Tormach 1100MX - Page 32

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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 Expectations Reference30
Cutting Performance Reference30
Resolution and Accuracy Reference30
Specifications Reference31
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-Axis42
Lift and Move the Machine43
Required Tools43
Before You Begin43
Assemble the Lifting Bar Kit43
Connect the Machine for Lifting44
Lift the Machine44
Install the Drip Guard45
Install the X-Axis Motor Cover45
Install the Controller46
Install the Controller Arm46
Install the Monitor47
Make Monitor Connections47
Install the Pathpilot Controller48
Set up the Pathpilot Operator Console48
Install the Oiler49
Make Automatic Oiler Connections50
Make Manual Oiler Connections50
Set up the Manual Oiler50
Verify the Installation50
Power on the Machine50
Power off the Machine52
Verify Spindle Function52
Verify Axes Function52
Install Accessory Components53
Set up the Automatic Oiler53
Look for Leaks and Clear the Lines53
Specify the Interval Time53
Specify the Actuation Time54
Install the FRL Filter-Regulator-Lubricator54
Install the FRL54
Set up the FRL55
Make Air Connections55
Set up the Coolant Kit55
Install the Automatic Tool Changer (ATC)56
Required Tools57
Required Tools for Installation57
Required Tools for Verification57
Air Requirements57
Prepare the Machine57
Disassemble the Power Drawbar Button57
Install the Air Cylinder58
Mount the Automatic Tool Changer (ATC) Bracket58
Install the Main Assembly59
Level the Automatic Tool Changer (ATC)59
Prepare the Machine59
Examine Perpendicularity in the y Direction60
Examine Perpendicularity in the X Direction60
Examine the Alignment of the Carousel Door Opening60
Make Air Connections61
Make Electrical Connections62
Verify the Installation62
Adjust the Tool Alignment and Set the Tool Tray Height and Encoder Position63
Install the 4Th Axis64
Required Tools65
Unpack the 4Th Axis65
Lubricate the Rotary Table65
Adjust the Backlash66
To Set the Backlash by Positioning the Backlash Adjustment Screw66
To Set the Backlash by the Numbers66
Mount the Rotary Table67
Install the A-Axis Motor Driver67
Verify the Installation67
Install the Chip Pans68
Install the Backsplash and Splash Guard69
Install the Enclosure69
Before You Begin70
Required Tools70
Install the Enclosure Panels70
Install the Left Rear Panel70
Install the Left Side Panel71
Install the Left Side Window Retainers71
Install the Left Front Panel71
Install the Right Rear Side Panel72
Install the Right Rear Top Panel72
Install the Right Side Panel72
Install the Right Side Window Retainers72
Install the Right Front Panel72
Install the Left Top Panel73
Install the Right Top Panel73
Install the Front Upper Panel74
Install the Front Lower Panel74
Install the Rear Splash Shield74
Assemble the Linear Rails74
Install the Linear Assemblies75
Assemble the Front Doors76
Install the Front Door Assemblies76
Install the Door Latch77
Install the Floodlights77
Install the Side Windows78
Install the Access Panel79
Install the Stainless Steel Wear Guard80
Use the Maintenance Labels80
About the Maintenance Labels80
Write the Date on the Maintenance Labels80
Replace the Windows80
Set up the Door Lock Switch Kit80
Install the Door Lock Switch Kit80
Update Pathpilot82
Download and Install an Update File from the Controller82
Install an Update File from a USB Drive83
Enable the Door Lock Switch Kit83
Install the Pathpilot Operator Console84
Required Tools84
Prepare the Machine84
Remove the Right Side Window84
Remove the Operator Box84
Install the Mount Arm84
Mount the Console86
Assemble the Controller and Keyboard Tray86
Lift and Secure the Controller Assembly87
Make Electrical Connections88
Reassemble the Machine90
Set up the Pathpilot Controller90
Specify the Date and Time90
Specify the Keyboard Language90
Configure the Optional Touch Screen Kit90
System Basics91
System Reference92
Machine Table92
Spindle92
About the Spindle92
Axes92
Basic Controls Reference92
Machine Controls92
Pathpilot Interface93
Pathpilot Interface Overview95
About Pathpilot96
Notebook Section Reference96
Main Tab Reference96
File Tab Reference96
Settings Tab Reference97
Offsets Tab Reference97
Conversational Tab Reference97
Probe Tab Reference97
Status Tab Reference98
Persistent Controls Section Reference98
Program Control Area Reference98
Position Status Area Reference98
Manual Control Area Reference99
Keyboard Shortcuts Reference99
Manage Pathpilot Versions99
Download and Install an Update File from the Controller99
Install an Update File from a USB Drive100
Install a Previous Version of an Update File100
Pathpilot Tools and Features103
Create and Load G-Code Files104
Load G-Code104
Transfer Files to and from the Controller104
About System Files104
Preview G-Code Files104
Access Recent G-Code Files105
Close the Current Program105
Edit G-Code105
Edit G-Code with a Text Editor105
Edit G-Code with Conversational Programming105
Change the Step Order106
Create a New Job Assignment106
Load an Existing G-Code File106
Edit a Job Assignment106
Read G-Code106
Expand the G-Code Tab106
About the G-Code Tab106
Search in the Code107
Set a New Start Line107
Lead-In Moves108
Change the View of the Tool Path Display108
About the Tool Path Display109
Use Conversational Programming109
About Conversational Programming109
Create a Face on a Part109
About Facing110
Facing in Pathpilot110
Facing Reference111
Create a Profile on a Part111
About Profiling111
Profiling in Pathpilot111
Profiling Reference112
Create a Pocket on a Part112
About Pockets113
Creating Pockets in Pathpilot113
About Circular Pockets113
About Rectangular Pockets114
Create Hole Locations on a Part (Drill/Tap)114
About Drilling and Tapping115
Drilling and Tapping in Pathpilot115
Create a Drilling Sequence115
Create a Tapping Sequence116
Drilling and Tapping Reference116
Create Threads on a Part117
About Thread Milling117
Thread Milling in Pathpilot117
Thread Milling Reference118
Create Text to Engrave on a Part118
About Engraving119
Import a DXF File119
Working with Layers and Shapes119
Change the Layer or Shape Cut Order119
Adjust the Tree View Window120
Working in the Preview Window120
Machine Settings and Accessories120
Change the Network Name120
Select the Spindle Type120
Specify the Tool Change Method120
About Automatic Tool Changes121
About Manual Tool Changes121
Enable Accessories121
Enable the 4Th Axis Homing Kit121
Enable the Door Lock Switch Kit121
Enable Probing and Tool Measuring Options122
Enable the Rapidturn122
Enable the Touch Screen Kit122
About Soft Keyboards122
Enable the USB M-Code I/O Interface Kit122
Enable an Internet Connection122
Connect to Dropbox123
Enable Automatic Updates124
Set up G-Code Programs125
Use a Probe with Pathpilot125
Before You Begin125
Use a Probe to Find a Feature's Location125
Use a Probe to Set Work Offset Zeroes125
Set the X and y Work Offset Zero on the Corner of a Feature125
Set the Work Offset Zeroes on a Feature125
Use a Probe to Find the Center of a Feature126
Find the Center of a Pocket126
Find the Center of a Slot126
Find the Center of a Rectangular Boss126
Find the Center of a Circular Boss126
Find the Center Rotation of an A-Axis127
Set Tool Length Offsets127
Touch off the Tool Length Offsets127
Set a Known Reference Height127
Measure Tools Using a Known Reference Height128
Use an Electronic Tool Setter (ETS) to Measure Tools128
Use a Zero Setting Gauge to Measure Tools129
Set a Known Reference Height129
Verify the Calibration of the Zero Setting Gauge129
Measure Tools Using a Known Reference Height129
About Tool Offsets130
Set Work Offsets130
About Work Offsets130
View Work Offsets131
View Available G-Code Modes131
Run G-Code Programs131
Bring the Machine out of Reset131
About Reset Mode131
Disable Hard Stop Referencing132
View the Active Axis to Jog132
Jog the Machine132
Jog in Continuous Velocity Mode133
Jog in Step Mode133
View the Current Machine Position133
Reference the Machine133
About Referencing133
Start a Program134
About Cycle Start134
Cycle Start Reference134
Stop Machine Motion134
Operate the Coolant Pump134
About Coolant134
View the Active G-Code Modes134
View the Distance to Go134
About Distance to Go135
Control G-Code Programs135
Use the Feed Hold Function135
About Feed Hold135
Use the Feed Rate Override Function135
About Feed Rate Override135
Use M01 Break Mode136
About M01 Break136
Use the Maxvel Override Function136
About Maxvel Override136
Use Single Block Mode136
About Single Block136
Use the Spindle Override Function137
About Spindle Override137
Change the Feed Rate137
About Feed Rates137
Change the Spindle Speed137
About Spindle Controls138
Spindle Controls Reference138
Change the Tool Number138
About M6 G43138
Use a G30 Position138
About G30139
View the Tool Length139
Manually Enter Commands139
About the MDI Line DRO Field139
Admin Commands Reference139
Copy Recently Entered Commands140
Limit a G30 Move140
About G30140
Use Feeds and Speeds Suggestions140
Refresh DRO Field Values141
Use Additional Provided Information141
Enable Feeds and Speeds Suggestions in Conversational Routines141
Create Tool Descriptions142
Manually Enter Tool Descriptions142
Automatically Generate Tool Descriptions142
Tool Keywords Reference143
System File Management143
Manage System Files143
About System Files144
Create Backup Files144
About Backup Files145
Restore Backup Files145
Import and Export the Tool Table146
Import a .Csv File146
Export the Tool Table as a .Csv File146
Basic Operations147
Start the Machine148
Reference the Machine148
About Referencing148
Jog the Machine148
About Jogging149
About Continuous Velocity Jogging149
About Step Jogging149
Jog Controls Reference149
Jogging in Pathpilot149
Jogging with the Keyboard149
Jogging with the (Optional) Jog Shuttle149
Manually Control the Spindle150
Change the Spindle Speed Range150
About the Spindle150
Spindle Controls Reference151
Load G-Code151
Set up Tooling151
Install a Tool in a Set Screw Tool Holder151
Install a Tool in an er Collet Tool Holder151
Install a Drill Chuck in a Jacobs Taper Arbor152
Set Tool Length Offsets152
Touch off the Tool Length Offsets152
Set a Known Reference Height152
Measure Tools Using a Known Reference Height153
Use an Electronic Tool Setter (ETS) to Measure Tools153
Use a Zero Setting Gauge to Measure Tools154
Set a Known Reference Height154
Verify the Calibration of the Zero Setting Gauge154
Measure Tools Using a Known Reference Height154
About Tool Offsets155
Set Work Offsets155
About Work Offsets155
Operate the Coolant Pump156
About Coolant156
First Part Tutorial157
About this Tutorial158
Before You Begin158
Required Items and Tools158
Set up the Machine158
About Referencing158
Mount the Workpiece159
Set the Work Offsets159
Set the Z Zero159
Set the X/Y Zeroes159
About Work Offsets159
About True Positive Tool Length160
About X/Y Part Zeroes160
Set Tool Offsets160
Touch off the Tool Offsets160
Measure Tools Using a Known Reference Height160
Complete the Milling Operations161
Create a Pocket161
Load the Tool161
Write the G-Code with Conversational161
Run the Program162
Engrave the Text162
Write the G-Code with Conversational162
Run the Program163
Programming165
Programming Overview166
About G-Code Programming Language166
Comments and Messages166
G-Code Formatting Reference166
Line Numbers167
Words167
Letters167
Values167
Order of Execution168
Modal Groups169
Supported G-Codes Reference170
Programming G-Code171
About the Examples Used171
Rapid Linear Motion (G00)171
Linear Motion at Feed Rate (G01)172
Arc at Feed Rate (G02 and G03)172
Radius Format Arc172
Center Format Arc173
Arc in XY Plane173
Arc in XZ Plane173
Arc in YZ Plane173
Dwell (G04)174
Set Offsets (G10)174
Set Tool Table (G10 L1)174
Set Coordinate System (G10 L2)175
Set Tool Table (G10 L10)175
Set Tool Table (G10 L11)175
Set Coordinate System (G10 L20)175
Plane Selection (G17, G18, G19)175
Length Units (G20 and G21)176
Return to Predefined Position (G28 and G28.1)176
Return to Predefined Position (G30 and G30.1)176
Automatically Measure Tool Lengths with an ETS (G37 and G37.1)176
Move to G37 Position over ETS (G37.1)176
Move and Measure Tool Length (G37)177
Straight Probe (G38.X)177
Use the Straight Probe Command178
Cutter Compensation (G40, G41, G42)178
Dynamic Cutter Compensation (G41.1 and G42.1)179
Apply Tool Length Offset (G43)179
Engrave Sequential Serial Number (G47)179
Cancel Tool Length Compensation (G49)180
Absolute Coordinates (G53)180
Select Work Offset Coordinate System (G54 to G59.3)180
Set Exact Path Control Mode (G61)180
Set Blended Path Control Mode (G64)180
Distance Mode (G90 and G91)180
Arc Distance Mode (G90.1 and G91.1)180
Temporary Work Offsets (G92, G92.1, G92.2, and G92.3)181
Feed Rate Mode (G93, G94, and G95)181
Spindle Control Mode (G96 and G97)182
Programming Canned Cycles182
Canned Cycles Reference182
Supported Canned Cycles182
High Speed Peck Drill (G73)183
Cancel Canned Cycles (G80)184
Drilling Cycle (G81)184
Simple Drilling Cycle (G82)185
Peck Drilling Cycle (G83)185
Tapping Cycle (G84)185
Boring Cycle (G85)185
Boring Cycle (G86)186
Boring Cycle (G88)186
Boring Cycle (G89)186
Programming M-Code186
Supported M-Codes Reference186
Program Stop and Program End (M00, M01, M02, and M30)187
Spindle Control (M03, M04, and M05)187
Tool Change (M06)187
Coolant Control (M07, M08, and M09)187
Override Control (M48 and M49)188
Feed Override Control (M50)188
Spindle Speed Override Control (M51)188
Set Current Tool Number (M61)188
Set Output State (M64 and M65)188
Wait on Input (M66)188
Programming Input Codes189
Feed Rate (F)189
Spindle Speed (S)189
Change Tool Number (T)189
Advanced Programming189
Parameters189
Parameters Reference189
Parameter Syntax189
Parameter Scope190
Behavior of Uninitialized Parameters190
Parameter Mode190
Persistence and Volatility190
Intended Use190
Numbered Parameters Reference190
Read-Only Parameters190
Subroutine Parameters Reference191
Named Parameters Reference191
Expressions191
Binary Operators Reference191
Functions Reference192
Subroutines192
Subroutines Reference192
Conditional Subroutines Reference193
If/Endif193
If/Elseif/Else/Endif193
Repeating Subroutines Reference194
Looping Subroutines Reference194
Do/While194
While/Endwhile194
Machine Maintenance195
Maintenance Safety196
All Maintenance Procedures196
Swarf Maintenance Procedures196
Coolant Maintenance Procedures196
Maintenance Schedules196
Daily196
Weekly196
Monthly196
Semi-Annually196
Annually197
Regularly Maintaining the Machine197
Clean the Way Covers197
Clean the Coolant System197
About Cutting Fluid197
Cutting Fluid Reference197
Examine the Drawbar198
Examine the Enclosure Windows198
Lubricate the Machine198
About the Manual Oiler198
About the Automatic Oiler198
Lubrication System Reference199
Examine the Spindle Belt199
Examine the Pull Stud Clamp199
Prevent Rust199
Remove Rust199
Troubleshooting201
Troubleshooting Safety202
Getting Help202
Required Tools203
Frequently Found Problems203
Electrical Service204
Power Distribution Subsystem204
The Controller Won't Power on204
The Coolant Pump Won't Run205
Control Power Subsystem206
The Machine Won't Power on206
Axes Drive Subsystem207
All Axes Won't Move When Commanded208
One Axis Won't Move (or Only Moves in One Direction), and Other Axes Move208
DC-BUS Power Distribution Reference211
Axis Movement Is Noisy211
Can't Reference All Axes212
Limit Switch Function Reference214
Lost Motion on Axis Travel215
Spindle Drive Subsystem217
The Spindle Won't Turn218
Run and Direction Commands Reference221
Spindle VFD Trip Reference221
Machining Operations Are Loud ("Chattery")222
Can't Load or Unload a Tool, or the Spindle's Drawbar Drags against the Power Drawbar Cylinder's Piston Bolt224
Spindle Rotates on Contact, or Spindle Isn't Rigidly Clamped225
Diagrams and Parts Lists227
Base Machine Exploded View228
Base Machine Parts List229
Spindle Cartridge Exploded View230
Spindle Cartridge Parts List231
Spindle Head Exploded View232
Spindle Head Parts List233
BT30 Power Drawbar Cylinder Exploded View234
BT30 Power Drawbar Cylinder Assembly Parts List235
Power Drawbar Push Button Exploded View236
Power Drawbar Push Button Parts List237
Spindle Motor Cover Exploded View238
Spindle Motor Cover Parts List239
X-Axis Assembly Exploded View240
X-Axis Assembly Parts List241
Y-Axis Assembly Exploded View243
Y-Axis Assembly Parts List244
Y-Axis Saddle Exploded View246
Y-Axis Saddle Parts List247
X-Y Axis Assembly Exploded View248
X-Y Axis Assembly Parts List249
Z-Axis Assembly Exploded View250
Z-Axis Assembly Parts List251
Lubrication System Diagram253
Pneumatic Schematics255
Power Drawbar Pneumatics256
Automatic Tool Changer (ATC) Pneumatics257
Electrical Schematics259
Vac Power (Sheet 1)260
VDC Controls (Sheet 2)261
Axis Drive Bus (Sheet 3)262
Spindle Drive (Sheet 4)263
Machine Control Board (Sheet 5)264
Limit/Door Switches (Sheet 6)265
Accessory and Auxiliary Power (Sheet 7)266
Grounds (Sheet 8)267
Electrical Panel Layout and Fuse Table (Sheet 9)268
Operator Box Layout (Sheet 10)269
Wiring Table (Sheet 11)270

Tormach 1100MX - Page 32

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