ShopBot PRS Alpha User manual

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SBG 00360 Owners Manual CE Version 2015 11 16 Copyright 2015 ShopBot Tools, Inc
ShopBot User’s Manual International
Version
For PRS Alpha and Desktop Models
ShopBot Tools, Inc.
3333-B Industrial Drive,
Durham NC 27704
S hopBotTools.com
Technical Support
[e-mail]
1-888-680-4466

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SBG 00360 Owners Manual CE Version 2015 11 16 Copyright 2015 ShopBot Tools, Inc
Revision History
Date:
ECO:
Change:
Changed By:
2015 11 16
Updated format. No change to instructions
M. Cummings

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SBG 00360 Owners Manual CE Version 2015 11 16 Copyright 2015 ShopBot Tools, Inc
Table of Contents
Introduction ............................................................................................................................................................5
Section 1: Safety....................................................................................................................................................5
Basic Safety Rules:....................................................................................................................... 5
Warning Labels............................................................................................................................ 5
Section 2: Software Setup and Orientation................................................................................................. 8
Loading Software and Drivers ..................................................................................................... 8
Connect Shopbot to Computer................................................................................................... 8
Loading the correct settings file.................................................................................................. 8
Understanding the Shopbot control software ............................................................................ 9
The Basic ShopBot Command Principle ...................................................................................... 9
Entering Values (Parameters)...................................................................................................... 9
What's in a Part File .................................................................................................................. 10
Switching from English to Metric units:.................................................................................... 10
Testing each axis using the keypad ............................................................................................11
Understanding axis orientation................................................................................................. 12
Testing the router/spindle......................................................................................................... 13
Setting up for RPM control........................................................................................................ 13
Section 3: technical basics & planning your cuts................................................................................... 14
Selecting the right bit for your project...................................................................................... 14
Calculating feeds/speed with Chip Load:.................................................................................. 15
Changing bits............................................................................................................................. 16
Holding down material for cutting............................................................................................ 17
Screws ................................................................................................................................... 17
T-track tables and rails .......................................................................................................... 17
Clamps................................................................................................................................... 17
Press Fit Jigs .......................................................................................................................... 17
Adhesive................................................................................................................................ 17
Vacuum hold-down systems ................................................................................................. 18
Holding small parts within the material ............................................................................... 18
Section 4: Running a Part File ....................................................................................................................... 19
Zeroing the Z axis ...................................................................................................................... 19
To set up for the zeroing routine: ......................................................................................... 20

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SBG 00360 Owners Manual CE Version 2015 11 16 Copyright 2015 ShopBot Tools, Inc
Zeroing the X and Y axes ........................................................................................................... 20
Warming up the spindle............................................................................................................ 21
Previewing a file with an offset................................................................................................. 22
Running the cut......................................................................................................................... 22
Pausing or stopping a cut.......................................................................................................... 23
Surfacing the table .................................................................................................................... 23
Maintenance......................................................................................................................................................... 24
Daily checklist:........................................................................................................................... 24
Weekly checklist:....................................................................................................................... 25
Resources.............................................................................................................................................................. 26

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SBG 00360 Owners Manual CE Version 2015 11 16 Copyright 2015 ShopBot Tools, Inc
Introduction
This manual begins where the assembly guide ended. It is assumed that the machine is fully assembled and
connected to power.
For sections concerning software, this manual assumes that you have a basic familiarity with the CAD/CAM
software.
Section 1: Safety
Basic Safety Rules:
Learn and understand safe use of the machine. Do not allow untrained individuals to operate the machine
without supervision. Ensure everyone who operates or works near the machine knows 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 material is properly secured before cutting, and be aware of any small parts that may come loose
after being cut out. 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 hands on the rails of the ShopBot. Be aware that the machine may move unexpectedly in any
direction, which can cause serious injury if 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 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 (read more about this in section 2), using
sharp bits, and by always double-checking 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.
Warning Labels
ON/OFF SWITCH
INTERLOCK DISENGAGED-ENGAGED
(safety lock-out switch for power to the spindle/router)

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SBG 00360 Owners Manual CE Version 2015 11 16 Copyright 2015 ShopBot Tools, Inc
CAUTION:
PINCH POINT
Keep hands and clothing away from
carriage. Machine movement can result
in injury.
WARNING:
HAZARDOUS VOLTAGE
Contact may cause electric shock or burn.
Turn off and lock out system before
servicing.
WARNING: BITS SPINNING AT HIGH
SPEED CAN SHATTER OR START FIRE
Follow Safety Instructions while
operating machine. Ignoring
instructions can result in serious injury
or equipment damage.
WARNING: FLYING DEBRIS AND LOUD NOISE.
Wear eye and ear protection. Ignoring
instructions can result in serious injury or
equipment damage.

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SBG 00360 Owners Manual CE Version 2015 11 16 Copyright 2015 ShopBot Tools, Inc
SAFETY INSTRUCTIONS
- Keep shields in place and wear eye protection
- Do NOT locate metal fasteners near or in the cutting area
- Verify clearance of tool path before cutting
- Use bits that are clean, sharp and in good condition.
- Use bit manufacturer’s recommendation for speed and depth of cut.
- Insure that collet is in good condition and that bit is fully inserted.
- Machine must be supervised while in operation.
- Read user’s guide for more information about proper work piece mounting and use of router
bits.

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SBG 00360 Owners Manual CE Version 2015 11 16 Copyright 2015 ShopBot Tools, Inc
Section 2: Software Setup and Orientation
For software installation, refer to “Uninstall/Reinstall ShopBot and VCarve Software” document located under
“Software” on ShopBot website (www.shopbottools.com/ShopBotDocs/software).
Loading Software and Drivers
Do not connect the Shopbot to computer before installing the software and drivers!
Special note for schools and large companies: This software runs best with full administrative permissions
enabled. We strongly advise against setting up separate admin and user accounts on the control computer.
For international customers: The computer used to run the machine MUST have the language set to United
States English in order for the software to run correctly.
Connect Shopbot to Computer
After loading software, locate the USB 2.0 hub included with machine. Connect this to computer, and connect
main USB cable from control box to hub. ONLY this cable should go into the hub. Do not connect the RPM
controller cable (if applicable), flash drives, etc. Power on the machine, and double-click the Shopbot 3 icon to run
the control software.
If an error message is received regarding the connection, try some of the troubleshooting steps at
http://www.shopbottools.com/ShopBotDocs/maintenance.htm. Call or email Shopbot tech support if needed.
Loading the correct settings file
All ShopBot machines are controlled by the same software, so it's important to let the program know what kind of
machine is being used. All settings can be set at once by loading a default settings file.
A prompt will occur to allow a default settings file to load for the machine the first time the program is opened.
The following screen should appear:

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SBG 00360 Owners Manual CE Version 2015 11 16 Copyright 2015 ShopBot Tools, Inc
For machines built after 2007, double-click on PRS Shopbots. If loading a Desktop Tool, choose the file named
ShopBot_PRSDesktop2418.sbd. If loading an Alpha Tool, open the PRS Alpha folder and then choose the correct
table size of the machine. This will go back onto the main screen.
Understanding the Shopbot control software
The screen is divided into two main sections:
The console window (left) allows adjusting settings, loading part files, and entering commands. The position
window (right) is how the machine provides “feedback” in terms of its coordinates, switch positions, and alarms.
The Basic ShopBot Command Principle
Whether issuing instructions to the ShopBot from the Control Console or from a Part File, there is a standard Com-
mand Language for controlling the tool. Each ShopBot Command starts with two letters. For example, a [Z3] com-
mand stands for Zero the location of 3axes (X, Y, and Z). It is helpful to understand that all commands are located
within the drop-down menus in the console window. The first letter of each command corresponds to the menu
that it’s in. To load a part file, click on File > Part File Load, or enter an [FP] command.
Entering Values (Parameters)
In some cases, the command must be followed by parameters that fully define the move or action. For example:
An [M2] command (Move 2axes) will normally be followed by two parameters: an X coordinate and Y coordinate.
So [M2] 3,2 will move the machine to the (3,2) location on the table. However, this command can be used to
move only one axis by omitting one of the parameters. [M2] 3 will move only the X axis, and [M2] ,2 will move
only the Y axis. Notice the use of the comma as a placeholder for the X parameter.

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SBG 00360 Owners Manual CE Version 2015 11 16 Copyright 2015 ShopBot Tools, Inc
What's in a Part File
The list of instructions is provided through Part Files that are written or generated in other software and brought
into ShopBot. The list of instructions looks just like the list of Commands you would enter from the keyboard. On
each line of the list, there is a two-letter Command followed in most cases by parameters. A Part File can be a
short and simple list that looks like the following:
JZ, .5
J2, 10, 10
MZ, -.25
M2, 20, 10
M2, 20, 5
M2, 10, 5
M2, 10, 10
JZ, .5
This example instructs the tool to cut a rectangle. First (JZ, .5), jogs (moves at rapid speed) the bit up to make sure
it is above in the material when moving to the starting point. Next, the tool will jog to the XY location (10,10). This
is the starting point. Then the bit is moved down to -.25 (MZ, -.25) at Move speed now because it is cutting into
material. The next four commands move the bit to each corner of the rectangle. Once the part is cut, (JZ, .5) jogs
the bit up out of the material. This is a simple example, but should help explain how a part file works.
Switching from English to Metric units:
To work in metric units, click on Values on the
top menu bar, then choose Display Values. Or,
type a [VD] command to access this window.
Change the first field from inches to
millimeters. Click OK at the bottom right
corner of the window, which will save changes.

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Testing each axis using the keypad
Movement along each axis is possible using
move/jog commands, or with the keypad
move function.
Turn ON the control box if not already done.
Switch to move/cut mode by clicking on the
toggle switch within the position window
(reference the chart for clarification).
Type K on the keyboard to open the keypad
move window, and use the arrow keys to
move each axis.
Reference the chart below for instructions on
using the arrow keys. Some of the keys may
not apply, for example the A and B axes are
accessories and not found on all machines.

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Understanding axis orientation
It’s essential to understand how the X, Y, and Z axes are oriented on the machine, and how this relates to job setup
in the CAD/CAM software. Shown below is an example of a job and its corresponding orientation on each machine
model.
The bottom corner is referred to as the XY home location or “zero zero.”

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Testing the router/spindle
Full size and Buddy Tools only:
First, locate the key attached to the collet
wrench. This will have been located either inside
the control box or one of the hardware boxes
included with shipment.
Insert this key into the safety lockout on the main
control box, and turn the key to ENGAGED.
For routers: Make sure that the router’s power switch is in the ON position before proceeding.
In the main console window, type K to bring up the keypad move command. Notice the output toggle switches at
the bottom of this window. Click switch #1 to turn this output on. This should start the router/spindle for Desktop
models.
For PRS Alpha models only: after toggling output 1, press the green START button on your remote stop pendant.
To turn off the spindle, click the output 1 switch again or close the keypad window.
All machines: turn output 1 on through the keypad
Alpha Tools only: press the green start button
Setting up for RPM control
The following section only applies to Gantry or Buddy Tools equipped with a spindle.
If not already done, connect the RPM controller into computer. This is the black USB plug coming from the VFD on
a gray cable. Do not plug it into the hub alongside the main Shopbot USB; it should go straight into an empty port
on the computer.
In the main console window, click on Tools > Spindle RPM control and then drag this box below the position
window to keep it out of the way. It must remain open at all times in order for the software to communicate with
the VFD and change RPM. Click on “RPM” in the left corner of this box to see a settings window appear. Change
the following parameters:

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Start when SB3 Starts: 1
Hertz: 60 (this setting is for the US and Canada. It may vary by country).
Hertz Scale: 60
VFD 1: Yaskawa V1000
VFD 2: (leave blank, this setting is not used)
Click OK to save settings.
To test the function of the RPM controller, turn on the spindle and click on the listed RPM value in the spindle
control window. Change it to something different and hit Enter. The value on the VFD’s display should match what
was just entered at the computer.
Section 3: technical basics & planning your cuts
This section provides an overview of some basics to safely and efficiently plan projects.
Selecting the right bit for your project
Bit material: Router bits are made from a variety of materials. The most common are solid carbide, carbide-tipped
steel, and high-speed steel. Both solid carbide and carbide-tipped are good choices. High-speed steel bits are not
recommended as they dull quickly and must be re-sharpened.
Flute type: There are four basic flute types: Straight, spiral up-cut, spiral down-cut, and compression. Each type
has its own advantages and disadvantages, which are outlined in the chart below.
Good edge quality on most
materials
Moderate chip clearing abilities
Ideal for: general-purpose cutting
May chip or fray top face,
good quality on bottom face
when through-cutting
Excels at clearing chips and
dissipating heat, especially with
“o-flute” bits
Upwards force may cause part
lifting
Ideal for: plastics, aluminum, or
any material where heat buildup
is a concern
Best edge quality on top face,
may chip or fray bottom face
when through-cutting
May compact chips in a groove
Downwards force may help with
cutting thin sheets
Ideal for: plywood and laminates
(pocketing)
Clean edge on both top and
bottom face
Designed to cut veneered or
laminated materials at full depth
in one pass
Ideal for: plywood and laminates
(profile cutting)

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Number of flutes: The number of flutes on a bit is essential to
calculating proper feed and speed rates. For most applications, a bit
with 1, 2, or 3 flutes can be used, but feed rates and RPM must be
adjusted to maintain proper chip load.
End shape: Straight and up-spiral bits come in a variety of end
shapes. Square ends are most common, and are a good choice for
creating pockets and grooves, profile cutting, simple lettering, and
drilling operations. Ball (or rounded) ends are best for 3D carving.
V-carve bits are often used to create complex letters for sign making.
They can also be used to chamfer edges and create countersinks for
screw holes.
Calculating feeds/speed with Chip Load:
Chip load refers to the actual thickness of the chip cut by each
revolution of the cutter. It is the measurement that all feed/speed
calculations are based on.
A spinning bit generates friction and heat as it moves through the
material, and part of this heat is pulled away by the flying chips. A
larger chip load pulls away more heat, but also puts more stress on
the cutter. Each material has its own ideal chip load range that
balances heat dissipation with cutter stress.
A basic chart for common materials is available in the SB3 software. Click on Tools > Chip Load Calculator, then
click on Chip Load Help. Use this chart along with the Chip Load Calculator to determine a good starting speed for
each toolpath.
When calculating feeds/speeds for a toolpath, do not rely on the defaults in the tool database. Those values are
only placeholders and are not intended for any particular material.
What’s the difference between a
square-end bit and an end mill?
An end mill has cutting flutes that
extend across the bottom (end) of
the bit. It is designed for plunge-cutting
as well as lateral cutting.
“Square-end” is simply a description of
end shape. Square-end bits are not
always end mills, and end mills
do not always have square ends.
The first image below shows a true end
mill, and the second shows a straight-
fluted, square-end bit that is not an end
mill. A ramp-in must be applied to a
toolpath when using this type of bit.

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Changing bits
Note: Spindles and routers have different collet styles. Instructions for both are included.
Make sure that collet and nut are completely clean. A dirty collet will not grip the bit properly and can cause it to
slip during the cut. Use a wire brush, compressed air, and/or mineral spirits to remove dust or excess grease.
(For spindles only): Before inserting the bit, press the collet into the nut and listen for the “click.” If it doesn’t click,
press it in at a slight angle. Confirm that the collet is snapped in by holding the nut upside-down and letting the
collet hang freely.
(For routers only): 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 the bit into the collet. Make sure that the collet grips only the shank of the bit, keeping any parts of the flute
outside of the collet. Ideally, the shank of the bit should fill up at least 75% of the collet. Remember that more
gripping surface = better hold.
For spindles: snap the collet into the nut, then
flip it over to make sure it is snapped in securely
Check that no part of the flute enters the collet
Now thread the collet nut onto the router or spindle. It should go on very easily. If resistance is encountered, do
NOT apply more force. Stop and try again until it goes smoothly. Once the nut is finger-tight, check the bit again to
make sure that it has not slipped, and then use the included wrenches to fully tighten the nut.

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Holding down material for cutting
Choosing the right hold-down method can be challenging, but it is an essential part of project planning and should
not be treated as an afterthought. In addition, the operator needs to be aware of what will happen to parts as they
are cut from the surrounding material. Small parts can be caught by the cutter and thrown across the room,
causing serious injury or damage.
The following information is a brief overview to get started. Find further information by searching online for any of
these methods. The Shopbot user’s forum (www.talkshopbot.com/forum) is another great resource to see what
other users have done and share tips and advice.
Screws
If a spoilboard is set up, screw the workpiece directly to the table. This is a quick and easy method that works well
for most materials. However, this requires careful planning to make sure that all the screws are clear of the cut
path.
With larger jobs, consider creating a hold down toolpath based on the location of other toolpaths in the file. This
will create clearance holes for the screws in locations that are safe. When using an end mill for drilling, there is
very little lateral force on the piece so less holding power is needed. A few clamps on the edge of the board will be
sufficient to complete this initial run.
T-track tables and rails
The Shopbot Buddy and Desktop tools have an aluminum table base that is ideal for setting up moveable clamps
and fixtures. With the Gantry (full-size) machines, T-track rails (available from woodworking supply stores) can be
inlaid into the wood table. If using this method, ensure that the rails sit low enough below the surface that they
are out of the way when through-cutting.
Clamps
Whether working with a T-track table or a spoilboard, there are a variety of clamps that can be used to secure the
material. Clamps offer very 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 vertical clearance required.
Press Fit Jigs
Since most of the cutting force is lateral, a tight press-fit jig can sometimes provide sufficient holding force.
Consider using additional hold-downs if cutting aggressively or using a spiral up-cut bit.
Adhesive
Double-sided duct tape, carpet tape, and foam tape are excellent holding options. Both the table and work piece
must be clean, flat, and dust-free. More surface area = more holding power, so this may not be a good choice for
small projects. When through-cutting, make sure that the tape stays out of the cut path, as it may gum up the
cutting edge, reducing cut quality for the rest of the part.
Spray adhesive is another option. 3M makes an excellent product called Super 77, which forms an extremely
strong bond within 2-3 minutes. To avoid damaging the table, bond the workpiece to a scrap board that is clean
and flat, then clamp or screw this board to your table. Some people prefer to glue a layer of paper between the
workpiece and support board. This weakens the bond, but it makes removal much easier. Try both methods on
some scrap to compare.

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Vacuum hold-down systems
A well-built vacuum system can be one of the most convenient and effective hold-down methods. It is ideal for
repetitive cutting of plywood and other sheet materials.
Shopbot offers several kits for full-table vacuum systems on Gantry tools. For the Buddy and Desktop tools,
consider building a vacuum table or using a modular “puck” system. There are many resources online for
instructions on building small-scale vacuum tables.
Holding small parts within the material
Once the material is secure, it still needs to be decided what will happen to parts as they are cut out. Large parts
may shift 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 cutter.
There are two ways that this can be handled from within the software. The first option is to create tabs, or leftover
“bridges” of material between the part and its surrounding area. Most CAM programs will have an automated
feature for this. Further information is available within either program by clicking on Help > Help Contents.
Adding tabs in VCarve Pro
Example of tabs on a part
A second option is to leave an “onion skin,” or very thin layer of material at the bottom of a profile cut. Set the
final cut depth at slightly less than the thickness of your material (typically .010” - .030”, depending on material and
size). The advantage to 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 material, or if the table is not flat, then it may end up
cutting too deep or too shallow and this method will not work correctly.

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Section 4: Running a Part File
This section walks through the setup procedures before previewing or running the part file. It’s a good idea to
preview the file in the CAD/CAM software, and double-check all settings for bit size, cut depth, move speed, etc.
Zeroing the Z axis
Zero the Z-axis each time the machine is turned on or bits are changed. There is an option of zeroing to the top of
the material or to the table surface, depending on what would work best for the project.
Zeroing to top of material is a better choice when a precise cut depth
(cutting an inlay pocket, for example) is necessary.
Zeroing to table surface is a better choice when through-cutting parts
in wood. Because wood products naturally vary in thickness, the top
surface on any given area may be higher or lower than other areas.
Zeroing to the table surface will provide the most consistent through-
cutting results.
Specify whichever location is chosen in the CAD/CAM program (as
shown here for VCarve Pro). Failure to do this can result in ruined
material and/or broken bits!
The Shopbot comes equipped with an aluminum plate and grounding
clip, to allow for quickly and accurately zero the Z-axis using a software
routine.

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To set up for the zeroing routine:
Ensure the software is set to Move/Cut mode.
Place the clip on the bit if possible. Otherwise, place
it on the collet nut or the shaft of the spindle.
Set the plate down directly underneath the bit.
Touch the plate to the bottom of the bit to test the
circuit before running the routine. Check that input
#1 lights up on screen and goes off as soon as
contact is broken.
Click on Cuts > zero the z-axis with plate (or type a
C2 command). The Z axis will touch the plate twice
and then move up to a safe height. It is now
calibrated and ready to cut.
Before continuing, place the z-zero plate back in its holster and secure the grounding clip to a safe location (not on
the plate itself).
Zeroing the X and Y axes
The best way to zero the X and Y axes is by using the proximity switch homing routine. This routine instructs the
machine to touch off of each switch to establish a zero location, which creates an accurate and repeatable start
point. Click on Cuts > zero the XY axes (or type a C3 command). To make a permanent adjustment to the location
of the 0,0 point based on switches, click on Tools > Shopbot Setup. Click “next” until the screen that’s marked
“Shopbot setup: Prox switches” appears. Click the button marked “Click here to make it easy on me.” The program
will walk through setting up the new permanent zero location.
To set up a temporary zero location, simply move to the desired location. Write down these coordinates in case it
is necessary to return to the exact location later. Type a Z2 (for Zero 2 axes) command. Notice that the X and Y
coordinates now read zero. This is now the 0,0 location that the cut file will reference.