888-680-4466 • ShopBotTools.com
Control Box Wiring
For PRSstandard Tool
© Copyright 2016 ShopBot Tools, Inc. page 1
PRS Standard Control Box Wiring • May 10, 2016
© Copyright 2016 ShopBot Tools, Inc. page 2
PRS Standard Control Box Wiring • May 10, 2016
Table of Contents
Introduction:.............................................................................................................................................5
Installation:...............................................................................................................................................5
Powering the PRSstandard Control Box..................................................................................................5
Exploring the PRSstandard Control Box..................................................................................................5
Inside the PRSstandard Control Box.......................................................................................................6
Troubleshooting:.......................................................................................................................................7
Using the Roxtec Fixture..........................................................................................................................7
Connecting VFD and Spindle...................................................................................................................9
Connecting the VFD logic cable into control box.....................................................................................9
Attaching fan connection plug to HSD spindle........................................................................................9
Attaching fan cable to 24v power supply...............................................................................................10
Connecting power cable from VFD to spindle.......................................................................................10
Routing and connecting motor cables to motors..................................................................................10
Connecting Remote Stop Switch Cable................................................................................................12
Connecting the Cables from the Proximity Switch and Z zero Plate.....................................................13
Seal the Cable Entry...............................................................................................................................13
Ground the Dust Collection System.......................................................................................................13
Connect USB Cable...............................................................................................................................14
Remote Stop Switch..............................................................................................................................14
Mounting the Switch..............................................................................................................................14
© Copyright 2016 ShopBot Tools, Inc. page 3
PRS Standard Control Box Wiring • May 10, 2016
© Copyright 2016 ShopBot Tools, Inc. page 4
PRS Standard Control Box Wiring • May 10, 2016
Introduction:
The control box is installed on the front left of the machine. This document covers hooking up the motors, proximity switches, spindle, VFD, emergency stop, and the three button pendant.
Installation:
Please refer to PRS Assembly Guide for control box installation. This document can be found at http://
www.shopbottools.com/ShopBotDocs/files/PRSAlphaAssyGuideBinder.pdf.
Powering the PRSstandard Control Box
The power to the PRSstandard control box should be wired into a fused disconnect by a licensed electrician familiar with industrial equipment.
The power requirements for the PRSstandard control box and router/spindle vary according to configuration. A schematic for the power requirements for the specific configuration is inside the door of the
PRSstandard control box.
Note: Since the power requirements for a Porter Cable router and for a spindle are different, different
components are installed in the PRSstandard control box depending on which was requested. This is
NOT user configurable; configurations were specified at the time these components were ordered. If
different power requirements are necessary, please contact customer support.
Exploring the PRSstandard Control Box
Disconnect electrical power to the PRSstandard control box prior to this step!
After the electrician has hooked up the PRSstandard control box and router or spindle, open the side of the box with a screwdriver (quarter turn).
For safety reasons the door is designed lock open or closed unless the
main power disconnect is turned off.
Note: The PRSstandard control box has an interlock for the router/spindle. This interlock allows the power to the router/spindle to be disconnected, while not interrupting power to the machine. This adds additional
safety for manual tool changes during a cutting file.
Depending on the model, the control box may not look exactly the same
as illustrated.
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PRS Standard Control Box Wiring • May 10, 2016
Inside the PRSstandard Control Box
Note: Not all control boxes will be the same as pictured depending on specifications.
The contactors, located at the top of PRSstandard control box, are the large relays that control power
to the cutting head. They are controlled by software and relays on the control board for a router, and
the E-Stop (main power disconnect) for a spindle. The size of the contactor may vary with the power
requirements of the device it is powering.
1. Router/Spindle Interlock
2. Grounding Strip
3. Main Power Disconnect
4. Fuses
5. Contactors
6. Control Board
7. USB Cable
8. Roxtec Fixture
9. Motor Cables
10.Output Switches
11.Input Switches
12.Motor Drivers
13.Toroidal Transformer
The Fuses in the PRSstandard control box (US 60Hz power) are dependent upon the setup:
• Porter Cable router (single): 1 5A fuse, 1 15A fuse
• Spindle: 1 5A fuse, no other fuses (spindles are protected by fused disconnect before the PRSstandard Control Box.)
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PRS Standard Control Box Wiring • May 10, 2016
Troubleshooting: Although the fused disconnect should protect the PRSstandard control box, if power is lost to everything in the PRSstandard control box, check the fuses and replace them with identical parts if necessary.
Using the Roxtec Fixture
Remove the Roxtec Fixture and pull cables through the side side of the control box. Ensure there is at
least 10” of play available for the cables.
The Roxtec Fixture gives all wires a tight entry and will seal the control box against dust and debris.
Below is the manufacturer’s suggested installation procedure.
Lubricate the inside surfaces of the frame with Roxtec
Assembly Gel especially in the corners.
Insert the cables through the frame.
Adapt the modules, which are to hold cables. Peel off
layers until you achieve the gap seen in picture 4.
Achieve a 0.004” to 0.04” (0.1-1.0 mm) gap between the
two module halves when held against the cable.
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PRS Standard Control Box Wiring • May 10, 2016
Lubricate all modules thoroughly, both on the inside and the
outside surfaces, before installation.
Insert the modules from the back of the frame opening. If
possible, start with the largest modules.
To add more wires, loosen the fixture and remove as
many layers as required to accommodate the wires.
Then feed wire through and reinstall.
Tighten the compression unit firmly to seal the frame.
Maximum 7.83 ft. lb (10 Nm). A good indication is when
the assembly gel is squeezed out between the modules.
Notes:
• For optimum reliability, wait 24 hours or longer after installation before exposing the
cables to strain or pressure.
• Try to route cables perpendicularly through the frame.
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PRS Standard Control Box Wiring • May 10, 2016
Once all of the cables have been attached inside the control box, run the cables through the modules
and tighten the fixture to keep dust out of the control box. It may be necessary to run more than one
of the smaller cables in the same gasket. Do not tigten the Roxtec modules completely (step 7) until all
cables and wires are routed inside and out of the control box.
Connecting VFD and Spindle
Connecting the VFD logic cable into control box
The logic cable is pre-wired into the VFD from the factory. It is the one coming out of the VFD without
a connector. Inside it will be two wires, brown and white. This cable needs to be installed into the control box.
Be sure the VFD is powered off before proceeding!
Run the logic cable from the VFD through the Roxtec fixture
on the right side of the control box. Use any available cable
spaces or double up with an existing small wire.
Connect the brown wire and the white wire from the logic
cable into the VFD terminals on the Control Board labeled
“SPINDLE 1” (For a second spindle, you would use the terminals labeled “SPINDLE 2”). For Spindle #1, connect the brown
wire to the “F1” terminal and the white wire to the “C1” terminal. For a second spindle, use the terminal connections “F2”
and “C2”.
Attaching fan connection plug to HSD spindle
Be sure the VFD is powered off before proceeding!
Attach the fan connection plug to the front face of the HSD spindle.
Tighten the screw inside the fan connection plug.
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PRS Standard Control Box Wiring • May 10, 2016
Attaching fan cable to 24v power supply
The PRSstandard comes with a 24v power supply already
installed in the control box.
Strip back ~ ¼” of insulation from both the red and black
wires at the loose end of the cable from the fan connection plug.
Route the cable into the control box.
Connect the red wire to the right side of the fuse marked
“24 V” (circled at left). Connect the black wire to any
empty ground (G) connection in the blue terminals on the
board.
Connecting power cable from VFD to spindle
Plug the electrical connector into the HSD spindle power plug.
Depress the metal retainer clip until it snaps in place.
Re-connect and turn on the control box. Verify that the fan powers
up and starts turning when the control box is powered.
NOTE: Ensure power is turned off before proceeding!
Routing and connecting motor cables to motors
The motor cables are pre-wired to the PRSstandard control box
from ShopBot. Plug each motor cable to its color-coded motor. Route all the cables from the control box to the back of the
machine. The Red X2 motor cable needs to be fed through the
hole in the back endplate and gantry until it comes out the front
endplate.
The Blue (Y-axis) and White (Z-axis) cables should be routed
over the gantry through the Y-axis E-chain and to the Y- & Z-axis
motors.
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PRS Standard Control Box Wiring • May 10, 2016
The PRSstandard motors come with the mounting plate and pinions pre-installed. Slide the provided heat-shrink onto the cable before hooking it up. At this point the motors should be in their correct
mounting location on the machine and should have the corresponding color motor cable routed to the
correct motor.
Caution: Make sure that X1 and X2 are connecting to the correct motor!
Press connectors for the motors together. Making sure that the connectors are securely fastened, slide
the heat-shrink over the connection.
Use a heat gun or hair dryer to heat the heat shrink until it tightly envelopes the connection.
This is important; this process helps to keep out dust and debris from these connections and
helps to provide added safe guards against tampering and accidental disconnections.
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PRS Standard Control Box Wiring • May 10, 2016
Connecting Remote Stop Switch Cable
The PRSstandard comes with a Remote Stop Switch. Hitting this “Stop” button
will immediately stop the PRSstandard tool and keep it stopped until the switch is
unlocked. his button also turns off the router/spindle.
The blue wire terminal boxes at the bottom of the control board is where
the remote stop switch, X&Y proximity switches, and the Z zero plate are
connected. Refer to the wiring diagram above to wire in these peripherals.
Note: The terminal blocks can be removed to make wire insertion easier.
Note: Some of the terminal positions will have more than one wire.
To install the remote stop, route the cable into the control box and connect the white wire to G
(ground) and the black to 4/ST (input 4).
Note: Any ground (labeled “G”) will work for any ground wire. The ones labeled in the diagram
were selected for their proximity to other companion wire attachment points or to prevent too
many wires from going to one terminal block.
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PRS Standard Control Box Wiring • May 10, 2016
The blue wire terminal boxes at the bottom of the control board is where the remote stop
switch, X&Y proximity switches, and the Z-zero plate are connected. Refer to the wiring diagram above to wire in these peripherals.
Note: The terminal blocks can be removed to make wire insertion easier.
Note: Some of the terminal positions will have more than one wire.
To install the remote stop, route the cable into the control box and connect the white wire to G
(ground) and the black to 4/ST (input 4).
Note: Any ground (labeled “G”) will work for any ground wire. The ones labeled in the diagram
were selected for their proximity to other companion wire attachment points or to prevent too
many wires from going to one terminal block.
Connecting the Cables from the Proximity Switch and Z zero Plate
Insert the black wire from the proximity switch cable for the X-axis into the blue terminal block
labeled 2/PX (Input 2) on the control board. Insert the black wire from the proximity switch cable for the Y-axis and into 3/PY (Input 3) on the same terminal block. Join the blue wires from
both of the switches together into a G (ground) terminal and join the brown wires from both of
the switches and place them in the +24 (24V) terminal.
Verify that when the PRSstandard control box is powered up, a red LED in the body of each
proximity switch on the tool stays on until it is triggered by coming near a target.
Connect the Z-zero plate. The black wire goes in the 1/ZZ (Input 1) terminal and the green
wire goes into a G (ground) terminal. The red wire goes to +5 (5V) terminal.
Note: the 5V terminal is only used by the Digitizing Probe.
There is a USB cable connector wired into the control board. It is used for attaching the USB
cable that will connect the control box to a computer. This connector is on a short cable that
exits on the right side of the control board. Feed the longer 10ft cable supplied with the ShopBot through the Roxtec fixture and plug it into this connector. Do not plug the USB cable into
the computer yet.
Seal the Cable Entry
After all the cables have been attached into the PRSstandard Control Box and onto the machine, install gaskets around them and close Roxtec fixture. Double check that the cables are
properly installed and perform final adjustment and tightening.
Ground the Dust Collection System
If a dust collection system is installed, ground it to the System Ground. See the document
titled “Installing the PRS Dust Skirt” for details on grounding the dust skirt hoses and dust
collection device.
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PRS Standard Control Box Wiring • May 10, 2016
Connect USB Cable
Ensure the ShopBot control software is installed on the computer.
The USB cable provided is 10 feet long. If it is necessary to increase the length of the USB cable, use
a USB 2.0 hub at the junction between the cable sections. Using a cable longer than 10 feet, without a
hub as a booster, will increase electrical interference and may result in loss of signal.
Remote Stop Switch
The Remote Stop Switch comes with a long cable to allow the switch to be mounted in a convenient
location. Keep the remote stop switch away from devices that have their own power source, such as
the spindle or router, or a vacuum system.
Mounting the Switch
A good spot for mounting is on the front side of the X-Car, with the cable routed to the back of the tool
through the center of the beam. Holes are pre-drilled in this location. Other good locations are on the
side of the table, at the computer station, or on the wall near the ShopBot.
There are a number of ways to attach the switch. These include mounting tape, Velcro, or screws.
Four screws are provided in a plastic bag attached to the cable.
On the back of the remote stop switch there are some slots in the plastic, which allows the screws to be fastened into the switch.
Place the remote stop switch onto the X-Car and secure with four screws.
© Copyright 2016 ShopBot Tools, Inc. page 14