ShopBot PRS Gantry Tool Table Assembly Guide
Contents
1. For the Y axis the stop blocks and prox targets are already mounted on the gantry Locate the 8mm threaded hole to the left of the spindle router Roll the YZ car into position so that this hole is directly over one of the target bolts Thread the barrel prox switch into the hole until it comes to rest on the target Back it out several turns so that there is a 1 32 1 16 1 2mm gap between them Tighten the nuts onto the switch as you did with the X axis and then connect the Y axis prox switch cable marked with blue tape Doc 003594 rev 07 19 13 2013 ShopBot Tools Inc Shop hope ShopBot PRS Gantry Tool Table Assembly Guide 37 3 5 Mount the Z Zero Plate Assembly The Z zero plate assembly allows you to accurately calibrate the height of your Z axis before cutting All the z zero plate components are packed in a plastic bag inside the box of accessories along with the prox switches etc Locate the 30 gray cable and the two black 3mm screws in the z zero assembly kit Attach the gray Wago connector to the upper right side of the YZ car plate as shown here left The z zero plate comes with an optional holster to store the z zero plate when not in use To attach the holster simply remove the tape backing on the two pieces of aluminum channel and press it onto the YZ car so that the z zero plate can slide down into it Connect the matching Wago plug on the z zero assembly to the one you j2. 2013 ShopBot Tools Inc ShopBot ShopBot PRS Gantry Tool Table Assembly Guide 25 Attach the rail wipers The rail wipers are designed to keep the wheels and v rails free of excessive dust and debris This will greatly prolong the service life of your wheels and allow for smooth accurate operation of the YZ car The Y axis wiper kit includes 4 wiper caps with foam inserts and mounting hardware Use caution when opening the individual bags so that you don t lose any of the small mounting screws Place the foam inserts into the wipers and saturate with lightweight machine oil not included Secure a wiper assembly over each wheel on the YZ car with the included mounting screws Do not overtighten VV Y Section 3 Mounting the motors and other peripherals 3 1 Mount the motors Locate the X and Y axis motors there will be 3 total and the bag containing the pinion gears The motor plates are marked to indicate the axis Blue indicates a Y axis motor Red indicates X axis If you have purchased an accessory item such as a rotary indexer accessory motors are marked yellow Fit a pinion gear onto the shaft of each motor as shown here If you encounter resistance use the 1 8 hex key included to loosen the set screw s on the pinion Save this hex key It is used later in the installation Set the pinion so that it sits flush with the end of the motor shaft and tighten the set screw s As a final step apply
3. Install the X axis Upper E chain Bracket Mount the Upper E chain Bracket to the 14 20 tapped holes located in the side of the endplate using the 1 4 20 x 3 4 Button Head Screws and 1 4 lock washers Install the chain Attach the E chain to the tab that extends out from the Upper E chain Bracket using two sets of 10 32 Flat Head Screws 10 flat washers 10 lock washers and 10 32 hex nuts Attach the other end of the E chain to the holes located 3 64mm from the end of the trough closest to the center of the machine Use the same 10 32 hardware as in the previous step Mount Echain to holes in Trough Before continuing move the X axis back and forth through its full extent of travel The chain should never feel as though it is binding or under tension If this appears to be the case loosen the bolts holding the trough brackets onto the table sides and adjust the position of the trough until the chain can move freely Doc 003594 rev 07 19 13 2013 ShopBot Tools Inc ShopBot_ hopisot ShopBot PRS Gantry Tool Table Assembly Guide 45 All wires and cables coming off of the gantry will be carried in the X axis chain Use this checklist to inspect your cables before closing up the chain when you are finished X1 motor cable coming through the hole in the center of the gantry beam X2 motor cable located right above the Upper E chain Bracket Y motor cable Z motor cable X axis proximity s
4. Measure the table across both diagonals The measurements should be the same to within 1 16 If your measurements are the same skip this step and move on to mounting the table surface If your measurements are different you will need to adjust the rear table side Before continuing check the bolts holding the cross supports onto the rear table side and ensure that they are loose enough to slide within the grooves Doc 003594 rev 07 19 13 2013 ShopBot Tools Inc ShopBot_ ShopBot PRS Gantry Tool Table Assembly Guide 18 The example shown here is exaggerated to illustrate the correct method of squaring your table First Diagonal 133 FRONT TABLE SIDE Second Diagonal 135 REAR TABLE SIDE Move this side back 1 The rear table side should be moved 1 2 of the difference between the two measurements In this example there is a 2 difference between the diagonal measurements so the rear table side should be moved 1 Usea rubber mallet or a hammer and protective block of wood to knock the table into square Starting at the one side of the table check the cross supports against the rear table side with a square Fully tighten the bolts as you go and re check the diagonal measurements frequently as you work down the table When the table is square you are ready to mount the table surface Doc 003594 rev 07 19 13 2013 ShopBot Tools Inc ShopBot_ hopisot ShopBot PRS Gantry Too
5. ShopB nopso ShopBot PRS Gantry Tool Table Assembly Guide 1 ShopBot PRS Gantry Tool Table Assembly Guide This guide will walk you through the mechanical assembly of your ShopBot PRS Gantry tool It does not include instructions for wiring software training troubleshooting or maintenance Additional documentation is available at www shopbotdocs com Doc 003594 rev 07 19 13 2013 ShopBot Tools Inc _ShopBot_ hopisoT ShopBot PRS Gantry Tool Table Assembly Guide 2 Table of contents 1 Before you start 1 1 Tools and materials needed 1 2 Electrical precautions 1 3 Overview of your Shopbot PRS CNC Tool 2 Table Assembly 2 1 Visual guide to parts and hardware 2 2 Assembly steps 2 3 Square and level the table 2 4 Mount the table surface 2 5 Mount the rails 2 6 Place the gantry onto the rails 2 7 Place the YZ car onto the gantry 3 Mounting the motors and other peripherals 3 1 Mount the motors 3 2 Mounting a router or spindle 3 3 Mounting the VFD spindles only 3 4 Mount the end stops and proximity switches 3 5 Install the Y axis E chain 3 6 Install the X axis E chain 3 7 Install the dust skirt Doc 003594 rev 07 19 13 2013 ShopBot Tools Inc ShopBot_ hopisoT ShopBot PRS Gantry Tool Table Assembly Guide 3 Section 1 Before you start 1 1 Tools and materials required Frame assembly Framing square Level 6 or longer is ideal 8 straightedge if using a shorter
6. lock washers and 1 4 flat washers The screws will pass through the bracket and thread into the YZ car Doc 003594 rev 07 19 13 2013 ShopBot Tools Inc ShopBot_ ShopBot PRS Gantry Tool Table Assembly Guide 39 Mount one end of the E chain to the lower bracket Loop the chain up and around so that it sits on top of using two 10 32 flat head screws Position the the Y axis upper E chain bracket Mount the chain chain so that it loops towards the right when you using two 10 32 flat head screws 10 flat washers are looking at the front of the YZ car lock washers and 10 32 hex nuts After the E chain is installed move the Y axis back and forth across its full extent of travel The E chain should never as though it is binding or under tension If this appears to be the case loosen the bolts holding the lower bracket in place and adjust the bracket position until the chain moves freely Add wires to the Y axis E chain First route the X2 motor cable on the left side of the gantry through the hole in the center of the gantry beam Secure the cable to one of the holes on the side of the end plate with a wire tie to minimize any slack in the cable control box pictured for reference not mounted yet Doc 003594 rev 07 19 13 2013 ShopBot Tools Inc ShopBot oe ShopBot PRS Gantry Tool Table Assembly Guide 40 Open the Y axis E chain Starting at either end of the Y axis E chain use a flat
7. Discharges Electronic circuits are very sensitive to static and power surges Please have your electrician follow all wiring and grounding instructions 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 if the machine is not grounded Doc 003594 rev 07 19 13 2013 ShopBot Tools Inc Shophot ShopBot PRS Gantry Tool Table Assembly Guide 5 1 3 Overview of Your ShopBot PRS CNC Tool a ie lt k D l ao a es x e A 2 ake gt w ew b he P n P D aaa n S s We ve pre assembled many components of your machine to reduce the number of assembly steps In many places bolts or hardware are loosely fit in place to show you their intended location so you ll need to remove this hardware before fitting the component into place Use caution when lifting boxes and assembled components out of the crate There are several assembly steps where having an assistant will make things much easier In particular you will Heavy object need assistance unpacking the crate and lifting the gantry onto To avoid muscle strain or back injury use lifting aids the table rails Do not attempt to lift the gantry without and proper lifting techniques when removing assistance or replacing Terms to know Before you unpack the crate let s go over the some of the major componen
8. ShopBot Tools Inc ShopBot_ ShopBot PRS Gantry Tool Table Assembly Guide 47 Connecting to the Dust Collection System The dust skirt comes with 24 of flex tubing and a hose clamp You will need to supply additional hose and or rigid duct to connect to your dust collection system If you are using a Shop vac or similar small vacuum system for dust collection you may also need to purchase a reducing adapter to connect the two different hose sizes On the back side of the Z axis notice the slots To dust collector in the Y axis upper E chain bracket These can eg be fitted with two hose clamps for a 4 dust collection hose not included Before tightening the hose clamps make sure there is enough slack in the hose to allow the Z axis to move throughout its full range of travel To ShopBot dust skirt hy Grounding the Dust Skirt It is important to understand that dust collection systems generate a lot of static electricity If this static is not grounded disruptions to the control system can occur while cutting At the end of the dust skirt hose there is a small alligator clip connected to the wire within the dust Sek tse ae F to grounding wire in dust hose If you are using a similar wire reinforced collection evuiainn hose to connect to your dust collector simply strip system not included back an area of the wire and connect this clip to it Grounding clip attaches If you are using non reinforced
9. a little bit of the included grease to each pinion This helps to ensure smooth movement and prevent corrosion It is very important to mount each motor in its correct location Double check the markings on the motor plates as you mount them onto the tool Doc 003594 rev 07 19 13 2013 ShopBot Tools Inc Shops hope ShopBot PRS Gantry Tool Table Assembly Guide 26 For your convenience the mounting hardware 1 4 20 x 3 4 Button head screw 1 4 lock washer 1 4 flat washer is already fitted to the end plates and YZ car where the motors will be mounted Mount each motor in the positions shown here X1 motor X2 motor closest to control box Position of control box not yet mounted for reference The pinion gears on the motors need to engage tightly with the gear rack Have someone help you apply upward pressure approximately 15 20 lbs against the rack as you tighten the mounting bolts You can also use a Quick Grip clamp if you are working alone After all motors are mounted take a moment to be sure that both X and Y Cars are moving up and down the rails smoothly The motors will create some resistance but the motion should be smooth and even with all wheels riding on the rails and pinions fully engaged 1 Note it is safe to manually move the motors when the cables are disconnected from the control box Avoid moving motors by hand once the wiring is complete Doc 003594 rev 07 19 13 2013 Shop
10. installation For the X axis the stops will mount to the outside of each table side using the T nuts and socket head screws included in the bag marked end stops You will also need the 1 8 hex key that came with your pinion gears This image shows the position of the stops at the far end of the X axis away from the home position gt Loosely attach the included hardware to the stop blocks and then slide them into place on each end of the outside of the table sides gt Carefully roll the gantry to one end of the table until the wheels are resting within 4 of the end of the X rails Put a clamp on the rail to hold the car in place at that position Slide the stop blocks so that they are tight against the pinions on the two X motors Tighten the bolts to lock the stop blocks into place Repeat this step at the other end of the table VV V A Ray View behind X Car End Flate rj Pinion Position at End of Travel Wheel Bearing near End of Travel END STOP Location Doc 003594 rev 07 19 13 2013 ShopBot Tools Inc Shops nopsot ShopBot PRS Gantry Tool Table Assembly Guide 35 Install the proximity switches The proximity switches are used to calibrate the XY location of the tool and also signal the tool to stop movement before hitting the mechanical end stops They are triggered by a steel target in this case a hex bolt a 002470 Barrel prox switch 002739 10m prox cable 5 1
11. level Tape measure Set of standard and metric allen wrenches Standard ratchet and socket set Adjustable wrench Two Quick Grip style clamps recommended or C clamps a a a a a a Lightweight machine oil available at any home improvement or auto supply store Mounting the table surface Drill and standard size bits 1 Spade or Forstner drill bit 1 1 2 wood screws One gallon of general purpose wood glue Paint roller for spreading glue recommended but not required Et et Ta Lal Wel ea At least 2 sheets of material for your table surface For 96x48 tables you will need one sheet of Medium Density Fiberboard MDF and one sheet of 3 4 cabinet grade plywood When choosing plywood keep in mind that a higher number of plys typically creates a more stable board that is less likely to warp in other words don t use cheap 5 ply utility sheathing Tables larger than 96x48 will require more material per layer in order to cover the entire work area Note If you are installing a vacuum table please see the separate document titled Installing a Vacuum Hold down system Your material requirements will be different from the ones listed here Wiring the control box this document does not provide wiring instructions but it will be helpful to make sure you have all your tools first Incoming power cable please see the wiring diagram inside your control box for specifications Wire cutters and strippers N
12. note It is critical that you assemble your tool according to the measurements in the table drawing Doc 003594 rev 07 19 13 2013 ShopBot Tools Inc ShopBot_ l mana g rem ShopBot PRS Gantry Tool Table Assembly Guide 9 2 1 Visual guide to table parts and hardware Extruded aluminum table sides Upper supports angled sides Lower supports 90 sides Cross supports Table legs Gussets Except for the table levellers all of this hardware is included in the small box marked table hardware g Fer OOD O O O 5 16 Hex bolt lock washer flat washer hex nut gt E Ys 5 16 Button head cap screw T nut 1 2 Hex bolt lock washer flat washer hex nut 3 8 Carriage bolt lock washer flat washer hex nut iddedddadl tll LLtt TTT Trt Tr Table leveller Doc 003594 rev 07 19 13 2013 ShopBot Tools Inc ShopBot_ hopisoT ShopBot PRS Gantry Tool Table Assembly Guide 10 2 2 Assembly steps Attach hardware to the Table Legs Screw a leg leveler into the bottom of each Table Leg Place 5 16 hex bolts lock washers flat washers and then thread a 5 8 hex nut onto the Leg Leveler T nuts into the eight holes on each of the Table Legs as Leave this nut loose for now shown here Attach the legs to the table sides Attach the first leg by sliding the T nuts into the Hold a framing square against the leg and the extrusion grooves on the table si
13. risk of injury Place the gantry onto the rails according to the image shown below All four V wheels on the inside of the end plates should sit on the rails p ee ea a XY 0 0 Home position is at front corner Doc 003594 rev 07 19 13 2013 ShopBot Tools Inc ShopBot_ ShopBot PRS Gantry Tool Table Assembly Guide 22 Detail of V wheels engaging with the rail Mount a clamp onto one of the rails to prevent the gantry from rolling off the table during the next few steps Using the gantry as a guide for aligning the second rail Roll the gantry to the center of the table and make sure that the four wheels are all fully engaged with the rail Tighten the bolts directly under and around the gantry on the rear table side rail Move the gantry 12 in one direction and tighten a few more bolts adjusting the position of the rail if necessary Next move the gantry back in the other direction and repeat these steps working outwards from the center until the entire rail is straight and tight If you have a wheel that floats While moving the gantry down the length of the table all wheels should remain in contact with the rails If you have a wheel that floats above the rail at any point this needs to be corrected before you move on The most likely issue is that the rails are not perfectly parallel causing one of the wheels to ride up This can be corrected by loosening and carefully adjusting t
14. the holes on the YZ car plate so that they are pointed straight up 12 o clock position This places them in the lowest possible position and allows for maximum adjustment later on gt Loosely thread the nuts back onto the wheel studs gt Tilt the plate back towards the beam until the lower wheels are straddling the v rail Doc 003594 rev 07 19 13 2013 ShopBot Tools Inc ShopBot_ a SS a ShopBot PRS Gantry Tool Table Assembly Guide 24 Adjust the lower wheels Once they are in place the wheels need to be Test the wheel engagement by rolling the YZ car back and rotated into position so that they tightly engage the forth across the gantry Grab the wheel with one hand rail This allows for smooth controlled movement using light to medium pressure If the wheel stops and in the Y axis and maximum accuracy skids along the rail tighten the wheels slightly Use the flat wrench included with your hardware Do not over tighten the wheels The YZ car should glide kit to slowly turn each wheel clockwise until you smoothly across the gantry if you feel it binding up at any feel the wheel engage with the rail point then loosen the wheels slightly until it moves freely again Once the wheels are adjusted hold them in place Use the wrench to hold the each wheel in position with the wrench and double check that the nuts are while you tighten the nut on the wheel stud tightened securely Doc 003594 rev 07 19 13
15. 6 18 x 1 Hex bolt 5 16 18 Hex nut 5 16 Flat washer 5 16 18 T nut Start by installing the X axis switch targets on the rear table side Slide one of the T nuts into the lower middle groove of the extrusion Thread a hex nut onto one of the hex bolts add a flat washer and then loosely thread the bolt into the T nut Adjust the position of this assembly according to the diagram below Tighten the bolt into the T nut then tighten the hex nut down against the extrusion Fie Nl eo Py san a abbas J ee UA 9 re Doc 003594 rev 07 19 13 2013 ShopBot Tools Inc ShopBot_ hopisot ShopBot PRS Gantry Tool Table Assembly Guide 36 Hardware sequence for Proximity Switches amn 118 Barrel Nut gt Locate the 8mm threaded hole in the gantry end Roll the gantry away from the switch and thread one of plate Roll the gantry into position so that this hole the nuts onto the front side of the switch on the inside of is directly over one of the target bolts the end plate Thread the other nut onto the back side so that the end plate is sandwiched between the two Thread the barrel prox switch into the hole until it nuts comes to rest on the target Back it out several turns so that there is a 1 32 1 16 To complete this step connect the X axis prox switch 1 2mm gap between them cable marked with red tape by threading the nut on the connector onto the back of the switch
16. Bot Tools Inc _ShopBot_ et SS ShopBot PRS Gantry Tool Table Assembly Guide 27 Secure the motor cables If this is a PRS Alpha tool the motor cables will already be attached to the motor For PRS Standard tools you will need to connect the motor cables first The motor cables are labeled and color coded Just match each cable to its motor and connect the gray Wago plug J d a RIGHT both ends tightly connected WRONG notice the gap on the right side Link three wire ties together to create one long tie For each motor wrap the motor cable back towards the motor housing and secure it with the linked tie This will keep the cables safely out of the way and create a stress relief point and help to prevent damage to the motor in case the cables ever snag or pull Leave the other end of the motor cables loose for now We will run them back to the control box once the Y and X Axis E chain cable management system is installed Doc 003594 rev 07 19 13 2013 ShopBot Tools Inc ShopBot_ ShopBot PRS Gantry Tool Table Assembly Guide 28 3 2 Mounting a router or spindle Your Shopbot control box has been configured for either a router or a high speed industrial spindle Because of differences in wiring spindles and routers are not interchangeable If you need to mount a router on a tool configured for a spindle or vice versa contact tech support for instructions on how to make the necessary modifications to
17. antry Tool Table Assembly Guide 12 Attach the lower support Use the same order of 1 2 hardware hex bolt and flat washer on one side flat washer lock washer and hex nut on the back side to secure the lower support to the first set of table legs Your table should now look like this Doc 003594 rev 07 19 13 2013 ShopBot Tools Inc ShopBot_ hopisot ShopBot PRS Gantry Tool Table Assembly Guide 13 Slide the first cross support into position Add the Middle Legs Skip this step if you are setting up a 48x48 or 60x48 table Attach two 5 16 hardware assemblies 5 16 hex bolt flat washer lock washer T nut to each end of a cross support beam Then slide the T nuts into the bottom channels of the table sides and slide the cross supports into position For proper spacing of the cross supports please reference the table drawing in the back of this manual spacing will be different for each model Remember don t fully tighten any of the cross supports yet For the middle legs you will need to repeat some of the previous steps First you will need to add a second upper support However this support needs to be installed facing the opposite direction of the first one the middle leg will be sandwiched between two upper supports so keep that in mind during installation Upper support S gt Gusset Doc 003594 rev 07 19 13 T Upper support 2013 ShopBot Tool
18. de Place the leg according while you tighten the bolts to the table drawing in the back of this guide Doc 003594 rev 07 19 13 2013 ShopBot Tools Inc ShopBot_ l pete e re ShopBot PRS Gantry Tool Table Assembly Guide 11 Repeat this process with the other table side You should have one leg on each table side at this point Next temporarily attach a second table leg to the outside of each table side this will allow you to slide the rest of the components down the table sides without the legs getting in the way It should look like this Attach the first Upper Table Support and Gussets Attach two 5 16 hex bolts lock washers flat washers Insert a gusset between each table leg and upper support and T nuts to each side of one of the upper supports Attach this to the leg using 1 2 hardware hex bolt lock Slide the T nuts into the bottom channel of the far end of the washer flat washer on one side flat washer and hex nut table side where you have temporarily mounted the legs on on other side the outside of the rails Then slide this support all the way down to the other pair of table legs leaving approximately DO NOT fully tighten the bolts on the upper support 3 16 between the leg and the upper cross support for the You will need some room for adjustment when you gussets square and level the table after assembly Doc 003594 rev 07 19 13 2013 ShopBot Tools Inc ShopBot ShopBot PRS G
19. eedle nose pliers Standard sized Flat head and Phillips head screwdrivers Small suitable for electronics flat head and Phillips head screwdrivers Oooo oo Doc 003594 rev 07 19 13 2013 ShopBot Tools Inc ShopBot ShopBot PRS Gantry Tool Table Assembly Guide 4 1 2 Electrical precautions WARNING RISK OF ELECTRIC SHOCK The Control Box needs to be connected to your electrical service by a licensed electrician who has experience with industrial equipment Please do not risk personal injury or damage to your machine by having an unlicensed individual perform this job Connecting the power to your control box can be done before or after you complete assembly of the tool but it is easiest to wait until the tool is set up in its final position If you have purchased a high frequency spindle and or a vacuum blower these will also need to be connected by your electrician Wiring diagrams and specifications are located inside the door of the Control Box There are a few other electrical precautions you should be aware of Motor connections DO NOT connect or disconnect your motor cables while the control box is powered 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
20. epeat on the lower left corner of the VFD with the other mounting strap Locate the three pairs of holes on the center leg of the front side of your table The 10 VFD will attach to the upper and middle pairs Starting with the upper pair of holes thread another Button Use the remaining 1 4 20 x 5 8 Flat head screw head screw into the upper right corner of the VFD through washer and nut to secure the far right side of the the mounting strap and the table leg Secure using washer strap to the table leg Repeat with the lower strap and nut Repeat with lower right corner of the VFD Doc 003594 rev 07 19 13 2013 ShopBot Tools Inc ShopBot_ ShopBot PRS Gantry Tool Table Assembly Guide 31 This completes the mounting procedure for the 10 VFD Skip to the next section Connecting power to your Spindle Doc 003594 rev 07 19 13 2013 ShopBot Tools Inc ShopBot_ patel teat oe ShopBot PRS Gantry Tool Table Assembly Guide 32 Mounting a 16 VFD Countersinks facing up Locate the three pairs of holes on the center leg of the front side of your table The 16 VFD will attach to the upper and lower pairs skip the middle pair Attach the first mounting strap to the table leg as shown here using a 1 4 20 x 5 8 Flat head screw washer and nylock nut Repeat with the other mounting strap on the upper pair of holes Align the mounting holes at the corners of the VFD with the remaining hole
21. he rear table side s rail If the problem is constant throughout the length of travel first check that the rails are still level with each other Then measure between the rails at several points along the table to make sure they are correctly spaced according to the size of your machine tolerance is 1 16 or 16mm Distance between rails 65 13 16 77 13 16 89 13 16 125 13 16 outside to outside 167 12cm 197 64cm 228 12cm 319 56cm If these measurements are also correct please contact tech support for further assistance Doc 003594 rev 07 19 13 2013 ShopBot Tools Inc ShopBot_ ShopBot PRS Gantry Tool Table Assembly Guide 23 2 7 Place the YZ car onto the gantry For the next step place a clamp directly on either side of one of the end plates This will keep it from moving while you mount the YZ car Remove the lower wheels from the YZ car front and back view shown here and set them aside With the lower wheels removed place the YZ car onto the gantry The upper wheels will rest on the v rail on the top of the gantry beam Replace the lower wheels gt To fit the lower wheels back onto the YZ car tilt the entire assembly back towards you so that the bottom of the YZ car plate is pulled 1 2 away from the beam gt Notice the marks on the face of the lower wheels The wheels are eccentric meaning that they are mounted onto an off center threaded stud Place the wheels back into
22. head screwdriver to gently pry open the chain s access bars Use caution when moving the YZ car with the access bars open This can damage the chain Lay the YZ car cables into the chain keeping them as flat and organized as you can 1 IMPORTANT The spindle router power cord should remain separate from the other cables without crossing over them This will help prevent electrical interference issues amp Check that all necessary cables are inside the chain before closing the bars Spindle router power cord Spindle fan power cord if applicable Y axis motor cable Z axis motor cable Y axis proximity switch cable Z zero plate assembly cable vel TET A Tez isd p When all cables are inside the chain close the bars by pressing them down until you hear a click Create a small amount of slack in the cables by pulling them tight against the inside of the chain then pushing them back 1 2 1 Use a few of the included wire ties to secure the cables to the strain relief tabs at either end of the chain Doc 003594 rev 07 19 13 2013 ShopBot Tools Inc ShopBot_ l p a ShopBot PRS Gantry Tool Table Assembly Guide 41 Once the bars are closed you will need to secure the cables using wire ties and the strain relief tabs on the top side of the chain Wire Ties Start with the spindle router power cord Leave enough slack for the Z axis to move through its entire length of travel without the cord pu
23. ill need to square the spindle before continuing Doc 003594 rev 07 19 13 2013 ShopBot Tools Inc _ShopBot ShopBot PRS Gantry Tool Table Assembly Guide 29 To square the spindle Position the spindle over the table surface Once the spindle is square tighten the Place a square between the table surface and the side of the spindle bolts using a tire lug pattern to ensure as shown here Adjust the position of the spindle as needed that they are fully tightened 3 3 Mounting the VFD Applies to spindles only Skip this section if you are using a router The Variable Frequency Drive VFD controls the speed of the spindle It mounts to the table frame using the hardware kit labeled VFD mounting kit 000454 1 4 20 Nylock nut 000534 1 4 flat washer 002135 1 4 20 x 3 4 Button head screw 003064 1 4 20 x 5 8 Flat head screw Depending on the horsepower of your spindle you will have either a 10 or 16 VFD Both sizes use the same mounting hardware but placement is slightly different Measure the height of your VFD to determine which set of instructions to follow Doc 003594 rev 07 19 13 2013 ShopBot Tools Inc Shops nope ShopBot PRS Gantry Tool Table Assembly Guide 30 Mounting a 10 VFD Countersinks facing up Use a 1 4 20 x 3 4 Button head screw washer and nylock nut to attach the upper left corner of the VFD to the left most hole on the mounting strap R
24. l Table Assembly Guide 19 2 4 Mount the table surface for non vacuum tables l Please note If you are installing a vacuum hold down system on your machine please refer to the specific installation guide for vacuum tables The following instructions will not be correct for your setup If your table size is greater than 96x48 you will need to tile multiple sheets to cover the full working area Refer to the table drawing at the back of this guide for specs and measurements specific to your machine Base layer The base layer of your table should be a sheet of 3 4 Cabinet grade plywood When choosing plywood keep in mind that a higher number of plys typically creates a more stable board that is less likely to warp in other words don t use cheap 5 ply utility sheathing This layer will be bolted directly to the cross supports using 3 8 x 1 1 2 carriage bolts included in your hardware kit To locate the mounting holes gt Position the plywood on your table frame according to the table drawing It is imperative that you follow the table drawing on this step gt Clamp the sheet down to keep it from moving then use a 1 8 drill bit to drill pilot holes through the cross support holes up through the plywood Itis not necessary to drill out each hole we recommend using every other one creating a checkerboard pattern across the table gt Moving back to the top side use a 1 Forstner or Spade bit to dril
25. l a counterbore deep enough for the head of the carriage bolt to sit below the surface of the plywood gt Drill out the pilot holes with a 3 8 bit gt Press the carriage bolts into the clearance holes and through the cross supports using a mallet to tap them through if necessary gt Measure the spacing and location of the sheet one last time to make sure that it is positioned according to the table drawing gt Use the included 3 8 flat washer and hex nuts to secure the bolts For illustration purposes only Hole size spacing is not to scale Doc 003594 rev 07 19 13 2013 ShopBot Tools Inc _ShopBot hopisot ShopBot PRS Gantry Tool Table Assembly Guide 20 Spoilboard The Spoilboard is a sacrificial layer of 3 4 Medium Density Fiberboard MDF As it gets damaged over time you can re surface the board down to a perfectly flat work surface until the entire board has been used up then simply replace it with a new sheet For this step you will need about a gallon of wood glue gt Spread a thin even coat of glue across the entire surface of the base layer A cheap paint roller works great gt Have someone help you set the MDF sheet s onto the base Align this layer so that it lines up flush with the edge of the base and work quickly the glue will start to set within a minute gt For best results drive a handful of 1 1 2 wood screws into the MDF to clamp it to the base Be sure to remove these screw
26. lling tight DO NOT overtighten the wire ties DO NOT use wire ties inside the E chain Strain Relief Tabs After the cables are secured inside the chain locate the cable carriers included with the E chain kit These are installed by pressing them into the extrusion groove and twisting them one quarter turn clockwise Place two carriers in each groove evenly spaced between the lower e chain bracket and the end plate Position cable carriers evenly between E chain and end plate while using wire ties to secure cables to carriers Doc 003594 rev 07 19 13 2013 ShopBot Tools Inc ShopBot ShopBot PRS Gantry Tool Table Assembly Guide 42 As the cables exit the chain keep the spindle router cord separate while bundling the other cables into one or two cable ropes Make sure to include the X2 motor cable that you routed through the gantry beam as well as the X1 motor and the X axis proximity switch located on this side of the gantry Secure this bundle to one of the holes in the side of the end plate using a wire tie Cable management without an E chain Note This step only applies to tools with a 48 or 60 X axis Skip to the next section if you are working with a 96 table or longer If you are setting up a tool with an X axis of 60 or shorter or if you had purchased this tool before 2013 an X axis E chain is not included Continue to bundle the cable rope by adding wire ties eve
27. or sag lt ADJUST THESE LEGS Next use a framing square to check that the first cross support is square to the FRONT table side only Adjust if needed and then fully tighten the bolts on this side Repeat this step with the next cross support until everything attached to the front table side is square Tighten bolts into T nuts on the bottom of the front table side DO NOT tighten bolt patent es then fully tighten gusset bolts on the back table side Doc 003594 rev 07 19 13 2013 ShopBot Tools Inc ShopBot ShopBot PRS Gantry Tool Table Assembly Guide 16 Level the rear table side Level the rear table side by checking it against the front Place the level so that it spans the two table sides at one end then adjust the leveling feet on the back table side Once this is level move down to the next set of legs CHECK HERE ADJUST HERE ye DO NOT adjust the side that has already been made level TIP When checking a long span a longer level will give a more accurate reading We recommend using a level that spans the entire width of your table If this is not possible you can still place a shorter level on top of a straightedge Whatever you use for the straightedge make sure that it is actually straight with parallel sides Doc 003594 rev 07 19 13 2013 ShopBot Tools Inc Shophot ShopBot PRS Gantry Tool Table Assembly Guide 17 Square the rear table side
28. ry 12 16 Move the gantry along its full extent of travel to determine how much slack is needed in the cable rope Then secure it to the underside of the table using any unused holes in the cross supports until you reach the other table side where the control box will be installed Any leftover cable should be made into large loops and secured under the table Avoid making tight coils which can act as an antenna for electrical interference Doc 003594 rev 07 19 13 2013 ShopBot Tools Inc ShopBot_ hopisot ShopBot PRS Gantry Tool Table Assembly Guide 43 3 6 Install the X Axis E chain Applies to tools 96 and longer or by special order on smaller models The X axis E chain kit is a cable management system that carries all cords and cables from the machine to the control box The E chain itself will be located loose in the crate while the other parts and mounting hardware will be located in a labeled plastic bag These components are not interchangeable with the Y Axis E chain kit E chain trough 64 002158 or 74 002159 is Note Tables longer than 144 will require two or more pairs 12 E chain trough bracket Upper E chain bracket 003293 002156 E chain sized to match your table Please note The e chain will be shorter than the actual length of your table Doc 003594 rev 07 19 13 2013 ShopBot Tools Inc _ShopBot_ pP OW ShopBot PRS Gantry Tool Table Assembly Guide 44
29. s Inc ShopBot p aS ShopBot PRS Gantry Tool Table Assembly Guide 14 Next add another cross support Reference the spacing from the middle leg according to your table drawing Complete the middle leg installation by attaching the lower support to either side of the middle leg pair Add the final set of legs Slide the last remaining upper support into place then move the last two legs from the outside to the inside of the table sides Just like with the other legs bolt the gussets and upper support to the leg followed by the lower support Your table should now low like this Before moving on to the next step check to make sure that you don t have any leftover cross supports or gussets We have included extra pieces of all your table hardware so don t be too concerned if you have a few extra nuts and bolts left over Doc 003594 rev 07 19 13 2013 ShopBot Tools Inc Shophot ShopBot PRS Gantry Tool Table Assembly Guide 15 2 3 Level and square the table frame Level and square the front table side From this point on we will refer to the table sides as front and rear The front side of the table will be closest to the 0 0 point as indicated on your table drawing Using the longest level you have 6 or 8 feet is ideal set the level on the front table side and adjust the leg levelers until this table side is level Make sure that the center leg properly supports the beam and does not cause the table side to bow
30. s after 30 minutes 2 5 Mount the rails Remove the rails from the long white boxes that came strapped to your crate and locate the 5 16 x 3 4 Button head screws and 5 16 T nuts in your hardware package Place one screw into the counter bored holes in the top of each rail then loosely thread a T nut onto each screw As you did earlier make sure that the flange on the T nut faces the inside of the groove on the table side Orient one of the rails so that the V track is facing the outside of the table Guide the rail onto the table so that the T nuts fit into the groove on the top face of the table side Do not fully tighten the bolts on either rail Doc 003594 rev 07 19 13 2013 ShopBot Tools Inc Shophot ShopBot PRS Gantry Tool Table Assembly Guide 21 Push the rail assembly towards the inside of the table so that it sits flush with the inside face of the table side Start at one end of the table and tighten the bolts down the length of the rail As you do this check each side of the rail with a level or straightedge to be sure that the rail is perfectly straight Once this first rail is straight and the bolts are fully tight you can move on to the next step placing the gantry onto the rails DO NOT tighten the bolts on the second rail 2 6 Place the gantry onto the rails CAUTION The gantry is heavy and must be lifted by 2 or more people Use proper lifting techniques to reduce your
31. s on the mounting straps On the right side of the VFD thread a 1 4 20 x 3 4 button head screw through the VFD strap and table leg Secure using washer and nylock nut On the left side of the VFD the hardware will go through the VFD and strap only This completes the mounting procedure for the 16 VFD Doc 003594 rev 07 19 13 2013 ShopBot Tools Inc ShopB nopso ShopBot PRS Gantry Tool Table Assembly Guide 33 Connect power to your spindle ern B ee eee ee D instructions in serious injury Power is supplied to the spindle through the The spindle fan built into the spindle housing has a orange cord coming from your VFD Run this cord separate power cord that you will wire into the control underneath the table towards the rear table side box later Connect the plug and tighten the screw that and then plug it into the spindle Push the cord locks it into place lock up until you feel it click into place Doc 003594 rev 07 19 13 2013 ShopBot Tools Inc ShopBot_ hopisoT ShopBot PRS Gantry Tool Table Assembly Guide 34 3 4 Mount the mechanical end stops and proximity switches Mechanical end stops The mechanical end stops primarily exist to stop the gantry from rolling off the table When properly installed they are also a useful tool for squaring the gantry to the table frame The Y axis stops have already been installed but we will fine tune their position later in the
32. ts and get familiar with the terminology and directions we ll be using This is only a quick overview to help get you started For each assembly section there will be a visual guide with all parts and hardware clearly labeled Doc 003594 rev 07 19 13 2013 ShopBot Tools Inc ShopBot_ Major components a 4 gt Doc 003594 rev 07 19 13 ShopBot PRS Gantry Tool Table Assembly Guide 6 The base of your machine is referred to as the table frame The two long aluminum extrusions on each side are called table sides which create the path of travel for the X axis The table sides and related components are included in the long cardboard package secured to the top of your 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 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 also controls the height of the cutter head either a router or high speed spindle depending on your tool 2013 ShopBot Tools Inc ShopBot_ ShopBot PRS Gantry Tool Table Assembly Guide 7 Control box The control box is the brain of your machine and contains a control board motor drivers and numerous other electronic components that allow the tool to move
33. ust mounted on the YZ car 3 6 Install the Y Axis E chain The Y axis E chain kit is a cable management system for the Y and Z axis cords and cables The E chain itself will be located loose in the crate while the other parts and mounting hardware will be located in a labeled plastic bag Please note Tables longer than 96 will also include an X axis E chain kit The components are not interchangeable Typically the Y axis e chain will be the shorter than the X so compare the two if you are unsure which chain to use Doc 003594 rev 07 19 13 2013 ShopBot Tools Inc ShopBot_ ShopBot PRS Gantry Tool Table Assembly Guide 38 Begin by mounting the lower e chain bracket onto the top of the gantry Use two of the Twist in T nuts included with the E chain mounting kit Simply drop them into the grooves Loosely attach the lower mounting bracket using two 5 16 18 x 5 8 Flat head screws Position the bracket according to the diagram Distance from end plate to edge of lower echaln bracket See chart below Y axis cutting width Distance from end plate to first edge of lower bracket Measured gantry length eee 32 48 22 5 88 ES Gere er arerers 48 66 31 5 EEE 60 73 37 5 eee 72 90 43 5 109 126 61 5 Mount the Y axis Upper E chain Bracket onto the back of the YZ car Use two 1 4 20 x 1 2 socket head screws 1 4
34. wire wrap a bare copper wire around the outside of the hose and then route an additional wire through the inside of the hose Twist these together and connect them to the alligator clip on the Shopbot end Make a connection from the dust hose wire s to an exposed screw bolt or bare metal on the body of your dust collector This will direct all static discharge away from your Shopbot Doc 003594 rev 07 19 13 2013 ShopBot Tools Inc
35. witch coming through the hole in the center of the gantry beam Y axis proximity switch Spindle or router power cord Spindle fan cable if applicable Z axis proximity switch for ATC tools only Pneumatic air hoses for ATC tools and optional air drills or pneumatic assists a Me Th ee Ir e Sei Ea ey NOTE As with the Y axis E chain keep the spindle router power cord separate from the other cables This helps to prevent electrical interference that may cause connection problems while you are running the machine Doc 003594 rev 07 19 13 2013 ShopBot Tools Inc Shops hopisot ShopBot PRS Gantry Tool Table Assembly Guide 46 3 7 Install the Dust Skirt Flying objects Risk of eye injury Safety glasses required The dust skirt is designed to collect dust and small material chips It does not replace the need for good safety practices including wearing eye protection at all times when the machine is in operation Tighten thumb Screw once dust skirt is set to desired height 94 verre i i n Wenen i Position the dust skirt directly under the extrusion of the Z axis The mounting shaft of the dust skirt slides up into the This setup allows you to easily adjust the height of the bottom of the Z axis extrusion If needed loosen the dust skirt Simply tighten the thumb screw to hold the thumb screw on the back of the extrusion first shaft in place Doc 003594 rev 07 19 13 2013
36. with precision accuracy and power It connects to your PC through a single USB cable X Y Z axis and directions of travel X 0 Y 0 Home position VFD For spindles only This controls speed and power for your spindle The control box provides the VFD with on off signals but speed is controlled through an RPM controller unit which connects to your PC through a separate USB cable In all of our assembly and training instructions we will frequently refer to the machine by each axis so It will help to become familiar with them before you start Another frequently used term is the XY home position which is indicated here and on your table drawing at the back of this guide For a detailed explanation of your machine s coordinate location system please reference the full user s manual For now just make sure that you understand the directions of travel for the X Y and Z axis as well as where the XY home position is located Doc 003594 rev 07 19 13 2013 ShopBot Tools Inc ShopBot_ l ma na g ee ShopBot PRS Gantry Tool Table Assembly Guide 8 Section 2 Table assembly Time to get started The diagrams in this manual depict a ShopBot with a generic 96x48 table Depending on the size and shape of your tool the table layout may look a little different fewer or more legs different shape etc For specific dimensions reference the table drawing included in the back of this assembly manual Please
37. your control box Router option If you purchased the router option a mounting bracket has already been attached to your YZ car and aligned square to the Z axis gt gt Spindle option Remove the 10 32 grounding screw from the side of the mounting bracket Slide the router into the plastic sleeve inside the bracket Make sure that the hole in the plastic is located so that the ground screw can contact the router Tighten the 5 16 button head screw on the bracket to secure the router Replace the ground screw so that it touches the router Do not overtighten This completes the router installation Skip the next section mounting the spindle and VFD and continue with the section titled Installing the Proximity Switches Move the gantry back to the far end of the table and pull the Z axis down to its fully lowered position You will either need an assistant to hold the axis in place while you work or clamp it in place gt Your spindle has already been fitted with an aluminum mounting plate Hold the spindle up against the front of the extrusion so that the extrusion s clearance holes are aligned with the threaded holes in the mounting plate gt Thread the included 5 16 18 x 1 1 2 socket head bolts through the back of the extrusion into the mounting plate Do not use washers gt Tighten the bolts just enough to pull the spindle plate flat against the extrusion Do not tighten the bolts any further as you w
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