Tormach 1100M - Visual Installation Guide

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4: INSTALLATION

©Tormach® 2023

Specifications subject to change without notice.

Page 38 Tormach 1100M® Operator's Manual (Version 1223A)

For the most recent version, see tormach.com/support

4.1 VISUAL INSTALLATION GUIDE

Main Page

Table of Contents5
Safety21
Intended Use22
Machine Standards22
American National Safety Institute (ANSI)22
Occupational Safety and Health Administration (OSHA)22
Safety Overview22
Safety Messages22
Personal Injury22
Property Damage23
Safety Decals23
On the Electrical Cabinet Door23
Next to the Main Disconnect23
On the Spindle Nose24
Information Decals24
Serial Number Plate24
Machine Safety24
General Shop Safety24
Operational Safety25
General25
Tooling26
Workholding26
Electrical Safety26
Noise Exposure26
About Your Machine29
Performance Expectations30
Cutting Performance30
Resolution and Accuracy30
Machine Specifications31
Site Requirements33
General Site and Space Requirements34
Site Requirements34
Space Requirements34
Operator Workstation Reference34
Electrical and Power Requirements35
Electrical Requirements35
Power Requirements35
Options for Non-Conforming Sites35
Installation37
Visual Installation Guide38
Before You Begin39
Installation Tools and Items39
Move the Pallet39
Assemble the Machine Stand39
Unpack the Machine Crate41
Install Core Components42
Install the Y-Axis Bellows Spacers42
Install the Axis Motors43
Y-Axis Motor43
X-Axis Motor44
Z-Axis Motor44
Lift and Move the Machine45
Required Tools45
Before You Begin45
Assemble the Lifting Bar Kit45
Connect the Machine for Lifting46
Lift the Machine46
Install the Tool Tray and Drip Guard47
Install the Controller47
Install the Controller Arm48
Install the Monitor49
Make Monitor Connections49
Install the Pathpilot Controller50
Set up the Pathpilot Operator Console50
Install the Oiler51
Make Automatic Oiler Connections51
Make Manual Oiler Connections52
Set up the Manual Oiler52
Verify the Installation52
Power on the Machine52
Power off the Machine54
Verify Limit Switch Function54
Verify Axes Function54
Verify Spindle Function55
Install Accessory Components56
Set up the Automatic Oiler56
Look for Leaks and Clear the Lines56
Specify the Interval Time56
Specify the Actuation Time57
Install the Power Drawbar57
Required Tools57
Air Requirements57
Installation57
Prepare the Machine58
Disassemble the Original Drawbar58
Assemble the Power Drawbar59
Install the FRL61
Set up the FRL62
Make Air Connections62
Adjust the Power Drawbar64
Adjust the Drawbar Tension64
About Drawbar Tension64
Adjust the Initial Setup65
Install the Flood Coolant Kit66
Adjust the Coolant Pump Motor Strapping66
Set up the Flood Coolant Kit66
Install the Automatic Tool Changer (ATC)67
Required Tools68
Required Tools for Installation68
Required Tools for Verification68
Air Requirements68
Before You Begin68
Disassemble the Power Drawbar Button68
Install the Air Cylinder69
Mount the Automatic Tool Changer (ATC) Bracket69
Install the Main Assembly70
Level the Automatic Tool Changer (ATC)70
Prepare the Machine70
Examine Perpendicularity in the y Direction71
Examine Perpendicularity in the X Direction71
Examine the Alignment of the Carousel Door Opening71
Make Air Connections73
Make Electrical Connections73
Verify the Installation73
Adjust the Power Drawbar74
Adjust the Drawbar Tension74
About Drawbar Tension75
Adjust the Initial Setup75
Adjust the Tool Tray Load Position76
Verify the Alignment77
Set the Tool Change Height77
Adjust for Rotational Play77
Install the 4Th Axis78
Install the M/MX A-Axis Driver (PN 38954)78
Set the Driver DIP Switches78
Install the A-Axis Motor Driver79
Set up the 6 In. or 8 In. Rotary Table79
Required Tools79
Unpack the 4Th Axis80
Lubricate the Rotary Table80
Adjust the Backlash80
To Set the Backlash by Positioning the Backlash Adjustment Screw81
To Set the Backlash by the Numbers81
Mount the Rotary Table81
Set up the Microarc 482
Required Tools82
Install in Machine82
Center the Chuck Mounting Plate83
Verify the Installation84
Install the Chip Pans84
Install the Backsplash and Splash Guard85
Install the Enclosure86
Before You Begin86
Required Tools87
Install the Enclosure Panels87
Install the Left Rear Panel87
Install the Left Side Panel87
Install the Left Side Window Retainers87
Install the Left Front Panel88
Install the Enclosure Splice Plate88
Install the Right Rear Panel88
Install the Right Side Panel88
Install the Right Side Window Retainers88
Install the Right Front Panel89
Install the Left Top Panel89
Install the Right Top Panel90
Install the Upper Front Panel90
Install the Front Lower Panel90
Install the Rear Splash Shield91
Assemble the Linear Rails91
Install the Linear Assemblies91
Assemble the Front Doors92
Install the Front Door Assemblies93
Install the Door Latch94
Install the Floodlights94
Install the Side Windows94
Install the Access Panel95
Install the Stainless Steel Wear Guard96
Use the Maintenance Labels96
Write the Date on the Maintenance Labels96
Replace the Windows97
Set up the Door Lock Switch Kit (Optional)97
Install the Door Lock Switch Kit97
Update Pathpilot99
Download and Install an Update File from the Controller99
Install an Update File from a USB Drive99
Enable the Door Lock Switch Kit100
Install the Pathpilot Operator Console100
Required Tools101
Prepare the Machine101
Remove the Right Side Window101
Remove the Operator Box101
Install the Mount Arm101
Mount the Console102
Assemble the Controller and Keyboard Tray102
Lift and Secure the Controller Assembly104
Make Electrical Connections105
Reassemble the Machine107
Pathpilot Operator Console Drill Template108
Set up the Pathpilot Controller109
Specify the Date and Time109
Specify the Keyboard Language109
Configure the Optional Touch Screen Kit109
Update Pathpilot109
System Basics111
System Reference112
Machine Table112
Spindle112
About the Spindle112
Axes112
Basic Controls Reference112
Machine Controls112
Pathpilot Interface113
Pathpilot Interface Overview115
About Pathpilot116
Notebook Section116
Main Tab116
File Tab116
Settings Tab117
Offsets Tab117
Conversational Tab117
Probe Tab118
Status Tab118
Persistent Controls118
Program Control Area118
Position Status Area119
Manual Control Area119
Keyboard Shortcuts119
Manage Pathpilot Versions119
Download and Install an Update File from the Controller119
Install an Update File from a USB Drive120
Install a Previous Version of an Update File120
Pathpilot Tools and Features123
Create and Load G-Code Files124
Load G-Code124
Transfer Files to and from the Controller124
About System Files124
Preview G-Code Files124
Access Recent G-Code Files125
Close the Current Program125
Edit G-Code125
Edit G-Code with a Text Editor125
Edit G-Code with Conversational Programming125
Change the Step Order126
Create a New Job Assignment126
Load an Existing G-Code File126
Edit a Job Assignment126
Read G-Code126
Expand the G-Code Tab126
About the G-Code Tab126
Search in the Code126
Set a New Start Line127
Lead-In Moves127
Change the View of the Tool Path Display128
About the Tool Path Display128
Use Conversational Programming129
About Conversational Programming129
Create a Face on a Part129
About Facing130
Facing in Pathpilot130
Facing Reference130
Create a Profile on a Part130
About Profiling131
Profiling in Pathpilot131
Profiling Reference132
Create a Pocket on a Part132
About Pockets133
Creating Pockets in Pathpilot133
About Circular Pockets133
About Rectangular Pockets133
Create Hole Locations on a Part (Drill/Tap)134
About Drilling and Tapping135
Drilling and Tapping in Pathpilot135
Create a Drilling Sequence135
Create a Tapping Sequence136
Drilling and Tapping Reference136
Create Threads on a Part136
About Thread Milling137
Thread Milling in Pathpilot137
Thread Milling Reference137
Create Text to Engrave on a Part138
About Engraving138
Import a DXF File138
Working with Layers and Shapes139
Change the Layer or Shape Cut Order139
Adjust the Tree View Window139
Working in the Preview Window139
Machine Settings and Accessories139
Enable an Internet Connection140
Connect to Dropbox140
Enable Automatic Updates141
Change the Network Name142
Select the Spindle Type142
Change the Screen Orientation142
About Portrait Screen Layout143
Specify the Tool Change Method144
About Automatic Tool Changes144
About Manual Tool Changes144
Disable Limit Switches144
Limit G30 Moves145
About G30145
Enable the On-Screen Keyboard145
About Soft Keyboards145
Enable the USB M-Code I/O Interface Kit146
Enable Tooltips146
Enable the Door Lock Switch Kit146
Enable Feeds and Speeds Suggestions in Conversational Routines147
Specify Probing and Tool Measuring Options147
Use the Rapidturn Interface147
Specify the 4Th Axis Rotary Type147
Enable the 4Th Axis Homing Kit147
Use a USB Camera148
About USB Cameras148
Manual Recording148
Automatic E-Stop Loop Recording ("Dashcam")149
Review Video and Image Files149
File Naming Convention150
G-Code Commands150
File Naming Conventions150
Use M01 to Take Pictures150
Set up G-Code Programs151
Use a Probe with Pathpilot151
Set up the Probe151
Use a Probe to Find a Feature's Location151
Use a Probe to Set Work Offset Zeroes151
Set the X and y Work Offset Zero on the Corner of a Feature151
Set the Work Offset Zeroes on a Feature151
Use a Probe to Find the Center of a Feature152
Find the Center of a Pocket152
Find the Center of a Slot152
Find the Center of a Rectangular Boss152
Find the Center of a Circular Boss152
Find the Center Rotation of an A-Axis153
Set Tool Length Offsets153
About Tool Offsets153
Touch off the Tool Length Offsets154
Set a Known Reference Height154
Measure Tools Using a Known Reference Height154
Use an Electronic Tool Setter (ETS) to Measure Tools155
Use a Height Gauge to Measure Tools155
Set Work Offsets156
About Work Offsets156
View Work Offsets156
View Available G-Code Modes157
Run G-Code Programs157
Bring the Machine out of Reset157
About Reset Mode157
View the Active Axis to Jog157
Jog the Machine157
Jog in Continuous Velocity Mode158
Jog in Step Mode158
View the Current Machine Position158
Reference the Machine158
About Referencing159
Start a Program159
About Cycle Start159
Cycle Start Reference159
Stop Machine Motion159
Operate the Coolant Pump159
About Coolant159
View the Active G-Code Modes160
View the Distance to Go160
About Distance to Go160
Control G-Code Programs160
Use the Feed Hold Function160
About Feed Hold160
Use the Feed Rate Override Function161
About Feed Rate Override161
Use M01 Break Mode161
About M01 Break161
Display Information and Capture Images During an M00 or M01 Break161
Display Information with Images161
Display Information with Text162
Capture Images with a USB Camera162
Use the Maxvel Override Function162
About Maxvel Override162
Use Single Block Mode162
About Single Block162
Use the Spindle Override Function163
About Spindle Override163
Change the Feed Rate163
About Feed Rates163
Change the Spindle Speed163
About Spindle Controls164
Spindle Controls Reference164
Change the Tool Number164
About M6 G43164
Use a G30 Position164
About G30165
View the Tool Length165
Manually Enter Commands165
About the MDI Line DRO Field165
Admin Commands Reference165
Copy Recently Entered Commands166
Use Feeds and Speeds Suggestions166
Refresh DRO Field Values167
Use Additional Provided Information167
Create Tool Descriptions167
Manually Enter Tool Descriptions168
Automatically Generate Tool Descriptions168
Tool Keywords Reference168
Use Cycle Counters (M30 and M99)169
Monitor Cycle Counters169
Change Cycle Counter Values169
System File Management170
Manage System Files170
About System Files170
Create Backup Files170
About Backup Files171
Restore Backup Files171
Import and Export the Tool Table172
Import a .Csv File172
Export the Tool Table as a .Csv File172
Basic Operations175
Start the Machine176
Reference the Machine176
About Referencing176
Jog the Machine176
About Jogging177
About Continuous Velocity Jogging177
About Step Jogging177
Jog Controls Reference177
Jogging in Pathpilot177
Jogging with the Keyboard177
Jogging with the (Optional) Jog Shuttle177
Manually Control the Spindle178
Change the Spindle Speed Range178
About the Spindle178
Spindle Controls Reference179
Load G-Code179
Set up Tooling179
Install a Tool in a Set Screw Tool Holder179
Install a Tool in an er Collet Tool Holder179
Install a Drill Chuck in a Jacobs Taper Arbor180
Set Tool Length Offsets180
About Tool Offsets180
Touch off the Tool Length Offsets180
Set a Known Reference Height181
Measure Tools Using a Known Reference Height181
Use an Electronic Tool Setter (ETS) to Measure Tools182
Use a Height Gauge to Measure Tools182
Set Work Offsets182
About Work Offsets183
Operate the Coolant Pump183
About Coolant183
First Part Tutorial185
About this Tutorial186
Before You Begin186
Required Items and Tools186
Set up Tooling186
Install a Tool in a Set Screw Tool Holder186
Install a Tool in an er Collet Tool Holder186
Set up the Machine187
About Referencing187
Mount the Workpiece187
Set the Work Offsets187
Set the Z Zero187
Set the X/Y Zeroes188
About Work Offsets188
About True Positive Tool Length189
About X/Y Part Zeroes189
Set Tool Offsets189
Touch off the Tool Offsets189
Measure Tools Using a Known Reference Height189
Complete the Milling Operations189
Create a Pocket190
Load the Tool190
Write the G-Code with Conversational190
Run the Program191
Engrave the Text191
Write the G-Code with Conversational191
Run the Program192
Programming193
Programming Overview194
About G-Code Programming Language194
G-Code Formatting Reference194
Line Numbers194
Words194
Letters195
Values195
Order of Execution196
Modal Groups197
Comments198
Supported G-Codes Reference198
Programming G-Code199
About the Examples Used199
Rapid Linear Motion (G00)199
Linear Motion at Feed Rate (G01)200
Arc at Feed Rate (G02 and G03)200
Radius Format Arc200
Center Format Arc201
Arc in XY Plane201
Arc in XZ Plane201
Arc in YZ Plane201
Dwell (G04)202
Set Offsets (G10)202
Set Tool Table (G10 L1)202
Set Coordinate System (G10 L2)203
Set Tool Table (G10 L10)203
Set Tool Table (G10 L11)203
Set Coordinate System (G10 L20)203
Plane Selection (G17, G18, G19)204
Length Units (G20 and G21)204
Return to Predefined Position (G28 and G28.1)204
Return to Predefined Position (G30 and G30.1)204
Automatically Measure Tool Lengths with an ETS (G37 and G37.1)204
Move to G37 Position over ETS (G37.1)204
Move and Measure Tool Length (G37)205
Straight Probe (G38.X)205
Use the Straight Probe Command206
Cutter Compensation (G40, G41, G42)206
Dynamic Cutter Compensation (G41.1 and G42.1)207
Apply Tool Length Offset (G43)207
Engrave Sequential Serial Number (G47)207
Cancel Tool Length Compensation (G49)208
Absolute Coordinates (G53)208
Select Work Offset Coordinate System (G54 to G54.1 P500)208
Set Exact Path Control Mode (G61)208
Set Blended Path Control Mode (G64)208
Distance Mode (G90 and G91)208
Arc Distance Mode (G90.1 and G91.1)209
Temporary Work Offsets (G92, G92.1, G92.2, and G92.3)209
Feed Rate Mode (G93, G94, and G95)209
Spindle Control Mode (G96 and G97)210
Programming Canned Cycles210
Canned Cycles Reference210
High Speed Peck Drill (G73)211
Cancel Canned Cycles (G80)212
Drilling Cycle (G81)212
Simple Drilling Cycle (G82)213
Peck Drilling Cycle (G83)213
Tapping Cycle (G84)213
Boring Cycle (G85)213
Boring Cycle (G86)214
Boring Cycle (G88)214
Boring Cycle (G89)214
Programming M-Code214
Supported M-Codes Reference214
Program Stop and Program End (M00, M01, M02, and M30)215
Display Information and Capture Images During an M00 or M01 Break215
Display Information with Images215
Display Information with Text215
Capture Images with a USB Camera216
Spindle Control (M03, M04, and M05)216
Tool Change (M06)216
Coolant Control (M07, M08, and M09)216
Override Control (M48 and M49)216
Feed Override Control (M50)216
Spindle Speed Override Control (M51)216
Set Current Tool Number (M61)217
Set Output State (M64 and M65)217
Wait on Input (M66)217
USB Camera Control (M301, M302, M303)217
Programming Input Codes218
Feed Rate (F)218
Spindle Speed (S)218
Change Tool Number (T)218
Advanced Programming218
Parameters218
Parameters Reference218
Parameter Syntax218
Parameter Scope219
Behavior of Uninitialized Parameters219
Parameter Mode219
Persistence and Volatility219
Intended Use219
Numbered Parameters Reference219
Read-Only Parameters219
Subroutine Parameters Reference220
Named Parameters Reference220
Expressions220
Binary Operators Reference220
Functions Reference221
Subroutines221
Subroutines Reference221
Conditional Subroutines Reference222
If/Endif222
If/Elseif/Else/Endif222
Repeating Subroutines Reference223
Looping Subroutines Reference223
Do/While223
While/Endwhile223
Machine Maintenance225
Maintenance Safety226
All Maintenance Procedures226
Swarf Maintenance Procedures226
Coolant Maintenance Procedures226
Maintenance Schedules226
Daily226
Weekly226
Monthly226
Semi-Annually226
Annually227
Regular Maintenance227
Clean the Way Covers227
Clean the Coolant System227
About Cutting Fluid227
Cutting Fluid Reference227
Examine the Drawbar228
Examine the Enclosure Windows228
Lubricate the Machine228
About the Manual Oiler228
About the Automatic Oiler229
Lubrication System Reference229
Examine the Spindle Belt229
Examine the Tormach Tooling System (TTS) Collet229
Prevent Rust229
Remove Rust229
Troubleshooting231
Troubleshooting Safety232
Getting Help232
Required Tools232
Frequently Found Problems233
Electrical Service234
Power Distribution Subsystem234
The Controller Won't Power on234
The Coolant Pump Won't Run235
Control Power Subsystem236
The Machine Won't Power on236
Axes Drive Subsystem237
All Axes Won't Move When Commanded238
One Axis Won't Move (or Only Moves in One Direction), and Other Axes Move238
Motor Resistance Reference241
DC-BUS Power Distribution Reference241
Axis Movement Is Noisy241
Can't Reference All Axes243
Limit Switch Function Reference244
Lost Motion on Axis Travel245
Spindle Drive Subsystem247
The Spindle Won't Turn248
Run and Direction Commands Reference251
Spindle VFD Trip Reference251
Machining Operations Are Loud ("Chattery")252
Can't Load or Unload a Tool, or the Spindle's Drawbar Drags against the Power Drawbar Cylinder's Piston Bolt253
Operator Console Troubleshooting254
The Screen Doesn't Respond to Touch Inputs254
The Screen Doesn't Display an Image or Respond to Power Button255
The Screen Is Scrambled or Illegible255
The Knobs Don't Respond256
The Buttons Don't Respond257
Diagrams and Parts Lists259
Base Machine Exploded View260
Base Machine Parts List261
Spindle Head Exploded View262
Spindle Head Parts List263
TTS Power Drawbar Cylinder Exploded View265
TTS Power Drawbar Cylinder Assembly Parts List266
Power Drawbar Push Button Exploded View267
Power Drawbar Push Button Parts List268
Spindle Motor Cover Exploded View269
Spindle Motor Cover Parts List270
X-Axis Assembly Exploded View271
X-Axis Assembly Parts List272
Y-Axis Assembly Exploded View274
Y-Axis Assembly Parts List275
Y-Axis Saddle Exploded View277
Y-Axis Saddle Parts List278
X-Y Axis Assembly Exploded View279
X-Y Axis Assembly Parts List280
Z-Axis Assembly Exploded View281
Z-Axis Assembly Parts List282
Enclosure Exploded View284
Enclosure Parts List285
Lubrication/Oil System Diagram287
Pneumatic Schematics289
Power Drawbar Pneumatics290
Automatic Tool Changer (ATC) Pneumatics291
Electrical Schematics293
Vac Power (Sheet 1)294
VDC Controls (Sheet 2)295
Axis Drive Bus (Sheet 3)296
Spindle Drive (Sheet 4)297
Machine Control Board (Sheet 5)298
Limit/Door Switches (Sheet 6)299
Accessory and Auxiliary Power (Sheet 7)300
Grounds (Sheet 8)301
Electrical Panel Layout and Fuse Table (Sheet 9)302
Operator Box Layout (Sheet 10)303
Wiring Table (Sheet 11)304
Operator Console Schematic305

Tormach 1100M - Visual Installation Guide

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