Colombo Spindle with Yaskawa V1000

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Introduction

The Colombo spindle and Yaskawa V1000 variable frequency drive (VFD) come preprogrammed and should require only basic wire hookups prior to operation. Refer to the guide from the manufacturer that comes with your Colombo spindle for latest updated instructions. This document applies to

Colombo spindles with Yaskawa V1000 3HP & 5HP variable frequency drives for the PRSalpha and

PRSstandard control boxes. Be aware that some variants of Colombo Spindle have a 24v spindle fan which requires a 24v power supply.

Contact information

ShopBot Tools, Inc.

3333B Industrial Dr

Durham, NC 27704

919-680-4800 or 888-680-4466 www.shopbottools.com

SBG 00320 Colombo Manual 14 12 01.doc Copyright 2014 ShopBot Tools, Inc

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Table of contents

Introduction ......................................................................................... 1

Contact information ...................................................................... 1

Connect spindle power cable .................................................................. 3

Route power cable into box and connect ground wire ........................ 3

Contactor configurations ............................................................... 4

Connect power conductors ............................................................ 5

Connect the VFD to the control board ...................................................... 5

PRSalpha control box (built after 06/2014) ...................................... 5

PRSalpha control box (built before 06/2014).................................... 6

PRSstandard control box ............................................................... 6

Connect 24 volt spindle fan .................................................................... 7

PRSalpha control box (built before 06/2014).................................... 8

PRSstandard control box ............................................................... 9

Testing and troubleshooting ................................................................. 10

Using the ShopBot keypad with the Colombo spindle ...................... 11

Troubleshooting ................................................................................. 11

If the spindle is rotating the wrong direction .................................. 11

If there is no power to the VFD .................................................... 12

PRSalpha control box (built after 06/2014) .................................... 12

PRSalpha control box (built before 06/2014).................................. 12

SBG 00320 Colombo Manual 14 12 01.doc Copyright 2014 ShopBot Tools, Inc

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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.

Connect spindle power cable

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

Route power cable into box and connect ground wire

• After the ShopBot control box and the VFD are mounted, run the black power cable from the

VFD to a vacant cord grip in the control box. Note that this is not the Rotec cable window intended for the smaller motor and sensor cables.

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

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

SBG 00320 Colombo Manual 14 12 01.doc Copyright 2014 ShopBot Tools, Inc

Contactor configurations

Determine the contactor configuration of your control box.

Note: The “domestic” configuration applies to the United States, Canada, and Mexico.

Control boxes for all other countries are shipped with the “international” configuration.

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Domestic – 1 spindle

Connect to #1

Domestic – 2 spindles

Connect first spindle to #1, second spindle to #5

International – 1 spindle

Connect to #2

International – 2 spindles

Connect first spindle to #2, second spindle to #6

SBG 00320 Colombo Manual 14 12 01.doc Copyright 2014 ShopBot Tools, Inc

Connect power conductors

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

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Single phase spindles

2T1 – Black wire

6T3 – White wire

After all power wires are in place, tighten the cord grip nut.

Connect the VFD to the control board

Three phase spindles

2T1 – Black wire

4T2 – White wire

6T3 – Red wire

The VFD receives start and stop instructions from the ShopBot control box using a small brown or grey cable. This cable will be factory installed at the VFD end and must be attached to the control board.

PRSalpha control box (built after 06/2014)

• Locate the F1 and C1 terminals for one spindle. A second spindle would connect to F2 and C2.

• Strip back approximately 1/4” (6mm) of insulation from both the black and white. The red wire is not used and should be clipped back.

• Route the cable through the Roxtec cable window.

• Connect the black wire to the F1 position (F2 if spindle 2).

• Connect the white wire to the C1 position (C2 if spindle 2).

SBG 00320 Colombo Manual 14 12 01.doc Copyright 2014 ShopBot Tools, Inc

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PRSalpha control box (built before 06/2014)

• Connect the two-conductor cable labeled “VFD”, included with the control box, into the VFD terminals on the control board labeled “VFD1”. For a second spindle use the terminals labeled

“VFD2”. Connect the black wire to the “FWD” terminal and the white (or green) wire to the

“DCM” terminal.

• Make sure that the VFD and control box are OFF before continuing. Locate the brown cable coming from the VFD. Run this cable through the Roxtec cable window on the right side of your control box.

• Connect the black and white wires from this cable into the terminal blocks on the control board labeled

VFD(1). For a second spindle, use the terminal labeled

VFD(2). These terminal blocks are located near the lower left corner of the control board.

• Connect the black wire to the FWD terminal and the

white wire to the DCM terminal. The red wire is not used and should be clipped back.

PRSstandard control box

Route the brown cable from the VFD into the control box. Locate the terminal block marked

“Spindle 1” on the corner of the control board.

Connect the black wire to F1, and the white wire

to C1.

SBG 00320 Colombo Manual 14 12 01.doc Copyright 2014 ShopBot Tools, Inc

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Connect 24 volt spindle fan

Some Colombo spindles also have a cooling fan that runs with 24 volt power. If it does there will be a small grey cable labeled “24 volt” coming from either the spindle or the VFD. There will be two wires

(red and black) in this cable which must be attached to a 24 volt power source in your control box. All

PRSalpha and PRSstandard models released after 9/5/07 come with a 63/24v power supply in the control box. The 63 volt side powers the drivers and the 24 volt side powers spindle fans and relay boards. If your model does not have a 24 volt power supply, you will need to add one.

PRSalpha control box (built after 06/2014)

The updated PRSalpha control card for AR style motors has 24 volt power available specifically for the spindle fan.

• Locate the fan terminal on the left side of the control board.

• Strip back approximately 1/4 inch (6mm) of insulation from both the red and black wires at the loose end of the cable from the fan connection plug.

• Run the cable through the Rotec cable window.

• Connect the red wire to the position labeled “FAN+”.

• Connect the black wire to the position labeled “FAN-”.

SBG 00320 Colombo Manual 14 12 01.doc Copyright 2014 ShopBot Tools, Inc

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PRSalpha control box (built before 06/2014)

Earlier PRSalpha control boxes have a 24 volt power supply, but no dedicated position on the control board. The fan cable will get power directly from the 24 volt power supply.

• Locate the 24v power supply already installed in the control box.

• If not already done, strip back approximately 1/4 inch (6mm) of insulation from both the red and black wires at the loose end of the cable from the fan connection plug.

• Run the cable through the Rotec cable window.

• Connect the red wire to an available positive (+) terminal.

• Connect the black wire to an available negative (-) terminal.

SBG 00320 Colombo Manual 14 12 01.doc Copyright 2014 ShopBot Tools, Inc

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PRSstandard control box

PRSstandard control boxes get power from a toroid transformer. The positive power will come from the

24 volt fuse and the ground will be at an available ground passion on the control board.

• Locate the 24v fuse and an available control board ground terminal (labeled

“G”).

• Strip back approximately 1/4 inch

(6mm) of insulation from both the red and black wires at the loose end of the cable from the fan connection plug.

• Route the cable inside the control box.

• Connect the red wire to the right side of the fuse marked "24 V DC" circled at left.

• Connect the black wire to any empty

ground (G) connection on the control board. Ground positions are indicated at left with arrows.

SBG 00320 Colombo Manual 14 12 01.doc Copyright 2014 ShopBot Tools, Inc

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Testing and troubleshooting

Test the spindle fan

Before you run your first test cut, verify that the spindle fan is running properly. This is very important for the safe operation of your spindle!

To test:

• Turn on your control box.

• Check that all emergency stop switches are disengaged (twist counter-clockwise to release).

• On PRSalpha tools, press the blue RESET button on your 3-button pendant.

Your spindle fan should now be running. If not, ensure it is connected to the proper 24 volt power source and ground location.

Engage the interlock switch

Note the spindle lockout switch on the front of your control box (All PRS models built after 2012). In order for the spindle to run this must be set to ENGAGED, using the key that came attached to one of your collet wrenches.

To change bits, turn the key to DISENGAGED and remove it. If the spindle is wired through the control box properly, this prevents any chance of the spindle powering on while you are changing the bit.

SBG 00320 Colombo Manual 14 12 01.doc Copyright 2014 ShopBot Tools, Inc

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Using the ShopBot keypad with the Colombo spindle

The ShopBot control keypad can also be used to run the spindle(s) when you want to warm up the spindle or do diagnostics:

• Open the keypad from the ShopBot control software using the [K]eyboard command.

• Click on Output #1 to run spindle #1 and/or Output #2 to run spindle #2 (light turns green). Note that #1 or #2 can also be activated with the ALT-1 or ALT-2 keystrokes.

• On the PRSalpha, push the green START button to run the spindle.

• On the PRSstandard, push OK on the software spindle start prompt.

• When the keypad is closed, the FWD signal from the ShopBot control box to the spindle will be cut off and the spindle will stop. The keypad will time out after a few minutes.

Troubleshooting

If the spindle is rotating the wrong direction

WARNING

Spinning the spindle in reverse can cause serious damage to tooling, spindles, and machine which can result in the collet nut loosening and causing tooling failure and personal injury. Do not opperate spindle in reverse.

• Disconnect power to contol box and VFD.

• Carefully remove the VFD face and disconnect data cable connecting the face to the body.

• Reverse wiring (on any two legs) going to the spindle. These are labeled T1 (U), T2 (V), or T3 (W).

Any two of them can be switched to reverse the direction of rotation.

• Reconnect data cable and replace the VFD face.

SBG 00320 Colombo Manual 14 12 01.doc Copyright 2014 ShopBot Tools, Inc

If there is no power to the VFD

• Check that the power disconnect for the spindle is on.

• Check that the spindle/router settings on the control board are set to the spindle side.

PRSalpha control box (built after 06/2014)

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Locate the spindle/router switches near the middle of the control board. The close-up shows switch #1 set for spindle operation and switch #2 set to router operation.

PRSalpha control box (built before 06/2014)

Locate the spindle/router jumpers on the control board next to the yellow LED lights. The close-up shows jumper #2 set for router operation and jumper #1 set for spindle operation.

SBG 00320 Colombo Manual 14 12 01.doc Copyright 2014 ShopBot Tools, Inc