Router to Spindle Upgrade RBK Box

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1 ShopBotTools.com Router to Spindle Upgrade RBK Box ShopBot Tools, Inc B Industrial Drive, Durham NC Copyright 2016 ShopBot Tools, Inc. page 1

2 Copyright 2016 ShopBot Tools, Inc. page 2

3 Table of Contents Introduction...5 Parts List...5 Tool List...5 Preliminary Setup...6 Contactor Removal...7 Removing Wires and Fuses...8 Reassembly...9 Spindle Installation...11 Introduction...11 Removing Router...11 Router Mount Removal...12 Spindle Mounting...13 Spindle Connecting...14 Wiring Diagram (120V Router Configuration)...16 Wiring Diagram (220V 1Phase Spindle Configuration)...17 Wiring Diagram (230V 3Phase Spindle Configuration)...18 Copyright 2016 ShopBot Tools, Inc. page 3

4 Copyright 2016 ShopBot Tools, Inc. page 4

5 Introduction This document describes changing a 110 RBK Router control box to a Spindle control box, and converting the power system from 110v (10270) to 220v single phase spindle (10272) or 220v three phase spindle (10273) depending on the spindle purchased. The ShopBot (15355) Router to Spindle Upgrade Kit for RBK control boxes is needed for this conversion. It is advised that licensed electricians perform this upgrade for liability reasons and local code requirements. Parts List Spindle Upgrade Kit: Spindle with Mounting Plate Attached Contactor Wires Fuses Labels 6 1/4 bolts Tool List Screwdriver, Flathead Screwdriver, Philips Square, Carpenter Wrench, Allen, 1/8 Wrench, Allen, 3/16 Wrench, Allen, 1/4 WARNING! Electric Shock Can Kill! Use extreme caution when working near electrical circuits. Dangerous voltages exist inside the power supply that can cause serious injury or death. Use extreme caution throughout this installation. Copyright 2016 ShopBot Tools, Inc. page 5

6 Preliminary Setup Disconnect the incoming power from the control box. Make sure the power has been shut off at the main panel before opening the door to the control box. A new 220v circuit will be installed to supply power to the box at a future point in this document. Make sure that the RBK Router to Spindle Upgrade Kit (15355) shown below is on hand. With power to the control box disconnected, open the control box door. Remove the wires supplying power to the top side of the main disconnect switch and ground. The ground from the incoming power will be located on the grounding bar at the bottom of the control box. Remove this cable from the control box. A new 220V single phase line or a 230V 3phase line (based on spindle requirements) will need to be added later in this installation. Remove the voltage sticker that is over the main disconnect (120VAC) and replace it with the label provided (220V or 230V). This will help to keep things easily recognizable for future diagnostics. Copyright 2016 ShopBot Tools, Inc. page 6

7 Contactor Removal The existing contactor will be swapped with a larger capacity contactor included in the kit. Insert a flathead screwdriver into the tab at the base of the contactor and gently pry outward until the contactor releases from the din rail mounting. Note that the wires are still connected to the contactor. Copyright 2016 ShopBot Tools, Inc. page 7

8 Removing Wires and Fuses Remove the contactor wires starting with position A1 (Blue/ White K1-) and position A2 (Blue K1+A). These will be reconnected to the new contactor later. Copyright 2016 ShopBot Tools, Inc. page 8

9 Trace the last two wires from the existing contactor and remove them from the control box. Remove (Red 1LF1) from the bottom of the 2nd fuse holder. Remove (White 1N) and (#2 White 1N) from the bottom of the main disconnect 4T2. The other end is on small terminal connection under where the contactor was located. Remove (Red 1L) from the top of the 2nd fuse holder and connect it to the bottom of the main disconnect - position 2T1. Remove both the 10 &15 amp fuses. Loosen the screws on each side of the two jumpers and remove the jumpers by sliding them toward the top of the control box. Keep these jumpers for later use. Reassembly The contactor, both fuses (10 & 15amp), four wires (Red 1L, Red 1LF1, White 1N, & #2White 1N), and two jumpers should be removed from the control box. Install Blue/white wire (K1-) into position A1 along the top of the new contactor and the Blue wire (K1+A) in position A2 on the bottom of new contactor. Connect one end of the Black L1 wire into contactor position (1L1). Connect Black 3L wire into contactor position (5L3). Make sure all connections into the contactor are tight and remount onto the din rail. Place the top edge onto the din rail and then lower the bottom edge. A flathead screwdriver may be necessary to lift the tab so that contactor locks firmly to the din rail. Copyright 2016 ShopBot Tools, Inc. page 9

10 Take the loose end of the Black L1 wire from the contactor and wire it into the main disconnect at position (2T1). This connection will be shared with a Red wire going to the top of the 1st fuse holder. Install the Black 3L wire from the contactor and the Black 3L wire from the kit and wire them into the main disconnect at position (6T3). The loose end of the 2nd Black 3L will connect to the top of the 2nd fuse holder. Locate the Black 3LF1 wire in the kit and secure one end to the bottom of the 2nd fuse holder and the other end to the top left position on the terminal connections. Use one of the Jumpers removed earlier on the top middle set of terminal screws. From left to right, the top row of the terminal connection should be: Black (3LF1), Jumper from screw 2 & 3, and Red (1L that was already in place). The bottom row of screws should remain the same. Install two 5amp fuses from the kit into the fuse holders. Remove the label above the fuse holders and replace with the 5amp fuse label from the kit. Use the wire ties provided for cable management as necessary. Remove the Blue wire (K1+) from the blue terminal block on the control board. Clip the ferruled end of (K1+) and replace it with the forked crimp connector included in the kit. Copyright 2016 ShopBot Tools, Inc. page 10

11 Loosen the right side of the 24V DC 2 amp fuse connection (middle glass fuse) and secure the new forked connection for (K1+) with the existing wire marked (24+F6). Double check all connections and screws. When certain that all is in order, bring the incoming 220V or 230V into the control box and wire into the top of the main disconnect. Spindle Installation Introduction It is imperative to follow these directions closely. Spindle misalignment can result in bad cuts, inaccurate locations, and poor bit life. A spindle that is not properly tightened can produce run-out which creates bad cuts, poor surface finish, inaccurate dimensions, and increased wear on bits. Pay close attention during spindle installation and regularly inspect and readjust as required. Removing Router It is recommended to remove the router from the mount before removing the mount from the Z-axis, but this is not required. If not removing the router separately, skip to Removing router mount section. It is recommended to have a helper as the router/mount combo is heavy and unwieldy to hold in one hand while removing bolts. This can result in injury, damage to the router and mount, or damage to the table/floor. 1. Cut zip ties and remove power cord from the router and E-chain. If satisfied with the cable routing, remember the current path as the spindle power could be routed identically. Copyright 2016 ShopBot Tools, Inc. page 11

12 2. Use an 1/8 Allen wrench to loosen the set screw holding the router in place. This will be the screw protruding from the right side of the router mount. 3. While supporting the router, use a 3/16 Allen wrench to loosen the screw that clamps the router mount onto the router. 4. Lift router from mount. Router Mount Removal While supporting the mount, use a 1/4 Allen wrench to remove four bolts and the router mount from the YZ-car. Copyright 2016 ShopBot Tools, Inc. page 12

13 Spindle Mounting There are six holes in the YZ car - the bottom four holes were used to mount the router and the top two are only used to mount the spindle. The six tapped holes on the spindle mounting plate correspond with the holes on the YZ car. The holes not used by the spindle are for other spindle models and will not be used. Hold up the spindle to the YZ car and loosely attach the six screws into the spindle to hold it in place. Put spindle over the cutting surface and use a square on the side as shown to adjust the spindle until it is perpendicular. Copyright 2016 ShopBot Tools, Inc. page 13

14 Move the tool down far enough in the Z-axis to allow access to all six screws. Tighten screws to hold spindle in the proper alignment. Once screws are snug, tighten them according to the diagram on the right. Spindle Connecting Plug the spindle power cable into outlet on front of spindle and secure with metal clip. Copyright 2016 ShopBot Tools, Inc. page 14

15 Connect fan power into three pronged connection above spindle power. Secure with small Philips head screw in center of connector. Copyright 2016 ShopBot Tools, Inc. page 15

16 Wiring Diagram (120V Router Configuration) Copyright 2016 ShopBot Tools, Inc. page 16

17 Wiring Diagram (220V 1Phase Spindle Configuration) Copyright 2016 ShopBot Tools, Inc. page 17

18 Wiring Diagram (230V 3Phase Spindle Configuration) Copyright 2016 ShopBot Tools, Inc. page 18

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