Control Box Wiring - ShopBotTools · through the cable entry, connect the black wire and the white wire from the grey cable into the terminal blocks labeled “C1” and “F1”,

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Control Box WiringFor PRSalpha Tool

PRS A AR Control Box Wiring • June 29, 2017




Table of Contents

Introduction .............................................................................................................................................5Installation ...............................................................................................................................................5The PRSalpha Control Box .....................................................................................................................5Inside the Control Box .............................................................................................................................6Connecting VFD and Spindle ..................................................................................................................7Connecting VFD Spindle .........................................................................................................................8Attaching Fan Cable ................................................................................................................................8Powering the Fan ....................................................................................................................................9Connecting VFD Cable ............................................................................................................................9Connect Motor Cables ..........................................................................................................................10Install Emergency Stop Switch and Three Button Pendant ..................................................................11Wire Proximity Switches and Z Zero Plate ............................................................................................12Using the Cable Entry ...........................................................................................................................13





Introduction:

The ShopBot PRSalpha 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.

WARNING: This equipment is supplied by two sources of power. Contact may cause electric shock or burn. Turn off and lock out system before servicing.

Installation:

Please refer to PRSalpha Assembly Guide for control box installation. This document can be found at http://www.shopbottools.com/ShopBotDocs/files/PRSAlphaAssyGuideBinder.pdf.

The PRSalpha Control Box

Disconnect electrical power to the control box.

Open the side of the box with a screwdriver (quarter turn). Note that the door cannot be opened or closed unless the power switch is turned off.

The control box has an interlock for the router/spindle. This interlock allows the power to the router/spindle to be disconnected without interrupting power to the machine. The switch must be engaged for the router/spindle to run. This provides added safety during manual tool changes.

The contactors, located at the top of control box, are large relays that control power to the equipment. They are controlled by the tool software and during an emergency stop. The size of the contactor may vary with the power requirements of the device it is powering. Additional contactors for additional devices (for example, a second router or spindle) are added to the left of the standard contactors.

The fuses in the control box (US 60Hz power) are dependent upon the setup:

Porter Cable router (single): 1 x 20A fuse, 1 x 3A fuse, & 1 x 15A fuse

Porter Cable routers (two): 1 x 20A fuse, 1 x 3A fuse, & 2 x 15A fuses

Spindle: PRSalpha spindle boxes only have fuses for the power supplies and alpha motor drivers, 1 x 20A fuse & 1 x 3A fuse. No other fuses are needed for spindles since they are protected by a fused disconnect before the control box itself. For specifications on branch circuit protection required for the spindle and control box, please refer to the documentation included in the door of the control box.



Troubleshooting:

Although the fused disconnect should protect the control box, please check the fuses and replace if necessary if power is lost to any part of the control box.

Inside the Control Box

Depending on the model, the control box may not look exactly the same as illustrated.

1. Disconnect switch

2. Grounding strip

3. Fuses

4. 24V power supply

5. 5V power supply

6. Contactors

7. Motor drivers

8. Cable entry

9. Inputs/Output

10. Emergency stop switch

11. 3 button pendant connector

12. AC power cord grips

Note: #10 and #11 now have connectors instead of terminal blocks on newer boards for a simpler install.



Connecting VFD and Spindle

Run Power to the VFD

Power to the VFD must be connected to the proper contactor in the PRSalpha control box. This is necessary for the safety systems to work correctly if the emergency stop button is pressed. All VFDs supplied by ShopBot have a power cable pre-installed at the factory.

Be sure to turn off the control box and disconnect from incoming power before starting installation.

After control box is in place and the VFD is mounted, run the black cable from the VFD through the cord grip. These can be found on the left end of the control box.

Insert the cable from the VFD through the cord grip, pushing enough wire into the control box to reach the spindle contactor(s) and the ground bus bar.

Refer to the documentation included in the door of the ShopBot control box to locate the contactors. Connect to contactor “M1” for a single spindle. (There will be an additional contactor to the left of contactor “M1” for a second spindle. This would be labeled “M5” and the documentation will specify where each spindle should be installed.)

Connect the green wire from the VFD power cable to the ground bus bar, located under the main disconnect in the control box.



Connect the line conductors from the VFD to the proper contactor using the following terminals:

For three phase spindles (shown to the left):

2T1 – Black wire4T2 – White wire6T3 – Red wire Ground bus bar – Green wire

For single phase spindles:

2T1 – Black wire4T2 – White wireGround bus bar – Green wire

Note: PRSalpha tools with single phase spindles made prior to mid-2015 (control box numbers 102XX) have an alternate wiring setup. If in doubt, have your electrician refer to the wiring diagram included in the control box door.

2T1 – Black wire6T3 – White wireGround bus bar – Green wire

Connecting VFD Cable

NOTE: Make sure the control box and VFD are OFF before proceeding. The VFD has been pre-wired with the grey VFD logic cable. Note that Colombo spindle models contain two grey cables, so be sure to use the cable labeled “VFD Logic”.

Once the VFD logic cable is run into the control box through the cable entry, connect the black wire and the white wire from the grey cable into the terminal blocks labeled “C1” and “F1”, respectively (for a second spindle, use the terminals labeled “C2” and “F2”). The red wire is not used and should be clipped back.

Attaching Fan Cable

NOTE: Skip this step for Colombo spindles, as the fan connection is integrated into the electrical connection.

Make sure that power to the control box is disconnected.

Locate the fan connection plug with the attached cable and attach to fan connector on the front of the spindle.

Tighten the screw inside the fan connection plug to secure in place.



Powering the Fan

The fan wire is pre-wired into the VFD on Colombo spindles. It is labeled “Fan 24V”. For all other spindles, use the fan cable installed in the previous step.

Strip back 1/4” of insulation from both the red and black wires at the loose end of the cable from the fan connection plug.

Connect the red wire to the terminal marked “FAN+” and the black wire to the “FAN-” terminal.

Connect Spindle Cable

Plug the connector on the end of the spindle cable into the mating connector on the spindle. Depress the metal clip until it snaps in place to lock the connection.

Turn on the control box. The fan should power up and turn.



Connect Motor Cables

CAUTION: Turn off power at the control box disconnect switch before proceeding.

Insert the bundle of cables from the X e-chain through the cable entry on the right end of the control box. Plug each motor cable into its corresponding driver (the black boxes arranged horizontally in the control box). The white plug fits the white receptacle on the driver in only one way. Ensure it is properly aligned and fully seated before proceeding.

From the entry point of the cables (right to left):

• The X1 cable (red band labeled “X1”) and the X2 cable (red band labeled “X2”) go to drivers “D1” and “D2” respectively, at the far right. As these two drivers are both located on channel 1, they move simultaneously. The two drivers can operate interchangeably, but reversing the order will change the diection of the X-axis.

• The Y motor cable (blue band labeled “Y”) is plugged into channel 2 (DR3), the third driver from the right.

• The Z motor cable (white band labeled “Z”) is plugged into channel 3 (DR4), the 4th driver from the right.

Additional motors (accessory Z, etc.) would be plugged into the additional drivers to the left of the four standard drivers. Ribbon cables would be connected to labeled pin blocks shown on the left in the above picture (DR5, DR6, or DR7) and the channel selected using the corresponding jumpers on the right end of the board.



Install 3 Button Pendant

WARNING: It is imperative to install and locate the 3 Button Pendant at the operator station. Improper installation may cause bodily harm or tool damage!

The 3 Button Pendant allows the reset, start and extra emergency stop buttons to be set at the operator station away from the machine. Connect the three button pendant connector to the control board inside the control box (see diagram below).

Plug the connector from the Emergency Stop Button box into the control board inside the control box (see diagram below).

Connect Emergency Stop and 3 Button Pendant

Run the bundle of cables from the gantry to the control box and through the cable entry on the end of the control box. Plug in the longer connector (3 Button Pendant) into its corresponding socket on the board. Plug the smaller connector (for the Emergency Stop) into the socket beside the longer one.



Connect Proximity Switches and Z Zero Plate

The X, Y, and Z proximity switches and Z Zero Plate cable are pre-wired to the appropriate terminal blocks in the bundle of wires on the gantry. The pre-wired terminal blocks are connected to the input terminals on the bottom right edge of the interface board inside the control box (see picture below for correct placement).

X Prox (Red):

• Black wire - 2/PX• Blue wire - GND• Brown wire - +24VY Prox (Blue):• Black wire - 3/PY• Blue wire - GND• Brown wire - +24VZ Prox (White):• Black wire - IN5• Blue wire - GND• Brown wire - +24VZ Zero Plate (Green):• Black wire - 1/ZZ• Blue wire - GND• Brown wire - +5V

When the control box is powered up, a red LED in the body of the proximity switch on the tool will stay lit until triggered when it nears a metal target.



Using the Cable Entry

Once all of the cables have been attached inside the control box, install the modules around the cables, insert them in the cable entry 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 module. Do not tighten the cable entry completely (step 7) until all cables/wires have been routed inside and outside of the control box.

Lubricate the inside surfaces of the frame with Roxtec Assembly Gel, especially in the corners.

Insert end of cable into control box.

Adapt the modules that hold the cables. Peel off layers until you achieve the gap seen in step 4.

Achieve a 0.004” to 0.04” (0.1-1.0 mm) gap between the two module halves when held against the cable.



To add more wires, loosen the fixture and remove as many layers as required to provide space. Then feed through and reinstall.

NOTE: For optimum performance, allow for at least 24 hours after installation before exposing the cables to strain or pressure. Try to route cables perpendicularly through the frame.

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.

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.

Documents

Control Box Wiring - ShopBotTools · through the cable entry, connect the black wire and the white wire from the grey cable into the terminal blocks labeled “C1” and “F1”,