ShopBot PRSalpha User manual

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Quick-Start Guide for PRSalpha and PRSstandard tools
Introducon:
This document is intended to help you get started with your new Shop-
Bot. For more detailed informaon on any of these topics, please refer-
ence the ShopBot User’s Guide (www.shopboools.com/ShopBotDocs/
gantry.htm). See also the list of resources on the back page for more in-
formaon.
PRS Quick-Start Guide
(for PRS and Buddy tools)
Date: 11/16/2015
Revision: 11/16/2015
Owner: M. Cummings

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Quick-Start Guide for PRSalpha and PRSstandard tools
ShopBot Tools, Inc.
3333-B Industrial Drive
Durham, NC 27704
ShopBotTools.com
Technical Support
support@shopboools.com
[phone]
EC # Change Descripon Authority Date
Release to new format, incorporang all documents
updates through 7/23/15
M. Cummings 09/23/15
Updated document locaon, main parts picture, pro-
cess ow chart, TOC pages, removed acronyms page
M. Cummings 11/16/15
Revision History:

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Quick-Start Guide for PRSalpha and PRSstandard tools
Table of Contents
General Safety and Precauons....................................................................................................... 5
PRS Quick-Start Process Flow .......................................................................................................... 6
Main Parts of ShopBot PRS .............................................................................................................. 7
Secon 1. Soware Setup and Orientaon ..................................................................................... 8
Load Soware and Drivers.......................................................................................................... 8
Installing ShopBot Applicaons .................................................................................................. 8
Installing VCarve Applicaon ...................................................................................................... 8
Connect ShopBot to Computer................................................................................................... 9
Load Sengs File......................................................................................................................... 9
ShopBot Control Soware ........................................................................................................ 10
Axis Orientaon ........................................................................................................................ 11
Test Each Axis with Keypad....................................................................................................... 12
Test the Spindle/Router............................................................................................................ 13
Secon 2: Running a Part File ........................................................................................................ 14
Zeroing the Z Axis...................................................................................................................... 14
Z Axis Zeroing Process............................................................................................................... 14
Zeroing the XY Axes................................................................................................................... 15
Changing Bits............................................................................................................................. 15
Seng Up RPM Control ............................................................................................................ 16
Holding Down Material ............................................................................................................. 16
Screws .................................................................................................................................. 16
T-Track Tables and Rails ....................................................................................................... 17
Clamps.................................................................................................................................. 17
Press-Fit Jigs ......................................................................................................................... 17
Adhesive............................................................................................................................... 17
Vacuum Hold-Down Systems............................................................................................... 18
Holding Parts Within Material ............................................................................................. 18
Tabs ................................................................................................................................. 18
Onion Skin ....................................................................................................................... 19
Warming Up Spindle ............................................................................................................ 19
Previewing the File with Oset............................................................................................ 19

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Running the Cut ................................................................................................................... 20
Pausing or Stopping the Cut................................................................................................. 20
Soware Controlled Stop ................................................................................................ 20
Emergency Stop............................................................................................................... 21
Secon 3: Technical Basics............................................................................................................. 22
Bits............................................................................................................................................. 22
Calculang Feed Rates and RPMs with Chip Load .................................................................... 23
Switch from Inches to Millimeters............................................................................................ 24
Machine Maintenance................................................................................................................... 25
Resources....................................................................................................................................... 26
Table of Contents (cont’d)

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Quick-Start Guide for PRSalpha and PRSstandard tools
This safety summary contains general safety warnings that should be understood during operaon of
this machine. Failure to observe these precauons 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 locaon of the Emergency Stop switches at
all mes.
Eye and ear protecon 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 mes.
Make sure that your material is properly secured before cung, and be aware of any small
parts that may come loose aer being cut. If a small part catches the edge of a spinning bit, it
can be thrown forcefully in any direcon, causing injury or damage.
Never place your hands on the rails of the ShopBot. Be aware that the machine may move
unexpectedly in any direcon, which can cause serious injury if your hands are in the path of
movement.
Never wear gloves while operang 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 unaended. Understand that a spinning tool generates
fricon and heat, creang a risk of re. This risk is minimized by using correct chip load (please
see page 12), using sharp bits, and by always double-checking your les before cung. Be pre-
pared to pause or stop the cut if something seems incorrect or unsafe.
Keep a working re exnguisher within reach of the machine, for the reasons listed above.
General Safety and Precauons:

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Quick-Start Guide for PRSalpha and PRSstandard tools
PRS Quick-Start Process Flow
Load Soware
and Drivers (p. 8)
Connect ShopBot to
Computer (p. 9)
Load Sengs File
(p. 9)
Test Router/
Spindle (p. 13)
Set RPM Control
(p. 16)
Zero Z Axis (p. 14) Zero X and Y Axes
(p. 15)
Run the Cut (p. 20)
Warm Up the
Spindle (p. 19)

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Quick-Start Guide for PRSalpha and PRSstandard tools
Main Parts of ShopBot PRS
Main Parts of ShopBot Buddy

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Quick-Start Guide for PRSalpha and PRSstandard tools
This secon contains the installaon of soware and seng up the machine. It also explains funda-
mentals of the control soware; including basic commands, axis orientaon, and various components
(motors, spindle, etc.) outside of a part le.
Load soware and drivers
NOTE: Do not connect the ShopBot to your computer before installing the soware and drivers!
Special note for schools and large companies: ShopBot soware runs best with full administrave
permissions enabled. We strongly advise against seng up separate admin and user accounts on the
control computer.
For Internaonal customers: The computer used to run the machine MUST have the language set to
“United States (English)” in order for the soware to run correctly.
Installing ShopBot applicaons
1. Insert USB drive into USB port in computer.
2. Double-click on folder to view les.
3. Double-click on the folder called “1 Install Controller”. Double-click on “setup_sb3_8_32” and fol-
low the prompts for the setup wizard. Click “Finished” when completed.
Installing VCarve Pro applicaon
Double-click on the folder called “2 Install Design”. Double-click on “VcarveProShopBotEdion” and
follow the prompts for the setup wizard. Click “Finished” when completed.
Secon 1. Soware Setup and Orientaon

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Quick-Start Guide for PRSalpha and PRSstandard tools
When installaon is complete, three new icons appear on the screen: ShopBot 3, ShopBot Editor, and
VCarve Pro ShopBot Edion.
Connect ShopBot to computer
Connect USB cable from ShopBot control box to computer. Connect the RPM controller USB from vari-
able frequency drive (VFD) unit into another USB port on the computer.
Load sengs le
When prompted to load a default sengs le for the rst me, the following screen should appear:

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Quick-Start Guide for PRSalpha and PRSstandard tools
Double-click on “PRS ShopBots”, and choose “Standard”, “Alpha”, or “Desktop”, depending on your
model. Choose the correct table size for your machine, and this will bring you back to the main screen.
Note: Custom tools will not have a default seng preprogrammed in the soware. Chose the correct
type (Alpha or Standard), and the size closest to your tool. Edit the table limits for your table size using
“Values” and “Limits for table”. Save the new seng as a custom sengs le in the “Ulies” menu.
ShopBot control soware
The ShopBot control soware works in two modes: “Easy mode” (by default) shows only the necessary
funcons to set up and run a cut le. “Full mode” shows all available funcons and sengs. Switch be-
tween the two modes by clicking on the Help/opons buon in the red posion window.

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Quick-Start Guide for PRSalpha and PRSstandard tools
Axis orientaon
It is essenal to understand how the X, Y, and Z axes are oriented, and how this relates to job setup in
the CAD/CAM soware. Shown below is an example of a job in VCarve Pro and its corresponding orien-
taon on each machine model.
The boom le corner is referred to as the XY home locaon or “zero, zero” (See Secon 3 for more
informaon).

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Test each axis with the keypad
Turn ON the control box. Click on the yellow keypad window icon within the red posion window. If
the icon is not visible, click “move/cut” under “Mode” on the red posion window.
Use the buons on the keyboard (see below) to move the spindle/router along each axis.

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Test the spindle/router
Locate the key aached to the collet wrench. Insert this key into the safety lockout next to the power
switch and turn the key to “ENGAGE”.
Note: Older Desktop tools do not have an interlock switch. Instead, they have an on/o switch on
the underside of the VFD unit. It is illuminated red when o and green when on.
Routers: Make sure that the router’s power switch is in the ON posion before proceeding.
In the main console window, type “K” to bring up the keypad move command. Noce that output 4
lights up in the red posion window. Click output 1 to turn the output on. This will create a prompt to
start the router/spindle.
For PRSstandard models, press “OK” to start the router/spindle.
For PRSalpha models, aer toggling output 1, press the green “START” buon on the three buon
pendant.
To turn the spindle o, click the output 1 switch again or close the keypad window.
All models: turn on output 1 through keypad Alpha models only: press the start buon

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Quick-Start Guide for PRSalpha and PRSstandard tools
Secon 2. Running a Part File
This secon covers setup procedures performed prior to previewing or running the part le.
Zeroing the Z axis
The Z axis must be zeroed each me that the machine is turned on or bits are changed. Zeroing can
be done to either the top of the material or to the table surface.
Zeroing to the top of the material is a beer choice when a
precise cut depth is needed (when cung an inlay pocket, for
example).
Zeroing to the table surface is a beer choice when through-
cung parts in wood. Because wood products naturally vary in
thickness, the top surface of any given area may be higher or
lower than other areas. Zeroing to the table surface will pro-
vide the most consistent through-cung results.
Whichever locaon is chosen, the locaon must be idened
in the CAD/CAM program (as shown here for VCarve Pro). Fail-
ure to match what is specied in the soware with what is
done at the table can result in ruined material and/or broken
bits!
Z axis zeroing process
Ensure that the soware is set to Move/Cut mode.
Place the grounding clip on the bit, if possible. Other-
wise, place it on the collet nut or sha of the spindle.
Set the plate down directly beneath the bit.
NOTE: To test the circuit before running the zeroing
roune, touch the plate to the boom of the bit. Check
that input 1 lights up on the screen and goes o as soon
as contact is broken.
Click on the Z zero buon, or type a C2 command. The Z
axis will touch the plate twice and then move up to a
safe height. The Z axis is now calibrated and the ma-
chine is ready to cut.
Place the Z zero plate back in its holster. Remove the grounding
clip from the bit and secure it safely.

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Zeroing the XY axes
The best way to zero the X and Y axes is by using the proximity switch homing process. This process
instructs the machine to touch o from each switch to establish a zero locaon, which creates an accu-
rate and repeatable start point.
Click the XY Zero buon or type a C3 command to use this feature. To make a permanent adjustment
to the locaon of your 0,0 point based on the switches, click on [T]ools > ShopBot Setup, and “Next”
unl you see the screen that’s marked “ShopBot setup: Prox switches.” Then click “Click here to make
it easy on me.” The program will help set up the new permanent zero locaon.
To set up a temporary zero locaon, simply move the spindle/router to the desired locaon. Write
down these coordinates to ensure the exact locaon for later. Type a Z2 (for Zero 2 axes) command.
Noce that the X and Y coordinates now read zero. This is the new 0,0 locaon that the cut le will ref-
erence.
Changing bits
Note: Spindles and routers have dierent collet styles. Instrucons are included for both.
Make sure collet and nut are completely clean. If necessary, use a wire
brush, compressed air, and/or mineral spirits to remove dust or excess
grease.
Spindles: Before inserng the bit, press the collet into the nut and listen
for the “click.” If collet does not seat, press it in at a slight angle. Conrm
that the collet is snapped in by holding the nut upside-down and leng the
collet hang freely.
Routers: The router collet and nut are held together by a retaining clip.
It is not necessary to disassemble the components for cleaning or bit
changes.
Slide bit into collet. Make sure that
the collet grips only the shank of the bit, keeping any parts of the
ute outside of the collet. Ideally, the bit shank should ll at least
75% of the collet.
Thread collet and nut onto router or spindle. It should go on very
easily. DO NOT apply force if nut is resistant. Stop and try again
unl it goes smoothly. Once the nut is nger-ght, check the bit
again to make sure that it has not slipped. Use the included
wrenches to fully ghten nut.
Spindles: snap collet into nut,
then ip it over to ensure it is
snapped in securely
Ensure no part of ute enters collet.

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Quick-Start Guide for PRSalpha and PRSstandard tools
Seng up the RPM control
This secon only applies to PRSstandard and PRSalpha tools equipped with a spindle.
Ensure the RPM controller USB plug (from VFD unit) is connected to the computer.
In the main console window (should have a pic to idenfy this window), click on “Tools” and then
“Spindle RPM Control.” Drag the box below the posion window to keep it out of the way. It must re-
main open at all mes for the soware to communicate with the VFD unit.
Click on “RPM” in the le corner of the Spindle RPM box to open a sengs window. Change the follow-
ing parameters in the sengs window:
Start when SB3 Starts: 1
Hertz: varies by country 60 (US, Canada, Mexico and Japan)
50 (Europe, and most other regions)
Hertz Scale: Same as Hertz seng unless adjustment is required to match VFD unit
and soware RPM displays.
VFD 1: Yaskawa V1000
VFD 2: Leave blank unless tool is equipped with two spindles.
Click “OK” to save your sengs.
To test the funcon of the RPM controller, turn on the spindle and click on the listed RPM value in the
spindle control window. Change it to something dierent and then click “Enter”. The value on the VFD
unit display should match what was just entered.
Holding down material
Small parts can be caught by the cuer and thrown, potenally causing serious injury or damage.
Therefore, it is imperave to choose the proper hold-down method for the project. It is also important
to be aware of what happens to parts as they are cut from the surrounding material.
Screws
If a spoil board is present, the workpiece can be screwed directly to the table. This works well for most
materials. However, this requires careful planning to ensure that all screws are clear of the cut path.
To establish a less risky tooplpath, insert screws using the locaon of other toolpaths in the le. By
avoiding those, you can be condent that the clearance holes are safe. A few clamps on the edge of the
board will be sucient to complete this inial run.

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Quick-Start Guide for PRSalpha and PRSstandard tools
T-track tables and rails
A system can be set up using T-track rails (available from woodworking supply stores), inlaid into the
wood table. If using this method, be sure the rails sit low enough below the surface that they are out of
the way when through-cung.
Clamps
There are a variety of clamps that can be used to secure material. Clamps oer secure holding power,
and are ideal when there is no excess material to drive screws into. However, they usually require
more planning than other methods because of the vercal clearance required.
Press-t jigs
A ght press-t jig can somemes provide sucient holding force. Consider using addional hold-
downs if cung aggressively or using a spiral up-cut bit.
Adhesive
Double-sided duct tape, carpet tape, and foam tape are excellent holding opons for larger projects.
Because more surface area equals more holding power, this may not be a good choice for small pro-
jects. When through-cung, make sure that the tape stays out of the cut path, as it may gum up the
cung edge, reducing cut quality.
Super 77 spray adhesive is also an excellent opon. However, to avoid damaging the table, bond the
workpiece to a scrap board that is clean and at, and clamp or screw this board to the table. Another
opon is to glue a layer of paper between the workpiece and support board. .

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Quick-Start Guide for PRSalpha and PRSstandard tools
Vacuum hold-down systems
A well-built vacuum system is ideal for repeve cung of plywood and other sheet materials.
ShopBot oers several kits for full-table vacuum systems on our gantry tools.
Holding parts within the material
Tabs
Large parts may shi as they are cut free, leading to a small gouge or notch along the edge. Smaller
parts can be destroyed or even thrown across the room by the cuer.
There are two ways to handle this from within the soware. The rst opon is to create tabs, or leo-
ver “bridges” of material between the part and its surrounding area. Most CAM programs will have an
automated feature for this. The feature for VCarve Pro is shown here.
Adding tabs in VCarve Pro Example of tabs on a part

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Quick-Start Guide for PRSalpha and PRSstandard tools
Onion skin
An opon for tabs is to leave an “onion skin,” or very thin layer of material at the boom of a prole
cut. Set the nal cut depth at slightly less than the thickness of your material (typically .010’’ - .030’’,
depending on material and size). The advantage of this method is that the onion skin can be easier to
trim away than a series of tabs. However, if there is a lot of variance in the thickness of your material,
or if your table is not at, then you may end up cung too deep or too shallow and this method will
not work correctly.
Warming Up the Spindle
Note: This step is not necessary for ShopBot machines with routers.
To maximize the life of spindle bearings, warm up the spindle before cung, aer leng it sit idle for
longer than 4 hours.
Click on “Tools” then “Spindle RPM control” to open the spindle control window. Leaving this window
open, start the spindle warm up roune (C5 command). This will run the spindle at 9000, 10000, and
12000 RPM for 3 minutes each, and will turn o the spindle when nished.
Previewing a le with an oset
There are several ways to perform a “test run” without actually cung the material. First, enter Move/
Cut mode, and click on the “Cut Part” buon (or “File” and “Part File Load”). Select part le, and the
following screen will appear.
Locate the line marked “Oset in 2D or 3D.”
A 2D oset will cut the le at normal depth in a dier-
ent X,Y locaon on the table. Once the X, Y, and Z axes
are zeroed, simply move the cuer to the new locaon
and load the part le with a 2D oset. Its current loca-
on will be used as 0,0.
A 3D oset will cut at a dierent X, Y, and Z posi-
on. This is oen referred to as “air cung,” since
it allows you to run through the le in the air
above the material. To avoid cung into the
workpiece, make sure that the starng distance
between the bit and the material is greater than the maximum cut depth.
Click “START” or Enter on your keyboard to proceed.

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Quick-Start Guide for PRSalpha and PRSstandard tools
Running the cut
If the test run looks good, click on “Cut Part” (or type FP command), and select part le. At the Part File
(FP) setup screen (shown above), ensure “Oset in 2D or 3D” is set to “No Oset.” Click “START,” or
Enter on your keyboard. You’ll see the following screen:
For PRSalpha models, press the “Start”
buon on the three buon pendant BE-
FORE clicking OK.
For PRSstandard models, click “OK” and the
router/spindle will start automacally.
Pausing or stopping a cut
There are two ways to stop the tool while it is moving or cung a part le. An emergency stop cuts
power to the tool and stops it the fastest. A soware controlled stop, or pause, will decelerate the tool,
li the Z axis to a safe height and stop the router/spindle.
Soware controlled stop
The gentlest way to stop the machine during a cut is to hit the space bar on your keyboard. This will
bring the machine to a “so stop,” and will retain zero locaons. The so stop is useful during non-
emergency situaons when adjustments or correcons are needed.
Note: The “Stop” buon on PRSstandard tools acts as a so stop. For a true emergency stop twist
the main stop switch on the cover of the control box.