is designed to work with all ShopBot models, each with different table di- mensions, gear ratios, and other parameters. These settings are saved in an initiation (.INI extension) file that runs each time the software is started. The first time the software is connected to a tool, you’ll be prompted to set the default .INI settings file.
Page 84: Install Control Box Firmware
Section 10: PRS Alpha Control Box Wiring • May 2, 2016 Locate the ShopBot 3 icon on the desktop or Windows Start menu. Double click on the icon to launch the control software. When the program is opened for the first time, a prompt will appear to load a settings file.
Page 85 Section 10: PRS Alpha Control Box Wiring • May 2, 2016 In ShopBot 3, select “Utilities,” then “Install Control Box Firm- ware.” Follow 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.
Page 86: Shopbot Control Software Familiarization
Section 10: PRS Alpha Control Box Wiring • May 2, 2016 ShopBot Control Software Familiarization Easy and Full Modes ShopBot 3 software has two user interface formats; “Easy” and “Full” modes. Easy mode is the default, and works well to run parts after all set up has taken place.
Page 87: Shopbot Command Format
Detailed information and a full list of available commands are available in the ShopBot User Guide. In the ShopBot control software, commands are used to give specific directions to the machine. Any command that directs the machine to move must be followed by parameters. For example, an MX,20 command will “Move”...
Page 88: Set Stop Block Positions
Center Z plate between Z rail and the YZ plate flange. Position brackets 1” down from top of YZ plate. Remove backing tape from VHB tape and press the brackets onto the YZ plate. © Copyright 2016 ShopBot Tools, Inc. page 10-8...
Page 89: Secure Cables
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 underneath, along crossmember, with zip ties. © Copyright 2016 ShopBot Tools, Inc. page 10-9...
Page 91: Section 11. Secure Table And Spoil Board
Section 11: Secure Table and Spoil Board • May 2, 2016 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...
Page 92: Spoilboard
Have someone help set the MDF sheet(s) onto the base. Place the spoil board on top of baseboard with 1/4” of overlap on all sides. Place clamps and heavy objects onto spil board to help glue cure. © Copyright 2016 ShopBot Tools, Inc. page 11-2...
Page 93: Section 12. Setup And Fine Tuning
Input 1 – The Z zero plate and the fixed Z zero are connected on this input. When either of these plates are connected to a ground, the circuit is closed and input “1” on the ShopBot position screen will light up. The ShopBot ATC requires that the grounding clip be used during any zeroing of Z-axis.
Page 94: Machine Orientation
Tools can also be equipped with a rotational indexer. This allows the tool to be used as a CNC lathe or perform machining operations on more than one side of a part. The B-axis is assigned to the rotational axis and is measured in degrees. © Copyright 2016 ShopBot Tools, Inc. page 12-2...
Page 95: Setting Up Rpm Control
Important: The Spindle Control window must remain open during operation for the software to com- municate with the VFD and change RPM. Connect the RPM controller to the computer. Do not plug it into the hub alongside the main Shopbot USB; it should go straight into an empty port on your computer.
Page 96: System Check
Move the X-axis off the proximity target using the right arrow key. Note: If the axis is not moved off the proximity target, the other proximity switches will be disabled and the next step will not perform properly. © Copyright 2016 ShopBot Tools, Inc. page 12-4...
Page 97: Check Movement Distance
1/4” (5mm) before the movement axis reaches its hard stop. When the software receives this input it will stop the tool so that position is not lost. © Copyright 2016 ShopBot Tools, Inc. page 12-5...
Page 98: Shopbot Setup
Move the corner of the plywood base board at this point and then square it with the table sides. This is the proper position for the spoil board and will allow maximum tool coverage. © Copyright 2016 ShopBot Tools, Inc. page 12-6...
Page 99: Fine Tune Setup
Move machine to 0,0 location. Verify jog by typing JX, 24 or JY, 24. Again, the tool should move 24 inches (or 1000 mm) along the particular axis. If it doesn’t, go back to software setup and chose the correct default setting. © Copyright 2016 ShopBot Tools, Inc. page 12-7...
Page 100: Install Push Bars
Pop end caps into place at ends of side rails. The Gantry Tool Assembly is complete. For usage information, see the ShopBot Quick Start Guide, which was provided with tool delivery, and can be found at www.shopbottools.com/ShopBotDocs/gantry ShopBot Quick Start Guide.

This manual is also suitable for:

Prsstandard

ShopBot PRSalpha Assembly Manual

Quick Links

Need help?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for ShopBot PRSalpha

Summary of Contents for ShopBot PRSalpha

This manual is also suitable for:

Table of Contents