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Tormach PCNC 440 User Manual
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UM10372_PCNC440_Manual_0221A
Document P
art Number: 35672
©2021 T
ormach Inc.
TORMACH
®
PCNC 440
OPERA
T
OR
’S
MANUAL
IMPORT
ANT! R
ead and underst
and all operator
’
s manual saf
ety precauons and ins
trucons before at
-
tempng PCNC 440 ins
tallaon, operaon, or maint
enance.
™
2
Table of Contents
1. Overview
19
1.1 Specifications
20
2. Site Planning and Prep
21
2.1 General Site Requirements
21
2.1.1 Space Requirements
21
2.2 Electrical Requirements
22
2.2.1 Grounding
22
2.2.2 Plug Pattern
22
2.2.3 Ground Fault Interrupter (GFI) Use
22
2.2.4 Electrical Noise
23
2.2.5 Options for Electrically Non-conforming Sites
23
3. Installation
24
3.1 Receiving, Uncrating, and Initial Inspection
24
3.1.1 Shipment Arrival
24
3.1.2 Moving the Crate
24
3.1.3 Initial Uncrating
25
3.1.4 Shipping Damage or Shortages
25
3.2 Installation Sequence
25
3.3 Basic Installation Procedure
25
3.3.1 Stand Assembly
25
3.3.2 Remove Pallet Items
26
3.3.3 Lift and Move Mill
26
3.3.3.1 Remove Mill from Pallet
26
3.3.3.2 Lift Mill
26
3.3.4 Attach Mill to Stand
27
3.3.4.1 Non-Tormach Stands
27
3.3.5 X-axis Motor Cover Plate
27
3.3.6 X-axis Limit Switch Cover Plate
27
3.3.7 Manual Oiler
27
3.3.8 Flood Coolant System
27
3.3.9 Install the Monitor
28
3.3.10 Install the PathPilot Controller
28
3.4 Essential Controls Overview
30
3.4.1 E-stop, Start, Reset, and Main Disconnect
30
3.5 Power Off/Power On Procedure
31
3.6 Initial PathPilot Controller Configuration
32
3.7 Validate Basic Installation
33
3.7.1 Verify Limit Switch Function
33
3.7.2 Verify Axis Function
34
3.7.3 Verify Spindle Function
34
3.7.4 Installation Troubleshooting
34
3.8 Controller Customization
35
4. Operation
36
4.1 Control Locations
36
4.1.1 Operator Box
36
4.1.2 PathPilot Interface
36
4.1.3 Accessory Port
37
4.2 Initializing the Mill
37
4.2.1 Vital Reference
37
4.3 Jogging
37
4.3.1 Keyboard
37
4.3.2 Jog Shuttle
38
4.4 Spindle Controls
38
4.4.1 Spindle Control Via PathPilot Interface
38
4.4.2 Changing Spindle Speed Range
39
4.5 Tool Holders
40
4.5.1 Install Drawbar and TTS Collet
40
4.5.2 Change TTS Tool Holder
41
4.5.3 Tips on Using TTS
41
4.6 Part Setup/Workholding
42
5. Intro to PathPilot
43
5.1 Making Your First Part
43
5.1.1 Reference the Mill
43
5.1.2 Prepare the Workpiece
44
5.1.3 Prepare the Tools
44
5.1.4 Understand Mill Position, Work Offsets and Tool Offsets
44
5.1.5 Set the Length Units
45
5.1.5.1 Programming in Inches
45
5.1.5.2 Programming in Millimeters
45
5.1.6 Touch Off the Workpiece to Set Work Offsets
46
5.1.7 Touch Off the Workpiece to Set Tool Length Offsets
47
5.1.8 Write the G-code
48
5.1.8.1 Operation 1
49
5.1.8.2 Operation 2
51
6. PathPilot Interface
53
6.1 Overall Layout
53
6.2 Persistent Controls
54
6.2.1 Program Control Group
54
6.2.2 Position Status Group
56
6.2.3 Manual Control Group
57
6.3 Keyboard Shortcuts
60
6.4 Main Tab
61
6.4.1 Selecting a Recent G-code Program File
61
6.4.2 Working in the G-code Window
61
6.4.2.1 Setting a New Start Line
62
6.4.2.2 Expanding the G-code Window
62
6.4.3 Manually Entering Commands
62
6.4.3.1 Searching in the Code
62
6.4.4 Working in the Tool Path Window
64
6.4.4.1 Changing the View of the Tool Path Window
64
6.5 File Tab
64
6.5.1 Managing Files
64
6.5.1.1 Transferring Files or Folders from a USB Drive
65
6.5.2 Loading G-code
65
6.5.3 Editing G-code
66
6.5.3.1 Editing G-code with a Text Editor
66
6.5.3.2 Editing G-code with Conversational Programming
66
6.6 Settings Tab
67
6.6.1 Selecting the Tool Changer Type
67
6.6.2 Changing the Network Name
68
6.6.3 Disabling Reference Switches
68
6.6.4 Limiting a G30/M998 Move
69
6.6.5 Enabling Feeds and Speeds Suggestions in Conversational Programming
69
6.6.6 Enabling Accessories
69
6.6.6.1 Enabling CNC Scanner
69
6.6.6.2 Enabling Soft Keyboard
69
6.6.6.3 Enabling USB I/O Board
70
6.7 Offsets Tab
70
6.7.1 Tool Tab
70
6.7.1.1 Tool Measuring Techniques
71
6.7.1.2 Creating Tool Descriptions
72
6.7.2 Offsets Table
75
6.7.3 Tool Offset and Fixture Information Backup
75
6.7.4 Work Tab
76
6.8 Conversational Tab
76
6.8.1 Using Feeds and Speeds Suggestions
76
6.8.1.1 Adjusting DRO Values
78
6.8.1.2 Resetting DRO Values
78
6.8.1.3 Using Chip Load Information
78
6.8.2 Face Tab
79
6.8.3 Profile Tab
80
6.8.4 Pocket Tab
82
6.8.4.1 Rectangular
82
6.8.4.2 Circular
83
6.8.5 Drill Tab
85
6.8.6 Thread Mill Tab
87
6.8.7 Engrave Tab
89
6.8.8 DXF Tab
91
6.8.8.1 Working with Layers and Shapes
91
6.8.8.2 Working in the Preview Window
92
6.9 Probe Tab
92
6.9.1 XYZ Probe Tab
93
6.9.2 Rect/Circ Tab
94
6.9.3 Probe/ETS Setup Tab
95
6.10 ADMIN Commands
95
7. Programming
96
7.1 Definitions
96
7.2 G-code Programming Language
99
7.2.1 Overview
99
7.2.2 Block
99
7.2.3 Real Value
99
7.2.4 Number
99
7.2.5 Formatting G-code Blocks
100
7.2.6 Optional Program Stop Control – (M01 BREAK)
103
7.2.7 Additional G-code Formatting Notes
104
7.2.7.1 Repeated Items
104
7.2.7.2 Order of Execution
104
7.2.7.3 Error Handling
106
7.2.7.4 Modality and Modal Commands
106
7.2.7.5 Modal Groups
106
7.2.7.6 Default Modes
107
7.3 G-codes
107
7.3.1 Rapid Linear Motion – G00
109
7.3.2 Linear Motion at Feed Rate – G01
110
7.3.3 Arc at Feed Rate – G02, G03
111
7.3.3.1 Radius Format Arc
111
7.3.3.2 Center Format Arc
112
7.3.4 Dwell – G04
115
7.3.5 Set Offsets – G10
115
7.3.5.1 Set Tool Table – G10 L1
115
7.3.5.2 Set Coordinate System – G10 L2
115
7.3.5.3 Set Tool Table – G10 L10
116
7.3.5.4 Set Tool Table – G10 L11
117
7.3.5.5 Set Coordinate System – G10 L20
117
7.3.6 Plane Selection – G17, G18, and G19
118
7.3.7 Length Units – G20, G21
118
7.3.8 Return to Pre-defined Position – G28, G28.1
118
7.3.9 Return to Pre-defined Position – G30, G30.1
119
7.3.10 Straight Probe – G38.x
119
7.3.10.1 Using the Straight Probe Command
120
7.3.11 Cutter Compensation – G40, G41, and G42
121
7.3.11.1 Cutter Compensation Off – G40
121
7.3.11.2 Cutter Compensation On – G41, G42
122
7.3.12 Dynamic Cutter Compensation – G41.1, G42.1
122
7.3.13 Apply Tool Length Offset – G43
123
7.3.14 Engrave Sequential Serial Number – G47
124
7.3.15 G49 Cancel Tool Length Compensation – G49
124
7.3.16 Absolute Coordinates – G53
125
7.3.17 Select Work Offset Coordinate System – G54 to G59.3
125
7.3.18 Set Exact Path Control Mode – G61
125
7.3.19 Set Blended Path Control Mode – G64
126
7.3.20 Distance Mode – G90, G91
126
7.3.21 Arc Distance Mode – G90.1, G91.1
126
7.3.22 Temporary Work Offsets – G92, G92.1, G92.2, and G92.3
127
7.3.23 Feed Rate Mode – G93, G94, and G95
127
7.3.24 Spindle Control Mode – G96, G97
128
7.4 Canned Cycles
129
7.4.1 High Speed Peck Drilling Cycle – G73
131
7.4.2 Cancel Active Canned Cycle – G80
131
7.4.3 Simple Drilling Cycle – G81
132
7.4.4 Simple Drilling Cycle (dwell) – G82
134
7.4.5 Peck Drilling Cycle – G83
134
7.4.6 Boring Cycle (feedrate out) – G85
134
7.4.7 Boring Cycle (dwell, rapid out) – G86
135
7.4.8 Boring Cycle (dwell, manual out) – G88
135
7.4.9 Boring Cycle (dwell, feedrate out) – G89
135
7.5 Built-in M-codes
136
7.5.1 Program Stop and Program End – M00, M01, M02, and M30
136
7.5.2 Spindle Control – M03, M05
137
7.5.3 Tool Change – M06
137
7.5.4 Coolant Control – M07, M08, and M09
137
7.5.5 Override Control – M48, M49
138
7.5.6 Feed Override Control – M50
138
7.5.7 Spindle Speed Override Control – M51
138
7.5.8 Set Current Tool Number – M61
138
7.5.9 Set Output State – M64, M65
139
7.5.10 Wait on Input – M66
140
7.6 Other Input Codes
140
7.6.1 Feed Rate – F
140
7.6.2 Spindle Speed – S
140
7.6.3 Change Tool Number – T
141
7.7 Advanced Programming with Parameters and Expressions
141
7.7.1 Parameters
141
7.7.2 Parameter Types
143
7.7.2.1 Numbered Parameters
143
7.7.2.2 Subroutine Parameters
145
7.7.2.3 Named Parameters
145
7.7.3 Expressions
145
7.7.3.1 Binary Operators
145
7.7.3.2 Functions
147
7.8 Programming with Subroutines
147
7.8.1 Subroutine Labels and Subroutine Keywords
147
7.8.1.1 Defining a Subroutine
148
7.8.1.2 Calling a Subroutine
149
7.8.1.3 Conditional Subroutines
150
7.8.1.4 Repeating Subroutines
150
7.8.1.5 Looping Subroutines
151
8. Accessories
153
8.1 Stands and Enclosures
153
8.1.1 Full Enclosure Kit
153
8.1.2 Stand
153
8.2 Coolant System Options
153
8.2.1 Flood Coolant Kit
153
8.2.2 Spray Coolant
154
8.2.3 Coolant Hose and Accessories
154
8.2.4 Tramp Oil Pillow
154
8.3 Mill Options
154
8.3.1 LED Spindle Light
154
8.3.2 External Contactor Kit
154
8.3.3 USB M-code I/O Interface Kit
155
8.3.4 Kress Spindle Kit
155
8.3.5 Probe
155
8.3.5.1 Calibrating Probe Tip
156
8.3.5.2 Measuring Probe Tip Diameter
157
9. Maintenance
158
9.1 Regular Maintenance
158
9.1.1 Rust Prevention
159
9.1.2 Way Covers
159
9.1.3 Flood Coolant System
159
9.1.4 Lubrication System
159
9.1.4.1 Manual Oiler Specifics
160
9.1.5 Drawbar and TTS Collet
161
9.2 Spindle Belt
161
9.3 Advanced Maintenance
161
9.3.1 Overview
161
9.3.2 Definitions
162
9.3.2.1 How to Measure Lost Motion
162
9.3.3 Gib Adjustment
164
9.3.3.1 Overview
164
9.3.3.2 Adjustment Procedure
164
9.3.4 Angular Contact Bearing Preload Adjustment
165
9.3.4.1 Overview
165
9.3.4.2 Adjustment Procedure
166
9.3.5 Geometry Adjustment of Precision Mating Surfaces
167
9.4 Spindle Bearing Adjustment
167
9.5 Transporting the Mill
167
10. Diagrams and Parts List
169
10.1 Spindle Head Assembly (exploded view)
169
10.2 Z-axis Column Assembly (exploded view)
171
10.3 X-Y Axis Assembly (exploded view)
173
10.4 Electrical Cabinet
176
10.5 Connections
178
10.6 Stepper Connections
179
10.7 Lubrication System
180
11. Electrical Schematics
181
11.1 PCNC 440 Electrical Schematic
181
11.2 PCNC 440 4th Axis Wiring
182
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Tormach PCNC 440 Specifications
General
Brand
Tormach
Model
PCNC 440
Category
Racks & Stands
Language
English
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