The ShopBot Automatic Tool Changer (ATC) automates the bit changing process during projects that require multiple tool changes. Powered by an HSD ES915 5hp spindle, the ShopBot automatic tool changer (ATC) is now available for our PRSalpha CNC systems. It can also be installed on existing PRSalpha CNCs. The ATC system includes the HSD spindle, a pneumatically assisted Z axis, six-position tool bank,  fixed-position Z-zero plate, chuck holder, pneumatically operated dust skirt and ATC interface card. Additional tool positions may be added. The 4ft tool can accommodate 8 total tools, the 5ft can accommodate 10, and the 6ft can accommodate 12 tools.

The Automatic Tool Changer reduces the time a project must remain on the machine by automatically changing cutting bits between cuts, thus eliminating the need for the CNC operator to change and calibrate tools by hand. The ATC allows the PRSalpha to cut complete projects where different tooling is required

The ShopBot ATC is available in the following voltages:

(#12520) HSD ATC 5HP 220V 1PH

(#12521) HSD ATC 5HP 380/460V 3PH

(#12540) HSD ATC 5HP 230V 3PH

The ShopBot ATC can be an upgrade to E series (aluminum table sides) PRTalpha machines with the addition of a Retro Z-axis. The E series table allows for crucial table positioning without a complete rebuild of the table. See ATC Table Setup before installation.

ATC Installation (Mechanical)

This document will assume that, except for the Table assembly (drawings provided at the end of this section) the ShopBot has been assembled using the instructions provided in the ShopBot Assembly Manual. We will assume that the ShopBot is at a point in which it is able to connect and move under the control of a computer. Wire/cable management may be left until the ATC installation has been completed.

Table Setup **** Very Important ****

The location of the table bed is extremely critical for ATC. Excess overages in the X dimension could mean tooling collisions, insufficient cutting area, and dropped tooling. Use the Table Drawing included with your manual or select the correct drawing here.

Table Setup (earlier PRTalpha models)

If you are just setting up your ShopBot please skip down to next section, this is for installation of the ATC on slightly older tools. Since the chances are that your table is already assembled we need to move the X rails down some so that the table is in the correct relation to the table sides (which hold the X rails). This will be done by loosing the bolts that are attached to the table side extrusions. When loose, the table sides will be slid down in the positive X direction until the table in the position called out in the table drawings for your size ShopBot. Reference the table drawings at the end of this section for table positioning.

Mounting the Spindle

The ShopBot ATC is equipped with a 5HP HSD spindle. The spindle is electric fan cooled but also has air cooled lower bearings. The air required for the lower bearings is 60 psi (4 bar). The spindle also has an internal drawbar that holds the tool cones in place during cutting; this requires 90-100 psi (6-7 bar). Air lines will be run and connected during the pneumatic installation section of this document.

With the ShopBot powered up, position the YZ-car so that it is in a location that the front and back of the Z-axis may be reached. Using the Keypad mode (K), move the Z-axis to a height close to the table’s surface. Stand the spindle on end as seen to the left. Position the Z-axis up or down using the Keypad mode again until the holes in the Z-axis align with the mounting holes in the spindle plate. Using the (6) 5/16 x 1 1/2” socket heads tighten the spindle securely to the Z-axis.

Mounting the Dust Collection Guide

 

Remove the black plastic cap from the top of the Z-axis by prying with a flat head screwdriver. Using the (2) ¼-20 x 1/2” button heads, and (2) ¼-20 T-nuts preassemble the hardware thru the dust hose guide bracket. It maybe necessary to slit the top sticker down the left side of the Z-axis extrusion. Slide the bracket down into the extrusion and tighten the bolts. Replace the black plastic cap when tight. Use the hose clamps provided to run a 4” dust collect hose to the dust skirt from an overhead dust system. Hold off until the end to connect, due to possible interference thru the rest of the installation.

Mounting the Upper Y-axis E-Chain Bracket with Solenoids.

The pneumatic assist and solenoids will be pre-mounted on the upper Y-axis E-chain bracket. Using (2) ¼” lock and flat washers and (2) ¼-20 x ½” socket head screws, align the holes in the Y-axis E-chain bracket with the tapped holes (if looking from the front of the Z-axis) on the back left side. Tighten the socket heads securely in place.

Mounting the Tool Bar

Using (4) 5/16x ¾” button heads, (4) 5/16 flat washers, and (4) 5/16 T-nuts preassemble the tool bar mounting bracket. Insert the tool bar mounting brackets with hardware into the bottom extrusion of the tool bar (tab facing up).

Then position the tool bar inside 2nd slot from the top of the table side extrusion. Position the tool bar off the end of the table based on the table drawings. Note: It may be necessary to adjust this dimension in or out slightly so that the spindle is able to reach the clips on PRTalpha models.

Level the tool bar by placing a level on the fixed Z zero plate (pre-attached to tool bar). Once level securely tighten all 5/16” button heads in tool bar mounting bracket.

Mounting the Tool Chuck

The tool chuck is used to hold the tool holder cone while changing collets and bits. This will be mounted to the inside of the table side or on the wall (wherever it is convenient really).

Use the 5/16 x 3/4” button heads and T-nuts to mount the tool chuck in the second slot from the bottom of the table extrusion. We suggest mounting this closest to the tool bar so that it convenient to the tool holders, but if it this is not optimal for your setup, mount it where it is most convenient.

Mounting the Main Air assembly

 

Using (2) 5/16x 3/4 button heads and (2) 5/16 drop in T-nut, mount the pneumatics in the bottom extrusion slot on the back table side. Position the pneumatics as close to center of the table as possible.

Mounting the ATC Dust Skirt

You will most likely want to hold off on installing the ATC dust skirt until after you have run the calibration routine. It is easier to perform the routine without the dust skirt. This will be detailed later, come back to this section after the calibration routine in done.

 

Using (2) 5/16x 3/4 button heads and (2) 5/16 drop in T-nut, mount the pneumatics in the bottom extrusion slot on the back table side. Position the pneumatics as close to center of the table as possible.

Using the (4) M6x10mm socket heads tighten the spindle securely to the side of the spindle. Note: The slot in the ATC dust skirt allows for varying degrees of height adjustment to accommodate tooling lengths and varying projects. This height may need to be adjusted to make sure there is no interference while making tool changes and while still providing an adequate amount of dust extraction.

ATC Installation (Pneumatic)

This portion of the installation will cover the pneumatic system and its routing and the hook-ups required

Main Air Supply

The ShopBot ATC requires 100 psi of air (7 bar) for normal operations. The main air supply should be clean, dry, un-oiled air. It may be necessary to apply inline filters (not supplied) to achieve this requirement.

Caution: Do not attach a charged air line directly to the pneumatic assembly during installation. This assembly should only be charged once the system is completed.

Locate the 3/8” tubing provided. Insert one end into the push-in fitting on the regulator side of the assembly (marked 1).

Route the rest of the tubing through the Echains up to the YZ car. See the Y-axis Echain section of the PRS Gantry Assemble section for routing cables etc. through the EChains.

Take the 3/8” tubing (UB3/8U) and route it to the back right side of the spindle (as if facing the spindle). Connect the tubing into the open push-in connection Tee (marked 1).

Locate the ¼” tubing. On the back left side of the spindle (as if facing the spindle) is a small regulator. At the bottom of this regulator there is a push-in connector that is most easily accessed from the other side. Insert the ¼” tubing into the push-in connector (marked 2).

In order to make sure that the Z axis travel is not shortened due to hose length, move the Z axis as close to the table surface as possible. Route the ¼” tubing from small regulator to the front side of the spindle and connect to the push-in marked 4 bar (marked 2).

Using the smaller 5/32” tubing, connect the top push-in connector of the Tee on the back right side of the spindle (marked 3).

Cut neatly to length and connect to the front push-in connector on the blocking valve for the pneumatic assist (marked 3).

Using the ¼” tubing, connect the bottom push-in connector of the same Tee located on the back right side of the spindle

Cut neatly to length and connect to the top push-in connector on the blocking valve for the pneumatic assist located on the left side of the spindle (marked 4).

Located on the back left side of the spindle, use the ¼” tubing in the first push-in to the right of the regulator (marked 5).

Neatly route the ¼” tubing to the front side of the spindle and connect to the push-in marked 6-7 bar (marked 5).

These last two connections on the solenoid control the back gate to the ATC dust skirt. It is important to hook up the pneumatics to the dust skirt before running the calibration routine only to keep the loose air lines from whipping carelessly when the air is applied to the system. Located on the back left side of the spindle, use the 5/32” tubing in the second push-in to the right of the regulator (marked 6).

Connect this tubing to the push-in Tee on the dust skirt closest to the front of the spindle (marked 6).

Located on the back left side of the spindle, use the 5/32” tubing in the last push-in to the right of the regulator (marked 7).

Connect this tubing to the remaining Tee push-in on the dust skirt (marked 7).

The main air supply should be supplied to the filter and regulator assembly with a standard air line that has a 1/4” female quick disconnect (not supplied).

Attach the air hose to the male end of the disconnect, located on the assembly.

ATC Installation (Electrical)

This portion of the installation will cover the electrical system and its routing and the hookup requirements. If you have received your ShopBot ATC new with a table there will be instructions that do not pertain to you. Some portions are not relevant because these portions will have been performed at ShopBot Tools, Inc. prior to shipping.

Installing the ATC Interface Board

WARNING! ELECTRIC SHOCK CAN KILL Use extreme caution when working near live electrical circuits. Dangerous voltages exist inside the power supply that can cause serious injury or death These instructions are intended for use by a licensed electrician.

Turn off all power going into the alpha control box. Place the ATC interface into the rails on the left of the control box. It may be necessary to drill 2 small holes if the vintage of your control box does not have these holes already.

The wiring harness that comes attached to the ATC interface board will need to be connected to the control board. This will require that the existing connection be removed and reinstalled into the new terminal blocks of the new harness. It is recommended that the old connections be labeled before removing so that they can be placed back in the correct positions once the wiring harness is in place.

Remove the two pin terminal block from the control board marked VFD(1) and replace it with the two pin terminal block on the wiring harness.

Remove the five pin terminal block from the control board marked outputs 24V+,8,7,6,5, and replace it with the left most five pin terminal block on the wiring harness.

Remove the five pin terminal block from the control board marked outputs 4,3,2,1,gnd and replace it with the middle five pin terminal block on the wiring harness.

Remove the five pin terminal block from the control board marked inputs 5,6,7,8,+24 and replace it with the right most five pin terminal block on the wiring harness.

Connect the Emergency Stop Switch and the 3-Button Pendant

The ShopBot 3-Button Pendant allows you to place the reset, start and extra emergency stop buttons at a convenient location away from the PRSalpha Control Box. It has been prewired so that hooking it up to your PRSalpha Control Box entails plugging the terminal block from the pendant into the control board inside the PRSalpha Control Box. Your PRSalpha Control Box may differ slightly from pictures in the manual depending on which model you have. If you have a 3-Button Pendant, your PRSalpha Control Box will not have Start/Reset buttons.

Note: If you try to run the ShopBot without the E-Stop connected, Input #4 will flash red on the computer screen and the ShopBot Control Software will not allow the ShopBot to move.

Run the cables from the 3-Button Pendant and the separate E-stop switch into the PRSalpha Control Box through the Roxtec opening and plug in the terminal blocks as shown below.

Below: The PRSalpha Control Box before the terminal block from the 3-Button Pendant is attached. Note that the terminal block for the separate E-Stop has not been attached yet.

Below: The terminal block from the separate E-Stop has been plugged in and the 3Button Pendant block is being positioned.

Below: Terminal blocks from the 3-Button Pendant and from the separate E-Stop in place.

Connect Cables from the Proximity Switch and Z-zero Plate

Inside the PRSalpha Control Box, take the Proximity Switch cable for the X-axis and place its black wire into Input 2 on the blue terminal block on the control board. Then take the Proximity Switch cable for the Y-axis and place its black wire into Input 3 on the same blue terminal block on the Control Board. The blue wires from both of the switches are placed in Gnd (ground). The brown wires from both of the switches will be placed in the +24V position on the blue output terminal block. Note that the terminal blocks can be removed to make wire insertion easier.

When the PRSalpha Control Box is powered up a red LED in the body of the proximity switch out on the tool will stay bright until it is triggered by coming near a target.

Now, connect the Z-zero plate and the fixed Z-zero plate mounted to the machine. Both of these cables will be wired into the same input since they perform similar functions. The only difference is that the fixed Z-zero plate will only have a single black wire. The black wires from both the fixed and Z-zero plate goes in the Input#1 terminal and the white wires goes into a ground terminal (Gnd; you can use the one on the Input terminal block or the one on the Output block). The red wire goes to 5+ (it is only used by the Digitizing Probe).

Connecting the Z-axis Prox Switch

Locate the prox switch on the back side of the Z-axis. This is located just under the Z-axis motor. Using the 90 degree prox switch cable, plug the cable onto the back of the prox switch and screw the connection tight with the thumb screw. This cable will be pre-wired and marked as Z-axis prox and cooling air, route through the Y-axis Echain and into the control box.

Inside the control box, route the prox cable to the lower edge of the ATC interface board. Connect the blue three pin terminal block to the location marked Z Prox Switch Note: The 24V (+24) and ground (GND) will be used in this terminal block when attaching the solenoids cooling air in later sections.

Connecting the Solenoids

Locate the row of Solenoids mounted on the upper Y-axis Echain bracket. Connect them with the cables provided. The cables will be marked accordingly. Connect the solenoid with its matching cable. Route these cables through the Y-axis Echain and into the control box.

Bring the cable marked Cooling Air into the control box. Route the cooling air cable to the lower edge of the ATC interface board. Since there is not a dedicated location for this connection on the board we are going to share the connection from the Z Prox Switch. Connect the blue wire from the cooling air cable into ground (GND) and the black wire to 24V (+24).

Bring the cable marked Dust Skirt into the control box. Route the Dust Skirt cable to the ATC interface board. Connect the blue three pin terminal block to the location marked Dust Skirt.

Bring the cable marked Tool Release into the control box. Route the Tool Release cable to the ATC interface board. Connect the blue three pin terminal block to the location marked Tool Release.

 

Connecting the Spindle

 

Locate the spindle cables. Remove the small socket head screw from the front face of the spindle’s plug (4mm allen wrench needed). Plug the cables into the mating plug of the HSD spindle and secure socket head screw so that plug in locked in place. Route the cabling from the spindle through the Y-axis Echain into the control box and over to the left side of the ATC interface board. The spindle cable should all ready have the terminal blocks ready for installation from ShopBot Tools, Inc.

 Connect the longest blue terminal block to the ATC interface board in the location marked Spindle Sensor Cable. Connect the other blue terminal block to the location marked Frequency Drive Logic

Connecting the Pressure Switch 

 

Locate the pressure switch on the back side of the incoming air supply pneumatics mounted under the back table side. Use the spade connectors on the provided cabling and connect the white wire to the tab marked (COM) and the black wire to the tab marked (NC). Route the other end with the two pin terminal block into the control box. Mark this cable as Pressure Switch.

Inside the control box, route the pressure switch cable to the ATC interface board. Connect the blue two pin terminal block to the location marked pressure switch

NEXT: Install the ATC Software and Setup ATC