Shopbot 003065 User manual

888-680-4466 • ShopBotTools.com

Assembly Guide

For PRSstandard Tools

For all PRS tools shipped after 6/15/2017

Contents:

● PRS Gantry Assembly Guide

● Quick-Start Guide

● Table Drawings

● Maintenance Information

●Wiring Diagram located on inside door

of Control Box

Table of Contents 
Contents: 1 
PRS Gantry Assembly Guide 1 
Quick-Start Guide 1 
Table Drawings 1 
Maintenance Information 1 
Wiring Diagram located on inside door of Control Box 1 
Table of Contents 3 
Introduction 9 
General Safety and Precautions 9 
PRS Tool Assembly Process Flow 10 
Main Parts of ShopBot Gantry Tool 11 
Section 1. Setup and Assembly Overview 13 
Electrical Precautions 13 
Other Electrical precautions: 13 
Safety 13 
Unpacking the Crate 14 
Major Components: 15 
Section 2. Table Assembly 17 
Introduction 17 
Hardware 18 
Tools Required 19 
Marking the Table Sides 19 
Mount Table Levelers to Legs 20 
Install Table Legs 20 
Table Sides for 12” and 24” Z-Axis Configurations 22 
Stabilize with Lower Table Supports 22 
Connect Side Assemblies 23 
Install Middle Lower Table Support 23 
Insert T-Nuts in Bottom Slot 24 
© Copyright 2021 ShopBot Tools, Inc.                                                                                                                                                                3 

Mount Table Supports and Gussets to Table Legs 24 
Secure Table Supports and Cross Supports to Table Sides 26 
Install Cross Supports 26 
Square the Table 27 
Leveling the Table 28 
Install Rails 29 
Adjust Front Rail 29 
Section 3. Gantry Installation 31 
Introduction 31 
Tools Required 32 
Install Gantry 32 
Adjust the Rails 33 
Mount the X-Axis Stop Blocks and Proximity Targets 33 
Section 4. Cable Carrier Installation 35 
Introduction 35 
Hardware 36 
X-Axis Cable Carrier 37 
Install Trough Brackets for ShopBots with 6” Z’s 37 
Install the X-Axis Trough:  6” Z-Axis 38 
Machines with 12” and 24” Z-Axis 38 
Cable Carrier to Upper X Bracket 39 
Cable Carrier to Lower X Bracket 39 
Test Cable Carrier Mobility on Both Axes 39 
X-Axis Cable Carrier Configurations 40 
Section 5. Control Box Installation 43 
Introduction 43 
Installation 44 
Section 6. VFD and Spindle Installation/Router Installation 45 
Introduction 45 
VFD Installation 45 
© Copyright 2021 ShopBot Tools, Inc.                                                                                                                                                                4 

Hardware 46 
Determining the VFD Model 46 
Voltage Amperage (Determines Size) 46 
Mounting the VFD 47 
Spindle Installation 48 
Hardware 48 
Attach Spindle 48 
Router Installation 49 
Section 7. Mounting X-Axis Motors 51 
Introduction 51 
Hardware 52 
Motors 52 
Mount Pinions to Motors 52 
Identify Motors 52 
Check Alignment of Pinions with Rack 53 
Adjust Pinions (If Required) 53 
Mounting Locations 54 
Position Motors on Tool 54 
Engage Pinions with Rack 55 
Section 8. Wire and Cable Routing 57 
Hardware 57 
Motor, Proximity Switch, and Stop Button Cables 57 
Spindle Cable 58 
Spindle Logic Cable 58 
Finishing 59 
Spindle Fan Cable Installation 59 
Proximity Switch Installation 59 
X Proximity Switch 59 
Pneumatic Air Hoses 60 
Mount Z Zero Plate Assembly 61 
Secure Cables 61 
© Copyright 2021 ShopBot Tools, Inc.                                                                                                                                                                5 

Section 9. Control Box Wiring for Standard Tools 63 
Powering the PRS Standard Control Box 63 
Exploring the PRS Standard Control Box 63 
Inside the PRS Standard Control Box 64 
Connecting Spindle Drive Inside the Control Box 65 
Making Connections on the Outside of the Box 66 
Handheld Pendant Operation 67 
Troubleshooting the Spindle Control System 68 
Troubleshooting the Motor Control System 71 
Section 10. Software Installation 73 
Introduction 73 
Hardware 73 
Computer Recommendations 74 
Computer Configuration 74 
Install ShopBot 3 Control Software and VCarve Pro Software 74 
Software Overview 74 
Connect ShopBot to Computer 75 
USB Communication Cable 75 
Load the Settings File 75 
Install Control Box Firmware 76 
ShopBot Control Software Familiarization 77 
Easy and Full Modes 77 
Full Display Overview 78 
ShopBot Command Format 78 
Movement Testing 79 
Section 11. Secure Table and Spoil Board 81 
Introduction 81 
Hardware 81 
Base Layer 81 
Spoilboard 82 
© Copyright 2021 ShopBot Tools, Inc.                                                                                                                                                                6 

Section 12. Setup and Fine Tuning 83 
Check Inputs and Outputs 83 
Machine Orientation 84 
Optional Axes 84 
Setting Up RPM Control 85 
System Check 86 
Check Movement 86 
Check Stops and Targets 86 
Check Limit Switches 86 
Check Movement Distance 87 
Test X-Axis Distance 87 
Test Y-Axis Distance 87 
Test Z Zero Function 87 
Proximity Switch Targets 87 
ShopBot Setup 88 
Z Zero Plate 88 
XY Zeroing Point 88 
Fine Tune Setup 89 
Square the Spindle 89 
Secure Mounting Screws 89 
Test Movement Distance 89 
Install Push Bars 90 
Install Dust Foot 90 
Install End Caps 90 
Section 13. Resources 91 
 
© Copyright 2021 ShopBot Tools, Inc.                                                                                                                                                                7 

PRSstandard Assembly Guide Introduction DocID:SBG00520

Introduction

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 the User Guide. 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 Emergency

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 fire. This risk is minimized by using correct

chip load, using sharp bits, and by always double-checking your files before cutting. Be

prepared to pause or stop the cut if something seems incorrect or unsafe.

Keep a working fire extinguisher within reach of the machine, for the reasons listed

above.

PRSstandard Assembly Guide Introduction DocID:SBG00520

PRS Tool Assembly Process Flow

PRSstandard Assembly Guide Introduction DocID:SBG00520

Main Parts of ShopBot Gantry Tool

PRSstandard Assembly Guide Section 1 DocID:SBG00520

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 final 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

specifications 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

unavoidable, 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

assembled components out of the crate.

Having an assistant will make things much

easier – particularly when unpacking the

crate and lifting the gantry onto the table

rails. Do not attempt to lift the gantry

without assistance.

PRSstandard Assembly Guide Section 1 DocID:SBG00520

Unpacking the Crate

ShopBot components arrive in two packages: a large wooden crate and a long box. Contact the

shipping company if either 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 of the crate, and a Phillips head screwdriver to uncrate the components. It will require two

people to lift out some of the heavier pieces.

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 fit in place to show their intended location. Remove this

hardware prior to fitting the applicable component into place.

PRSstandard Assembly Guide Section 1 DocID:SBG00520

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 fitted with linear

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).

PRSstandard Assembly Guide Section 1 DocID:SBG00520

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 computer through a single USB cable. The control box pictured here is for an alpha tool. Standard

control boxes are smaller in size.

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. The XY Home

Position is also indicated here.

PRSstandard Assembly Guide Section 2 DocID:SBG00520

Section 2. Table Assembly

Introduction

The ShopBot table provides a firm foundation for all other components. This section contains

instructions to assemble, square, and level the table for correct and optimal performance.

The diagrams in this manual depict a 96”x48” 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 and

shape of your tool (as well as any accessories included), but the same basic steps will be followed. The

table drawings provided at the end of this guide will detail specific measurements for other

configurations.

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 in its final 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 configured for 12” and 24” axes

have extra table side extrusions and table legs with added mounting holes.

PRSstandard Assembly Guide Section 2 DocID:SBG00520

Hardware

Except for the table levelers, all of this hardware is included in the small box marked “table

hardware”:

Part Name

Quantity

ShopBot P/N

Notes

Rail

2

001872

Table side

2

000925

Upper table support

4

000915

Different for other lengths

Lower table support

3

000921

Different for other lengths

Table cross support 48E

2

000926

Different for other lengths

Table leg

6

000919

Different for other lengths

Table gusset

6

000770

Different for other lengths

Part Name

Quantity

ShopBot P/N

Notes

1/2-13x1-1/2” Hex Bolt

See table drawing

001956

Used for components to leg

1/2" Lock Washer

See table drawing

000588

Used for components to leg

1/2" Flat Washer

See table drawing

000029

Used for components to leg

1/2-13 Hex Nut

See table drawing

000440

Used for components to leg

5/16-18x3/4” Hex Bolt

See table drawing

000529

Used for cross supports, leg

5/16” Schnorr Washer

See table drawing

004487

Used for leg

5/16” Flat Washer

See table drawing

000848

Cross supports, leg

5/16-18 T-Nut

See table drawing

002498

Legs, cross supports, rails

5/16-18x3/4” Button Head Cap

Screw

See table drawing

002033

Used for rails

5/8-11 Hex Nut

See table drawing

000160

1 per table leg

5/8-Table Leveler w/Nut

See table drawing

002926/0008

62

1 per table leg

3/8-16x1 1/2” Carriage bolt

See table drawing

000953

Used to secure base board

PRSstandard Assembly Guide Section 2 DocID:SBG00520

*Specific quantities can be found on the packing list enclosed with the hardware.

Tools Required

Marking the Table Sides

Remove table sides from packaging and lay them on the floor side-by-side. Locate where the Home

Position (X = 0) will be.

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.

Part Name

Quantity

ShopBot P/N

Notes

3/8” Lock washer

See table drawing

000092

Used to secure base board

3/8” Flat washer

See table drawing

000444

Used to secure base board

3/8-16 Hex nut

See table drawing

000452

Used to secure base board

Marker (or other writing tool)

Tape Measure

Wrench or Socket, 5/16”

Mechanical Square

Rubber Mallet

Wrench or Socket, 3/8”

Safety Straps (optional)

Wrench or Socket, 5/8”

Wrench, 1”

String/Twine (at least 30ft)

Wrench or Socket, 1/2”

Wrench, Allen, 5/16”

PRSstandard Assembly Guide Section 2 DocID:SBG00520

Locate your machine’s corresponding table drawing at the back of this assembly manual. Starting from

the Home Position, use a tape measure and permanent marker to indicate on the inside of the rails

where each table leg and cross support will attach.

If you haven’t already, it is helpful to then

move the rails into the general space

that the finished tool will occupy.

Note: This image indicates the rail

marking locations for a 96” tool. The

positions will differ for other table

configurations.

Orient table sides into approximate

location that the tool will occupy.

Mount Table Levelers to Legs

Remove table legs from packaging. Screw leveler approximately half way into

the bottom of each table leg. Thread a 5/8” hex nut onto the leg leveler. Keep

nut loose until table is leveled.

Thread the middle leg levelers all the way up to ensure that the feet do not

interfere during the leveling procedure.

Note: During assembly, some holes may require tapping to remove excess

powdercoating.

Install Table Legs

Insert eight T-nuts per table leg into the T-slots in the pattern shown, with the rough side down. Note the

line marked earlier for alignment. Make sure to insert the T-nuts for the middle table legs in the T-slots

prior to assembling the end table legs.

ShopBot 003065 User manual

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