ShopBot PRSalpha User manual

© Copyright 2016 ShopBot Tools, Inc. page 1
ShopBotTools.com888-680-4466 •
Assembly Guide
For PRSalpha and PRSstandard Tools

Assembly Guide for PRS Alpha and Standard Tools • May 2, 2016
© Copyright 2016 ShopBot Tools, Inc. page 2

Assembly Guide for PRS Alpha and Standard Tools • May 2, 2016
© Copyright 2016 ShopBot Tools, Inc. page 3
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................................................................................................................... 1-2
Terms to Know............................................................................................................................ 1-3
Major Components..................................................................................................................... 1-3
Section 2. Table Assembly .................................................................................................................. 2-1
Introduction ................................................................................................................................ 2-1
Hardware .................................................................................................................................... 2-2
Marking the Rails........................................................................................................................ 2-3
Mount Table Levelers to Legs..................................................................................................... 2-4
Install Table Legs ........................................................................................................................ 2-4
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 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 Installation .............................................................................................................. 3-1
Introduction ................................................................................................................................ 3-1
Hardware .................................................................................................................................... 3-2
Install Gantry............................................................................................................................... 3-3
Adjust the Rails........................................................................................................................... 3-3
Fine Tune the Rail Level.............................................................................................................. 3-4
Install the YZ Car ........................................................................................................................ 3-4
Test and Adjust Wheel Tension................................................................................................... 3-5
Mount the X-Axis Stop Blocks and Proximity Targets................................................................ 3-6
Adjust the Y-Axis Stop Blocks and Sensor Targets.................................................................... 3-7
Section 4. Cable Carrier Installation.................................................................................................... 4-1
Introduction ................................................................................................................................ 4-1
Hardware .................................................................................................................................... 4-2
Prepare the Cable Carriers ......................................................................................................... 4-3
Reversing the End Links............................................................................................................. 4-3

Assembly Guide for PRS Alpha and Standard Tools • May 2, 2016
© Copyright 2016 ShopBot Tools, Inc. page 4
Table of Contents (cont’d)
Y-Axis Cable Carrier ................................................................................................................... 4-4
Mount the Lower Y Bracket........................................................................................................ 4-4
Install Upper Y-Chain Bracket .................................................................................................... 4-5
Mount Cable Carrier to Lower Y Bracket ................................................................................... 4-5
Mount Cable Carrier to Upper Y Bracket ................................................................................... 4-5
X-Axis Cable Carrier ................................................................................................................... 4-6
Install Trough Brackets for ShopBots with 6” Z’s....................................................................... 4-6
Install the X-Axis Trough: 6” Z-Axis ............................................................................................ 4-7
Machines with 12” and 24” Z-Axis ............................................................................................. 4-7
Install the Upper X Cable Carrier Bracket .................................................................................. 4-8
Cable Carrier to Upper X Bracket............................................................................................... 4-8
Cable Carrier to Lower X Bracket............................................................................................... 4-9
Test Cable Carrier Mobility on Both Axes................................................................................... 4-9
X-Axis Cable Carrier Congurations......................................................................................... 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
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- and Y-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
Check Pinion/Rack Alignment.................................................................................................... 7-3
Adjust Pinions (If Required) ........................................................................................................ 7-3
Mounting Locations.................................................................................................................... 7-4

Assembly Guide for PRS Alpha and Standard Tools • May 2, 2016
© Copyright 2016 ShopBot Tools, Inc. page 5
Table of Contents (cont’d)
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
Y Proximity Switch ..................................................................................................................... 8-2
Z Zero Plate Assembly ............................................................................................................... 8-3
Route Wiring............................................................................................................................... 8-4
Mount Auxiliary Emergency Stop Switch ................................................................................... 8-4
Route Wiring (cont’d).................................................................................................................. 8-5
X Proximity Switch...................................................................................................................... 8-5
Route Wiring (cont’d).................................................................................................................. 8-6
Pneumatic Air Hoses .................................................................................................................. 8-6
Route Spindle Cable................................................................................................................... 8-7
Cable 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 Conguration........................................................................................................... 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................................................................................................ 10-3
Load the Settings File............................................................................................................... 10-4
Install Control Box Firmware .................................................................................................... 10-4
ShopBot Control Software Familiarization ............................................................................... 10-6
Easy and Full Modes .......................................................................................................... 10-6
Full Display Overview ......................................................................................................... 10-6
ShopBot Command Format ............................................................................................... 10-7
Movement Testing .................................................................................................................... 10-7
X Proximity Switch.................................................................................................................... 10-7
Set Stop Block Positions.......................................................................................................... 10-8
Check Y-Axis Proximity Switches............................................................................................. 10-8
Mount Z Zero Plate Assembly .................................................................................................. 10-8

Assembly Guide for PRS Alpha and Standard Tools • May 2, 2016
© Copyright 2016 ShopBot Tools, Inc. page 6
Table of Contents (cont’d)
Secure Cables .......................................................................................................................... 10-9
Section 11. Secure Table and Spoil Board........................................................................................ 11-1
Introduction .............................................................................................................................. 11-1
Hardware .................................................................................................................................. 11-1
Base Layer................................................................................................................................ 11-1
Spoilboard ................................................................................................................................ 11-2
Section 12. Setup and Fine Tuning ................................................................................................... 12-1
Check Inputs and Outputs ....................................................................................................... 12-1
Machine Orientation ................................................................................................................. 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
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

Assembly Guide for PRS Alpha and Standard Tools • May 2, 2016
© Copyright 2016 ShopBot Tools, Inc. page 7
General Safety and Precautions
This safety summary contains general safety warnings that should be understood during operation of
this machine. Failure to observe 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 • May 2, 2016
© Copyright 2016 ShopBot Tools, Inc. page 8
PRS Tool Assembly Process Flow
Setup and Assembly
Overview (Section 1)
Table 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)

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

Assembly Guide for PRS Alpha and Standard Tools • May 2, 2016
© Copyright 2016 ShopBot Tools, Inc. page 10

Section 1: Setup and Assembly Overview • May 2, 2016
© Copyright 2016 ShopBot Tools, Inc. page 1-1
Section 1. Setup and Assembly Overview
Electrical Precautions
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 nal position. If machine 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 door of the control box.
Other Electrical precautions:
Motor connections: DO NOT connect or disconnect motor cables while power to the control box is
on. This can damage or destroy the motors or drivers.
Induced currents: AVOID moving any axis by hand when 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
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 needs to be connected to electrical service by a licensed electri-
cian 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.

Section 1: Setup and Assembly Overview • May 2, 2016
© Copyright 2016 ShopBot Tools, Inc. page 1-2
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.
The components are packaged to avoid shifting during shipping. Use a large screwdriver to pry off the
clips on top on the crate, 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.
Many components of the machine come pre-assembled to reduce the number of assembly steps. In
many places, bolts or hardware may be loosely t in place to show their intended location. Remove
this hardware prior to tting the applicable component into place.

Section 1: Setup and Assembly Overview • May 2, 2016
© Copyright 2016 ShopBot Tools, Inc. page 1-3
Terms to Know
This is only a quick overview to get started. For each assembly section, there will be a visual guide
with all parts and hardware clearly labeled.
Major Components:
The base of the machine is referred to as the table
frame.
The two long aluminum extrusions on each side
are called table sides. Atop the sides 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 tted with V rails (for wheel
bearings) and gear rack. This forms the path of
travel for the Y-axis.
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).

Section 1: Setup and Assembly Overview • May 2, 2016
© Copyright 2016 ShopBot Tools, Inc. page 1-4
The control box is the “brain” of the machine and contains a control board, motor drivers, and other
electronic components that allow the tool to move with precision, accuracy, and power. It connects to
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 to the machine. Another frequent-
ly-used term is the XY home position, as indicated here.

Section 2: Table Assembly • May 2, 2016
© Copyright 2016 ShopBot Tools, Inc. page 2-1
Section 2. Table Assembly
Introduction
The ShopBot table provides a rm foundation for all other components. This section contains instruc-
tions to assemble, square, and level the table.
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. The table drawings provided will
detail the specic 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 nal location. Moving
the table after these steps may alter the level and square.
Note: This section shows a conventional table with a 6” Z-axis. Tables congured for 12” and 24” axes
have extra table side extrusions and table legs with added mounting holes.

Section 2: Table Assembly • May 2, 2016
© Copyright 2016 ShopBot Tools, Inc. page 2-2
Hardware
Part Name Quantity ShopBot P/N Notes
Table side 2 000925
Rail 2 001872
Lower table support 3 000921 Different for other lengths
Table gusset 6 000770 Different for other lengths
Upper table support 4 000915 Different for other lengths
Table leg 6 000919 Different for other lengths
Table cross support 48E 2 000926 Different for other lengths
Except for the table levelers, all of this hardware is 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 washer Varies 004487 Used for cross supports, leg
5/16” Flat washer Varies 000848 Cross supports, leg, control box
5/16-18 T-nut Varies 002498 Used for control box
5/16-18x3/4 Button head
cap screw Varies 002033 Used for control box
5/16-18x3/8 T-nut Varies 001569 Used for cross supports, leg

Section 2: Table Assembly • May 2, 2016
© Copyright 2016 ShopBot Tools, Inc. page 2-3
Part Name Quantity ShopBot P/N Notes
5/8-11 Hex nut Varies 000160 1 per table leg
Table leveller w/Nut Varies 002926/000862 1 per table leg
3/8-16x1 1/2 Carriage bolt Varies 000953 Used to secure base board
3/8” Lock washer Varies 000092 Used to secure base board
3/8” Flat washer Varies 000444 Used to secure base board
3/8-16 Hex nut Varies 000452 Used to secure base board
* Specic 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 oor side by side. Locate where the Home Posi-
tion (X =0) will be.
Locate the machine specic table drawing at the back of this assembly manual. This drawing provides
dimensions for the placement of the table legs and cross supports in relation to the end of the side
rails.
Note for international customers: The location of the table legs and cross supports along the X-rails
can be adjusted slightly to reect metric units.

Section 2: Table Assembly • May 2, 2016
© Copyright 2016 ShopBot Tools, Inc. page 2-4
Measuring from the X=0 location, use
a permanent marker to mark the inside
of the rails where each table leg and
cross support will attach to allow for
easy orientation.
Note: This image indicates the rail
marking locations for a 96” long tool.
The marks will differ for other table
congurations.
Move rails into approximate location,
orientation, and space 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 table leg into the T-slots in the
pattern shown. 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.

Section 2: Table Assembly • May 2, 2016
© Copyright 2016 ShopBot Tools, Inc. page 2-5
When the T-nuts are in place, position the table legs.
Support the legs so they stay ush during installation.
Secure the legs with 5/16” hex bolts, Schnorr washers,
and at washers.
Note: The Schnorr washers are to be located with
curve towards the bolt head. They can make threading
the bolts into the T-nuts difcult. 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-tighten the top and bottom bolts
when the leg is square. Do not tighten other bolts at this
time.

Section 2: Table Assembly • May 2, 2016
© Copyright 2016 ShopBot Tools, Inc. page 2-6
Install and square the remainder of the legs,
working from one side of the rail to the other.
Table Sides for 12” and 24” Z-Axis Configurations
Tables congured for 12” and 24” axes have
extra table side extrusions and table legs with
added mounting holes.
Assembly of these table congurations 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 again or close the keypad window.