ShopBot PRSalpha User manual

ShopBotTools.com888-680-4466 •

Assembly Guide

For PRSalpha and PRSstandard Tools

For all PRS tools shipped after 6/15/2017

Assembly Guide for PRS Alpha and Standard Tools • October 5, 2017

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

Other Electrical Precautions....................................................................................................... 1-1

Safety.......................................................................................................................................... 1-1

Unpacking the Crate................................................................................................................... 1-2

Major Components..................................................................................................................... 1-3

Section 2. Table Assembly .................................................................................................................. 2-1

Introduction ................................................................................................................................ 2-1

Tools Required............................................................................................................................ 2-3

Marking the Rails........................................................................................................................ 2-4

Mount Table Levelers to Legs..................................................................................................... 2-4

Install Table Legs ........................................................................................................................ 2-5

Table Sides for 12” and 24” Z-Axis Congurations.................................................................... 2-6

Stabilize with Lower Table Supports .......................................................................................... 2-7

Connect Side Assemblies .......................................................................................................... 2-7

Install Middle Lower Table Support ............................................................................................ 2-8

Insert T-Nuts in Bottom Slot ....................................................................................................... 2-8

Mount Table Supports and Gussets to Table Legs .................................................................... 2-9

Secure Table Supports and Cross Supports to Table Sides .................................................... 2-10

Install Cross Supports .............................................................................................................. 2-11

Level and Square Table ............................................................................................................ 2-12

Level the Table Sides................................................................................................................ 2-12

Square the Table Sides............................................................................................................. 2-13

Install Rails................................................................................................................................ 2-14

Adjust Front Rail ....................................................................................................................... 2-15

Section 3. Gantry Installation .............................................................................................................. 3-1

Introduction ................................................................................................................................ 3-1

Install Gantry............................................................................................................................... 3-2

Adjust the Rails........................................................................................................................... 3-3

Mount the X-Axis Stop Blocks and Proximity Targets................................................................ 3-3

Section 4. Cable Carrier Installation.................................................................................................... 4-1

Introduction ................................................................................................................................ 4-1

Hardware .................................................................................................................................... 4-2

Prepare the Cable Carrier........................................................................................................... 4-3

Reversing the End Links............................................................................................................. 4-3

X-Axis Cable Carrier ................................................................................................................... 4-4

Install Trough Brackets for ShopBots with 6” Z’s....................................................................... 4-4

Install the X-Axis Trough: 6” Z-Axis............................................................................................ 4-5

Machines with 12” and 24” Z-Axis ............................................................................................. 4-5

Install the Upper X Cable Carrier Bracket .................................................................................. 4-6

Cable Carrier to Upper X Bracket............................................................................................... 4-6

Assembly Guide for PRS Alpha and Standard Tools • October 5, 2017

Table of Contents (cont’d)

Cable Carrier to Lower X Bracket............................................................................................... 4-6

Test Cable Carrier Mobility on Both Axes................................................................................... 4-7

X-Axis Cable Carrier Congurations........................................................................................... 4-8

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

Lower the Z-Axis Extrusion ........................................................................................................ 6-6

Spindle Mounting Plate .............................................................................................................. 6-6

Attach Spindle ............................................................................................................................ 6-7

Replace Stop Screw................................................................................................................... 6-7

Section 6 Appendix: Table Leg Drawings................................................................................... 6-8

6” Table Leg....................................................................................................................... 6-8

12” Table Leg..................................................................................................................... 6-9

Section 7. Mounting X-Axis Motors .................................................................................................... 7-1

Introduction ................................................................................................................................ 7-1

Hardware .................................................................................................................................... 7-2

Motors ........................................................................................................................................ 7-2

Mount Pinions to Motors ............................................................................................................ 7-2

Identify Motors............................................................................................................................ 7-3

Check Alignment of Pinions with Rack ...................................................................................... 7-3

Adjust Pinions (If Required) ........................................................................................................ 7-3

Mounting Locations.................................................................................................................... 7-4

Position Motors on Tool.............................................................................................................. 7-4

Section 8. Wire and Cable Routing ..................................................................................................... 8-1

Hardware .................................................................................................................................... 8-1

Cable Routing Strategy .............................................................................................................. 8-1

Spindle Power Cable ............................................................................................................ 8-1

Motors and Signal Cables .................................................................................................... 8-1

Spindle Fan Cable Installation.................................................................................................... 8-2

Proximity Switch Installation ...................................................................................................... 8-2

X Proximity Switch...................................................................................................................... 8-2

Route Wiring............................................................................................................................... 8-3

Pneumatic Air Hoses .................................................................................................................. 8-4

Assembly Guide for PRS Alpha and Standard Tools • October 5, 2017

General Safety and Precautions

This safety summary contains general safety warnings that should be understood during operation of

this machine. Refer also to General Power Tool Safety Warnings found in User Guide. Failure to ob-

serve these precautions could result in injury.

Learn and understand safe use of the machine. Do not allow untrained individuals

to operate the machine without supervision. Be aware of the location of the Emer-

gency Stop switches at all times.

Eye and ear protection MUST be worn by the machine operator as well as any

bystanders or observers. Flying sawdust, material chips, and other debris can

cause serious eye injury.

Wear closed-toe shoes at all times.

Make sure that your material is properly secured before 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 gloves while operating the machine. As with any power tool, a glove

can get caught in moving or spinning parts and pull your hand into the machinery.

Never leave a machine running and unattended. Understand that a spinning tool

generates friction and heat, creating a risk of re. This risk is minimized by using

correct chip load, using sharp bits, and by always double-checking your les

before cutting. Be prepared to pause or stop the cut if something seems incorrect

or unsafe.

Keep a working re extinguisher within reach of the machine, for the reasons

listed above.

Assembly Guide for PRS Alpha and Standard Tools • October 5, 2017

PRS Tool Assembly Process Flow

Assembly Guide for PRS Alpha and Standard Tools • October 5, 2017

Main Parts of PRSalpha

YZ Car

Spindle

Gantry

Spoil Board

Table Side (Rail)

Control Box

VFD

Frame

E-chain

PRS Tool Assembly Process Flow

Main Parts of PRSalpha

YZ Car

Spindle

Gantry

Spoil Board

Table Side (Rail)

Control Box

VFD

Frame

E-chain

Section 1: Setup and Assembly Overview • October 5, 2017

Section 1. Setup and Assembly Overview

Electrical Precautions

A licensed electrician is required to complete the ShopBot setup. Connecting power to the control box

is easiest when the tool is set up and in its nal position. If the tool includes a high frequency spindle

and/or a vacuum blower, these will also need to be connected by an electrician. Wiring diagrams and

specications are located inside the control box door.

Other Electrical precautions:

Motor Connections: DO NOT connect or disconnect motor cables while power is on to the control

box. This can damage or destroy the motors or drivers.

Induced Currents: AVOID moving axes by hand when the control box is powered off. If it is unavoid-

able, do so very slowly. Spinning the motors can generate an electric charge and damage drivers or

other electronic components.

Static Discharge: Follow all wiring and grounding instructions - electronic circuits are very sensitive

to static and power surges. Avoid vacuuming around the machine before it is properly grounded, as

vacuums can generate a large amount of static electricity that can damage the control box.

Safety

WARNING: RISK OF ELECTRIC SHOCK

The control box must be connected to electrical service by a licensed electrician,

who has experience with industrial equipment. Personal injury or damage to the

machine may occur if an unlicensed individual performs this job.

Use caution when lifting boxes and assem-

bled components out of the crate. Having an

assistant will make things much easier – partic-

ularly when unpacking the crate and lifting the

gantry onto the table rails. Do not attempt to lift

the gantry without assistance.

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