tormach pcnc 1100 atc - microsoft · 2019. 4. 2. · atc before operating.it is the responsibility...

Tormach® PCNC 1100 ATC

A U T O M A T I C T O O L C H A N G E R

Operator Manual

IMPORTANT: Read and understand all operator manual safety precautions and instructions before attempting Automatic Tool Changer (ATC) installation, operation, or maintenance.

Questions or comments?Please email us: [email protected] rights reserved.

PCNC 1100 ATC Operator ManualUM10354_PCNC1100_ATC_0916A

©2014 Tormach® Inc.

1. Preface 2

1.1 Manual Overview 2 1.2 Safety 2 1.3 System Requirements 3

2. Preparation 4

2.1 Unpacking and Checking Shipment 4 2.2 Before You Begin 5 2.3 MountingtheATC 5

3. ElectricalInstallation 7

3.1 ElectricalInstallation 7

4. AirLines 12

4.1 AirLineConnectionandRequirements 12

5. SystemValidation 14

5.1 ATCCommunications 14 5.2 AlignToolTrayandSlots 15

6. OptionalAccessories 19

6.1 Foot Pedal Kit 19 6.2 FilterRegulatorLubricator 19 6.3 Pressure Sensor 21

7. Operation 22

7.1 GeneralTheoryofOperation 22 7.2 Loading/UnloadingTools 22 7.3 AutomaticTrayLoad/Unload 22 7.4 ManualTrayLoad/Unload 23 7.5 ToolTouch-offRoutine 23 7.6 ATCBypass 24

8. Maintenance&Troubleshooting 25

8.1 Support 25 8.2 Maintenance 25 8.3 Troubleshooting 25

9. Diagrams&PartsLists 32

9.1 ATCCarousel 33 9.2 ATC1100ColumnMount 34 9.3 TTSATCActuator 36 9.4 ATCControlModuleAssembly 38 9.5 TTSATCPneumaticSchematic 40 9.6 ATCElectrical 41

TABLE OF CONTENTS

PB 1UM10354_PCNC1100_ATC_0916A UM10354_PCNC1100_ATC_0916A

1.1 Manual Overview

Thismanual is intendedforusewiththeTormachToolingSystem(TTS)AutomaticToolChanger(ATC)–anaccessorytotheTormachPCNC1100mill(withPathPilot™controller).Readersareassumedtobefamiliarwiththeoperationanddocumentation for their particular milling machine. Forquestions of a general nature (e.g. applying tool heightoffset compensation) please refer to the PCNC 1100machine manual.

The Tormach Tooling System ATC can be used with allexistingpartprogramswithoutmodification,regardlessofexistingtoolnumberassignments.Forprogramsthatuse10toolsorfewertheATCmaybeusedforalltoolchanges.Forpartprogramsrequiringmorethan10tools,orforprogramsrequiring special toolingnotappropriate for anATC, suchasareversingtappinghead, itcanbeusedinconjunctionwithmanualchanges.Anytoolnumberbetween1and253maybeassignedtoapositioninthetooltray–youarenotconfinedtousingtoolnumbers1-10.This isconvenient ifyouhaveatoollibraryalreadysetupwithtoolnumbersandheightsmeasuredinyourtooloffsettable.Thetoolchangerremembers tools assigned to the tray, and prompts formanualspindleinsertionandremovalofnon-assignedtoolsatappropriatetimes.Toolsmaybeassignedtodifferenttraynumberssothat,forinstance,onecandedicategroupsoftrayassignmentstospecificjobsthatarerunfrequently.AlltoolsarecalledfromG-codewithstandardM6commands,orfrombuttonsontheATCcontrolscreen.

1.2 SafetyAny machine tool is potentially dangerous, especiallyautomatedtoolsundercomputercontrol.BecauseTormachdoes not know the details of your workshop or other local conditions, no responsibility can be taken for damageor injury caused by the use of themill andATC. It is theowner’s and operators responsibility to understand themill/ATC system integration and operation and to complywith any legislation and codes of practice applicable tocountryorstate.Ifthereisanydoubt,seekguidancefromaprofessionallyqualifiedexpertratherthanriskinjury.

ThesafetyofanyapplicationusingtheATCisultimatelytheresponsibilityofthoseperformingthesetupandoperation.Pleasedonottakethisresponsibilitylightly–usecommonsense and review all instructions on the operation andmaintenanceoftheATC.

Operator Safety

• Whenusingelectrictools,machinesorequipment,basicsafetyprecautionsshouldalwaysbefollowedto reduce the risk of fire, electric shock, andpersonalinjury.

• Read and understand this manual. Do not operate the ATC without knowing the function of everycontrolkey,button,andalignmentandreferencingprocedure.RefertothismanualorcontactTormachifanyfunctionisnotunderstood.

• Keephandsclearof theATCatalltimesduringtoolchangesorwhencommandinganyATCmotionfromtheATCcontrolscreenofthemill’scontrolsoftware.

• Avoid contact with moving parts. Before operatingthemillandATC,removealljewelryincludingwatchesandrings,necktiesandanyloose-fittingclothing.Tiebackhair.

• Keep hair away from moving parts.• Do not reach for the part, tool or fixture while

running a part program.• Keepworkareaclean.Clutteredareasinviteinjuries.• WearANSIapprovedeyeprotectionatalltimes.• Neveruselongerorlargertoolsthannecessary.• DonotusetheATCorpowertoolsindamp,wetor

poorlylitlocations.• Donotusetoolsinthepresenceofflammablegases

or liquids.• Useonlyidenticalreplacementpartswhenservicing.• TakeoffglovesbeforeyouoperatetheATC.Gloves

areeasilycaughtinmovingpartsorcuttingtools.• Neveroperatewithunbalancedtooling.• Never operate the ATC after consuming alcoholic

beveragesortakingstrongmedication.• Protect your hands. Stop the machine and ensure

thatthecontrollerisstoppedbeforeyou: * Change tools *Changepartsoradjusttheworkpiece *Makeanadjustment

• Keepwork areawell lit. Ask for additional light ifneeded.

• Always use proper feeds and speeds, as well asdepthandwidthofcut,topreventtoolbreakage.

• Usepropercuttingtoolsforthejob.

1. PREFACE

2 3UM10354_PCNC1100_ATC_0916A UM10354_PCNC1100_ATC_0916A

• Do not use dull or damaged cutting tools. Theybreakeasilyandbecomedangerousprojectiles.

• Be certain every operator understands the operationandsafetyrequirementsofthemillandATCbeforeoperating.Itistheresponsibilityoftheowner of theATC to provide and ensure point ofoperationsafeguardingperOSHAstandards.

Electrical Safety

The Tormach Tooling System (TTS) AutomaticToolChanger(ATC)operateson70VDC,fusedat 8 amps. It is powered from the DC Bus Board (PN 32005) inside the control cabinet of the

mill.Neveroperatethemachinetoolwiththecabinetdooropen.Nevermakeorchecktheseconnectionswiththemillpowered on.

Power to the ATC and other devices inside the controlcabinetmayretaindangerousvoltagesafterexternalpowerhas been removed. Do not modify these connections inanyway.Ifunsureabouttheconnections,callTormachoraqualifiedrepairtechnician.

1.3 System RequirementsTousetheTormachToolingSystemATC,yourmachinemustmeetthefollowingrequirements:

• Youmustprovideacompressedairsourcecapableofdeliveringclean,dryairat95PSIand2CFM.

• TheTormachPowerDrawbar (PN31706)mustbeinstalled.

• For PCNC 1100 machines serial numbers 1325and lower,youmusthavepreviously installed theSpindleDriveUpgradekit(PN31090).

• ForPCNC1100machines serial numbers 999andlower,youmusthavepreviouslyinstalledtheSeries3upgradekit(PN32010).

Required Tools• MetricAllenwrenchset• Screwdrivers• Box wrenches and large crescent wrench• Hotgluegun• 12” long wooden dowel or round stock


2.1 Unpacking and Checking Shipment

Upon receipt, carefully unpack the ATC and inspect toensure damage did not occur in transit and also to account for all parts. If anydamage is apparent, or partsmissing,pleasecontactTormachimmediately.

With an assistant, lift the ATC onto a sturdy surface orworkbenchtoprepareitforuse.

QTY Description PN1 ATCassembly —

4 ¼”airlines,onew/checkvalveandpushfitting 32226

1 ATCsquaretubemount —4 HexstandoffswithM8andM10studs —4 Flange nuts and washers —20 NylonM6x16hexbolts 322691 USBcable —1 ATCcommunicationRJ-11cable(512-515) 32783

1 Mainpowercable(503,504)terminatedwith 4 pin Molex and spades 35433

1 PDBpowercable(501,502)terminatedwith PDB connector and spades 35434

1 VFDinterconnectwiringkit(532-535) 332131 Coolanthosemountingplatew/fasteners —1 Powerdrawbarpowersupplyboard 319801 Operator Manual —

Thefollowingitemsmayormaynotbeincluded,dependingonmachineageandpowerdrawbarinstallation:

1. Drawbarwitheightspringwashers2. Powerdrawbarcontrolcircuitboard(ifrequiredbased

onageofyourpowerdrawbarinstallation).3. DCBusBoard(PN32005)

Checktheseitems.NotifyTormachofanydamageincurredduringtransitormissingpartssoanyclaimscanbemadewithin the shipping carrier’s deadline.

2. PREPARATION


2.2 Before You BeginTheTormachToolingSystemATCisdesignedformachineswith thepowerdrawbar (PN31706) installed.PCNC1100millingmachineswithserialnumbers1325and lowerwillneedtohavethespindledriveupgrade(PN31090)installedbefore installingtheATC.PCNC1100machineswithserialnumbers999andlowerwillalsohavetohavetheSeries3upgradekit(PN32010)installedbeforeinstallingtheATC.

Allmachineswillneedtohavethepowerdrawbarinstalledbefore installing theATC. See thepowerdrawbarmanual(includedwiththepowerdrawbarpackage)forinstallationinstructions.PCNC1100machinesserialnumbers1999andlowerwillneedtoreplacetheoldDCBusBoard(PN30661)withthenewbusboard(PN32005).

2.3 Mount ATCMountingandaligningtheATCtothemillisajobthatisbestdonewith twopeople. TheATCcarousel assembly,whichweighsapproximately50pounds,iscumbersometoliftandpositionaccuratelyespeciallywhenworkingoverthemill’schiptray.InstallationgoessmoothlywhenonepersonholdstheATCinpositionwhileanassistanttightensthefastenersthatconnectittothesquaretubemount.

Initial Hardware Installation

WARNING! Electrical Shock Hazard: Be sure to power off machine before making any electrical modifications. Failure to do so may result in serious injury or death.

Power Off/On Procedure

Power Off

1. Push red E-stop button in

2. Click Exit on screen; when prompted click OK to power off

3. Turn Main Disconnect Off

Power On

1. Turn Main Disconnect On

2. After software loads, turn red E-stop clockwise to release

3. Press green Start button

4. Click Reset on screen

MainDisconnect

1. Installationiseasiestifmillisawayfromthewall.2. Iffitted,relocatecoolanthosetospindlehead.

3. Iffitted,removethelefthandmachinearmfrommill.

4. If fitted, remove the upper coolant splash guards(backsplash)fromtheleftandrighthandchiptrays.

5. Thread theM8sideofhex standoffs intomill columnandtightensecurelywithawrench.

6. HangthetoolchangersquaretubemountontheM10studs.Securewithflangenutsandwashers.Theslotsarewider thanthestudtoallowforminordeviationsinholelocations,andtofacilitateasmalldegreeoftilt.


7. Withtheassistanceofanotherperson,fastentheATCtothemountusingthe4M10socketheadcapscrewsandflangenuts.

8. Due to stack up of part tolerances, flexibility, andbacklashinthelinearbearings,thechangermightsettleslightly,orsagfromhorizontalonitsmountingsystem.Thisisnormal.Compensateforminorsagbytiltingthemount slightly so the tool tray appears level using a bubblelevel.

NOTE: Be sure to adjust the mount so that the mill spindle cover sheet metal clears the ATC linear rail. The mount will be fine tuned later in the procedure. Do not tighten the flange nuts down at this point, as you will likely be sliding the ATC a bit before final tightening. Lightly snug the fasteners for now.

9. Reroutethecoolanthosebymountingthecoolanthoseclamp to the included coolant plate. Attach the plateto the underside of the spindle head using the two threaded holes on the underside of the spindle head casting.

Use level to get ATC approximately level

Watch for interference

between linear rail and

mill head


3. ELECTRICAL INSTALLATION3.1 Electrical Installation1. Removethefourcolumncoverplatescrewsfrombase

ofcolumnatthebackofthemill.TheZcolumncoverplate will be replaced with the ATC control module.Save the screws.

2. Lay the ATC control module plate with solenoidside downon the chip tray or the Y axis bearing boxtemporarily.

3. Remove the power drawbar electrical housing (Z axismotorconnectionboxcoverplate).

NOTE: If you purchased a power drawbar before June, 2011, you may need to change the power drawbar control circuit board.

CircuitboardslabeledRev1.2willneedtobereplaced.InthiscaseTormachshouldhaveincludedtheupdatedcircuitboardwithyourATC.

CircuitboardslabeledRev1.3andhigherdonotneedtoberemoved from the housing.

• Toreplaceanold(Rev1.2orearlier)circuitboard,disconnectandremovetheoldcircuitboard,takingnoteofthelocationsoftheconnectors.Whilenotnecessary,youmayfinditeasiertoremovetheairlinesandthecablecarrieraswell.

• Replacetheolddrawbarboardwiththenewone.It is easiest to replace the solenoid leads (red and black wire) before re-mounting the circuit board.Thesolenoidleadsgototheoppositesideofboardfromotherconnectors.This is theonlyconnectoronthatside(2pinnylon).

Connect the black VFD interconnect RJ11 cable (with thespadeterminalends) totheDB1connectoronthepowerdrawbar control board, and theATC communicationRJ11cabletotheDB3connectorasshowninthefollowingfigure.


4. RemovetheoldACadaptorpowersupplyandreplaceitwithwires501,502.Thesewireswillberoutedtothenew DC Bus Board.

NOTE: If power drawbar and ATC were purchased together, you will not have an AC adaptor power supply.

5. Routeallwires(thetwoRJ11cables,thebluespindledoorswitchinterfacewires,andthepowerwires503,504)throughthemillcolumn.

IMPORTANT: Twist blue spindle door switch interface wires to power drawbar circuit board (105, 105A) and red wires (105A, 106) inside column. These wires carry 110V AC and may cause EMF that disturbs USB signal transmission. Twisting wires cancels this EMF.

6. Re-securethedrawbarelectricalhousingtotheZaxismotorconnectionboxcoverplate.

Spindle Door

Switch In

terface

Optional F

oot

Pedal (DB2)

Power Draw

bar

Pendant (DB4)

ATC Communicatio

n

Cable (DB3)

PowerVFD In

terconnect

(DB1)


7. ConnecttheATCcommunicationRJ11cable(fromtheDB3connectoronthepowerdrawbarcircuitboard)andtheUSBcabletotheATCcontrolboard.

8. DropanyslackwiresfromtheATCcontrolmoduleintothe Z column, and secure the ATC controlmodule tothebackofthemillusingthesavedM5screwsandintoexistingcolumnholes.BesurethatextrawireslackdoesnotcontacttheYaxisballscrew.

9. Route theUSB cable through the bottomhole of theelectriccabinetintoanyUSBport.DonotusetheblueUSB ports.

CAUTION! Do not connect the USB cable to the controller until after the software installation is complete.

NOTE: Series 1 machines were not manufactured with this hole. If you have a pre-Series I machine, drill a 5/8” hole in the bottom of your electrical cabinet to route the USB cable to your PathPilot controller.

10. RuntheblueATCcontrolboardpowerleads(503,504)andthepowerdrawbarcircuitboardpowerleads(501,502)throughthewirechannelsfromtheholetothebusboardatthetopofthecabinet.

11. Series31100machinescomewiththecorrectDCBusBoard for usewith theATC. Series 3 owners can skipsteps12-13.Domakesuretoinstallthe5x20mmfusesin the DC Bus Board ATC and PDB fuse holders. Thisapplies to all model machines.

ATC Communication RJ11 Cable

ATC USB Cable

5/8” hole is pre-drilled in Series II

electrical cabinet


12. PCNC1100machines serialnumbers1999and lower:ReplacetheoldDCbusboard(PN30661)withthenewbusboard(PN32005).EnsureallfusesarepresentontheDCBusBoardbefore installation (thereshouldbenoemptyfuses).WhenremovingtheoldDCbusboard,catchthestandoffsandsavethescrews.Replacewiththenewboardon the samestandoffs. It isextremelyhelpful to tack glue the standoffs in place beforemountingtheboard.Aneasywaytodothisistoputadabofhotglueonthefastenersbeforeinsertingthemthroughtheboardholesandstandoffs.

NOTE: Refer to the DC bus board layout diagram on the following page when transferring wires.

13. Double-check the polarity of the capacitor, stepperdriver, and ATC connections before powering up themachine. Reversing polarity will destroy the stepper driversandATCcontrolboard.

14. Installthepowerdrawbardaughterboardpowersupply(PN31980)byslidingitontothespadeconnectorsonthenewDCbusboard(PN32005).Thisboardsuppliesthe12Vneededbythepowerdrawbar.

15. Route the RJ11 VFD interconnect cable along thebottomwiretraytotheVFD.RemovetheVFDcoverbyunscrewing the Phillips fastener on the face of the cover plate.

Daughterboard power supply for power drawbar PCB


32005 DC BUSLables and wire numbers

X+ 302X- 303

Y+ 304Y- 305

Z+ 306Z- 307A+ 324

A- 325

BRAKE RLY+ 328

BRK- 327BRAKE RLY- 329

BRK+ 326

J2-48VAC L15

J1-48VAC L25 CAP- 300

CAP+ 301

8 A

8 A

8 A8 A

2 A

8 A

15 A

8 A503 Optional ATC +

504 Optional ATC -

501 Optional PDB -502 Optional PDB +

DAUGHTERBOARDFOR OPTIONAL PDB

F1 = X AXISF2 = Y AXISF3 = Z AXIF4 = A AXISF5 = DC BRAKEF6 = MAINF7 = PDBF8 = ATC

F7F6

F1F2

F3F4

F5F8

S

17.Tidyupthewiresandreplacethecabletraycovers.16.InserttheblackandredwiresoftheRJ-11cableintopositionsT1andB3ontheVFD.Tomaketheseconnections,insertasmallflatheadscrewdriverintheholejustabovethewireterminaltoopentheterminal.

Black wire to

T1

Red wire to

B3

T1 Terminal Point

B3 Terminal Point


4. AIR LINES4.1 Air Line Connection and

Requirements

Itisrecommendedtouseafilter/dryer/lubricatorontheairlineusedtosupplytheATC.Airsupplyrequirementsdependonfrequencyoftoolchanges.Forsuccessfuloperation,yourcompressorwillneedtobeabletomaintain95PSItotheATC.Typicallyconsumptionforfrequent tool changes is less than 4 CFM at 95 PSI.

Please note that not all regulators are created equal. Inexpensive regulators tend to constrict air flow, whichmakesforlongermake-uptimesasthepowerdrawbarfires.While this isnot aproblem for thepowerdrawbarwhenoperated by hand (the user just waits the extra secondor two for the cylinder to fully pressurize), it can causeproblemswhenusing theATC,whichonlypauses500msbetweenthedrawbarfiringandtheZaxismoving.Betterregulatorsdonotrestricttheflowwhileregulatingpressure.

Connect Air Lines

1. Manuallypullthetooltraytotheretractedpositionbypulling on the motor enclosure or it will retract suddenly whenyoupressurizetheairlines.

2. Routetheairlines.Thelinesarelabeledateachend–connect them to the solenoids/fittingswith the samelabels.

3. Connect theair line fromyourcompressor to the leftsideinputconnectorlabeled“AIR-IN.”Youcanremovethepushfittinganduseaquickconnectagainstthefirsttee ifdesired,butwe’ve found iteasier toruntubingtoaquickconnectfittinginaneasier-to-reachlocation.

4. Threadthe¼NPTpushfittingintotheairinputportofthepowerdrawbar.Connectthepowerdrawbarairlinelabeled “D” (with the attached check valve) between

the“DRAWBAR”pushfittingontherightsideoftheATCsolenoid panel and thedrawbar input pushfittingonthedrawbarsolenoid.Thecheckvalveallowsairtopassin onedirectiononly – if you install it backwards thepowerdrawbarwillnotoperate.

5. Ifyouhavepurchasedtheoptionalpressuresensor(PN32329),spliceitintoairlineDandinserttheelectricalconnector into the jackon the columncoverplateasshowninthisphoto:

6. UsetheP-clamptosecurethegreyATCcontrolcabletotheboxbeam,allowingenoughslackforthecarousel’srangeofmotion:

1/4” Push Connector

Check Valve

Optional Air Pressure Sensor


The tray solenoid valve has adjustment screws on theexhaust filters. These can be adjusted to control the trayinandtrayoutspeeds.Thescrewshavebeenpre-adjustedbeforeshipping.Aircushionpinvalvesateitherendoftheaircylindercanbeadjustedtocontroldampingatextremeends of cylinder travel. These are also pre-adjusted. Toolchangetimeshouldnotbeadjustedtolessthan8seconds.Conversely,movingtooslowlywilltriggeranATCtime-outerrorcondition.

Adjustment Screws

Air Cushion Pin Valve


5. SYSTEM VALIDATION5.1 ATC CommunicationsConnecttheUSBcablefromtheATCcontrollertothePathPilotcontrollerandpoweronthePathPilotcontroller.Whenthesystemcomesup,poweronthemillingmachine,bringitoutofreset,andreferencetheaxes.EnabletheATCbycheckingtheATCcheckbuttonontheSettingsScreen.Youwillseeanewtablabeled“ATC”appearalongtherowofnotebooktabs.IfthePathPilotcannotestablishcommunicationwiththeATCwithinafewsecondsofenablingit,youwillseeanerrormessageinstructingyoutocheckthecablesorfusefortheATC.Otherwise,ifnoerrormessageisseen,theATCisworkingproperly.SwitchtotheATCtabforthefollowingsteps.

NOTE: If there is a tool in the spindle, remove it and set the Tool digital read out (DRO) to zero before continuing with these instructions.

Verifytheoperationofthetoolchanger:

1. Applyathinfilmofwayoil tothe linearrailsoftheATCslideassembly.Somechatter isexpecteduntiltheoilhaslubricatedthelinearbearings.


2. WiththetrayoutjogtheZaxisdownacoupleofinches.3. Make sure when doing this that the spindle cover

sheet metal will not hit the ATC linear rail. If thereis interference, adjust the X position of the ATC byloosening the fasteners that attach the ATC to thesquaretubemount.

4. OntheATCscreen,clickthe“GotoTrayLoadPosition”button.TheZaxiswillmoveuptothereferencepositionand the tray will move in.

5. On the status screen, verify that the tray in sensor isworking by looking at the tray in LED – it should beilluminated.Ifitisnot,pleaserefertotheMaintenance and Troubleshooting chapter.

6. Press the Retract button on the ATC screen. The trayshould retract.

7. Clickthe“ReferenceToolTray”buttonontheATCSetupscreen–itshouldfindandcenteronitshomeswitch.It will turn until it finds one end of the sensor, thenreverseandfindtheotherendofthesensor,andthencenterbetweenthesetwospots.

8. Testthedrawbarpendantwiththespindleoff.9. OntheATCscreen,clicktheColletOpen/Closedbutton.

Thedrawbarshouldoperateaccordingly.10. ClickColletOpen/Closedbuttonon theATCscreen. It

shouldfireandlatch.Nowhitthetop(Lock)buttononthe pendant. It should unlatch.

11. ClickBlastbuttonontheATCscreen.Youshouldheartheairstartandstopatthenozzlesinthetooltray.

12. With a tool in the spindle and the tray in the out position,startthespindleatlowspeedinmanualmode;onthestatusscreenverifythattheVFDRunningLEDisilluminated.

13. Optional pressure sensor verification: If you haveinstalledthepressuresensoraccessory(PN32329)youmayverifythatthePressureSensorLEDontheStatusis illuminatedunder lowpressureconditionsanddarkundernormalpressureconditions.

5.2 Align Tool Tray and Slots

Accurate alignment of the tool tray and slots, and thedrawbarthrow,arethemostimportantfactorsinassuringreliableand repeatable tool changeroperation.Takeyourtime, and take care to do this accurately. Videos of thealignmentprocedurecanbeviewedonourWebsite:http://www.tormach.com/upgrades_tts_atc.html

1. Before you begin the ATC alignment,we recommendreplacingyouroldTTScolletwiththenewoneincludedwiththiskit.Ifthisisbeinginstalledonanewmachine,then consider this collet a spare. Be sure to follow the procedureinthePowerDrawbarinstallationdocumenttoproperlysetthedrawbarpreload.

2. ItishelpfultogettheATCassemblyapproximatelylevelusing a bubble level before beginning the alignmentprocedure.

3. Makesurethespindleisinitiallyempty.Thereshouldbeno tool holder in the spindle at this point.

4. Clickthe“GoToTrayLoadPosition”buttonontheATCscreen.TheZaxiswill jogupandthetraywillactuatein,openingthetoolaccessdoor,andthedrawbarwillactuate.

5. Verify that the spindle is roughly in the centerof thecarousel door opening. If necessary, move the ATCforwardorbackwardbylooseningthefourflangenutsthatholdthesquaretubemounttothecolumn.


6. Insertalong(12-14”)dowelorpieceofroundstockintoa TTS tool holder. Insert the tool holder into the forkoftheexposedtrayslot.Note:thetoolholdershouldNOTrestontopofthewhiteplasticspring–thegrooveinthetoolholdershouldslidealongthemetalportionofthetoolfork.Usingotherverticallines(edgeofmillcolumn,Tslotsintable)sightalongthedowelandcheckwhether the dowel and the spindle axis are parallel in bothXandYplanes.

Loosen flange nuts to adjust Y location of tool changer

7. Ifthedowelandthespindleaxisarenotparallel,adjustthetiltoftheATCinbothXandYdirectionsuntiltheyare. • TiltintheYdirectionisfacilitatedbylooseningthe

flange nuts that hold the square tube mount tothecolumn,thengentlytappingtheATCtrapezoidmount with a mallet.

• TiltintheXdirectioncanbeadjustedbylooseningthe socket head cap screws that mount the ATCto the square tube, then turning the eccentricadjustmentscrews.ThisisbestdonewiththeATCinthe“TrayIn”position,asthecenterofgravityoftheunit inthe“TrayIn”positionwillallowyoutousebothadjustmentscrewstotilttheATC.

• Verifythatthetoolholdershank isparallel tothespindleaxisinbothXandYbyusinganangleblockor1-2-3blockwithastraightedge:

Socket head cap screws

Eccentric tilt adjustment screws

Center spindle nose in carousel door opening


againstthespindlewithyourfingerstoseethatitisroughlycenteredleftandrightofforkwhilemakingthisadjustment.

9. Removethetoolfromthetray,thenjogtheZaxisbackdownuntilthespindleisjustabovethetoolfork.Visuallycheck that the tray is level and on a parallel plane to the underside of the spindle. You should see the same distance between the tool fork and the spindle facearound the perimeter of the spindle.

10. Now, pull your hand away, and click “Reference tooltray.”Itwillreturntothenewlycenteredposition.Oncethefirstslotisoriented,allotherslotswillstopinthesamerelativeposition.TheATCwillrememberthisoffsetindefinitely,untilitisresetbythesameprocedure.ThisisnowthereferencelocationfortheATC.

We’renowreadytoverifythealignment.First,verifythatthe power drawbar is adjusted correctly. The drawbarshouldbeadjustedsothatatoolholderwillfalloutofthespindlewhenthedrawbarisactuated.Drawbaradjustmentisdiscussedinthepowerdrawbarinstallationmanual.

8. Once you are satisfied that the axis of the dowelis parallel to the spindle axis inbothXandY, jog thespindle down to the top of the Tormach tool holdershank. Do not go all the way down to the shoulder yet. Verifybyeye that it is roughly centeredon the colletcenter opening.

• To adjust the alignment of the tool holder to thecollet in the X direction, loosen the jam nut atthe end of the tray cylinder rod and move it to a roughlycenteredposition.Press“TrayIn”toverifytheadjustment.Youwill likelyhave to repeat thisprocedureseveraltimestogetthelocationcorrect.

• To adjust the alignment of the tool holder to thecolletintheYdirection,usethe“--“or“++”buttonson the ATC Setup screen Alignment section. It isbesttowiggletheforkwithyourthumbandindexfingertofeeltheextremesofthecarouselbacklash

Jam nuts on either side of carousel flange are used to

adjust X tool change position


Youshouldonlyhavetodothisonce.AtthispointalltheforkswillalignidenticallytothespindleandworkasSLOT1did.Youmayverify thisbyhitting the“GoToTrayLoadPosition” button and advancing through each of the toolpositions.Withthedrawbaractuated,insertatoolholderintheslot,jogdowntowardsToolChangeZ.Whenfinished,click“GoToTrayLoadPosition”tomovethespindleawayfromthetool,thenmanuallyremovethetoolfromthefork.Yoursystem,oncealignedandverified,isreadyforuse.

Test ATC Alignment

1. Click“GoToTrayLoadPosition”ontheATCscreen.2. PushtheTTStoolholderwithdowelintotheopenslot

in the tool tray. 3. Slowly jog Z down until the TTS shoulder touches

the spindlenose. It should slide smoothlyon theTTSshank.Ifitdoesn’t,thetrayismisaligned(notcenteredor perpendicular to the spindle), or the collet hasn’topened far enough to spring out for smooth entry. NOTE: If tray is not properly aligned there will be noticeable movement at the end of the dowel as the spindle slides down over tool shank. This must be corrected by adjusting either the tilt or the XY location of forks to ensure trouble-free operation.

4. Once you get aligned for a smooth descent, jog Z tothe shoulder.When the spindle is restingon the toolshoulder, click the “Set TC POS” button on the ATCscreen.

5. You’venowset the tool change locationof theZaxisfor all tool changes. This position is remembered asa machine coordinate, is saved at shutdown, and isindependent of all work or tool offsets establishedduringmachining.As longasZ is referenced, the toolchange will occur at the same place.

6. After setting the tool change location, jog the Z axisbackupoffofthetoolshankandremovethetoolfromthe fork.

Nowchecktheindividualforkalignment.Duringshippingorassembly,theforksinthetooltraycanshiftabitoffcenter.The tool holding forks need to all line up the same wayunderthespindle.Jogthespindleupslightly,thenontheATCControlscreenclicktheTrayFWDbuttontoindexthecarouseltothenexttoolfork.JogZdowntosothespindleistouchingthetopoftheforkspring.Pushthespringleftorrightuntilitisroughlycenteredusingthethumbandindexfingertechniqueemployedinstep7intheprevioussection(Align tool Tray and Slots).Ifthealignmentisoff,youmighthave to jogupand loosen thenylonbolts a tadfirst. Jogupandtightenthenylonboltsatcenteruntilsnugbutnotoverlytight.Repeattoalignalltheslots.

Use 10 mm wrench to adjust individual fork alignment


6. OPTIONAL ACCESSORIES6.1 Foot Pedal Kit

TheFootPedalKit(PN31728)provideseasyfoot-activationofthepowerdrawbarforhands-freeoperation.Toinstall:

1. Removethepowerdrawbarelectricalhousing.

2. PlugthefootpedalcableintotheFootPedalconnectorportonthepowerdrawbarcontrolboard(asshowninthefigurebelow).

Power Drawbar Pendant ATC VFD

FootPedal

3. Placethefootpedalinapositionthatallowsforeasyaccessduringmilloperation.

6.2 Filter Regulator Lubricator (FRL)

TheFilterRegulatorLubricator(PN32457)isrecommendedfor proper conditioning of supply air for both the powerdrawbarandtheATC.

NOTE: See Chapter 4, Air Lines, for recommended air supply requirements.

Toinstall:

1. Drilltwoholesintothebackofthesplashguard(orwherever is convenient for mills without a splash guard).

2. SecuretheFRLtothemountingbracketwithyourownequipment.

3. WrapthefittingsonthetwoNPTreducerswithTeflontapeandsecurethefittingsintotheFRLvalvehousings.

4. Splice the air supply line and insert a quick connect bushing(PN32212)toeachendoftheopenline.

5. ConnectthebushingstotheNPTreducers.


6. OpentheFRLfillportwithahexkey.7. Fill the port with standard air tool oil (using a small

funnelifnecessary).

NOTE: Before first use, air must be flushed from the FRL system.

NOTE: Proper function may be confirmed visually through the sight glass on the top of the FRL.

Adropletoflubricantwillformonthebottomofthestemlocated inside of the sight window.

1. Openthelubeadjustmentknob1/2turn(towards the+).

2. Flushallairbubblesfromthesystem.3. Whenairbubblesnolongerappearinthesight

windowandadropletoflubricantformsonthebottomofthestem,closethelubeadjustmentknob1/4turn(sothatitisopenapproximately1/4turnfromtheclosedposition).

AdjustmentKnob

Sight WindowSight window

Adjustment knob


6.3 Pressure Sensor

PressureSensor(PN32329)prevents the carousel from actuatingduringlowairsupplypressurecondition.

1. Splice air line D and insert the Pressure Sensor as shown.

2. Plug the male end of the electrical connector into the jackonthecolumncoverplate.SeeChapter4,Air Lines,foradditionalinformation.

Drawbar


7. OPERATION7.1 General Theory of Operation

TheTormachToolingSystemATCwillholduptotentoolsinasingletray.TheATCallowsmixingmanualandautomatictoolchangeswithinthesamepartprogram.Ifyourprogramrequires11ormoretools,theATCwillchangetoolsautomaticallyforalltoolsinitstray,andpauseforamanualchangefortoolsthatarenotassignedtothetray.Anytoolnumberbetween1and256maybeassignedtoapositioninthetooltray–youarenotconfinedtousingtoolnumbers1-10.Thisisconvenientifyouhaveatool libraryalreadysetupwithtoolnumbersandheightsmeasuredinyourtooloffsettable.Thereisnoneedtorememberwhichslotaparticulartoolhasbeenassignedto–simplycallthetoolnumberinG-codewithanM6commandandtheATCwillretrievetheappropriatetool.

7.2 Loading/Unloading Tools

TherearetwowaystoloadandunloadthetooltrayinpreparationformachiningusingtheATC.InautomatictoolloadingviatheStoreCurrentToolbutton,theATCwillloadthetoolthatiscurrentlyinthespindleandstoreitinthenearestopentrayslot.Inmanualtoolloading,thetraywillslideinandthetraydoorwillopen,allowingtheoperatortomanuallyplacetoolsintothetray.Thefollowingsectionsdetailthesetwomodesofoperation.

7.3 Automatic Tray Load/Unload

TherighthandsideoftheATCcontrolscreencontainsthebuttonsandaDROusedtostoreandretrievetools.Toloadatoolintothetray:


1. Loadthedesiredtoolintothespindle.2. Enter the tool number in the tool DRO (bottom right

portionofscreennexttotheM6G43button).Donotforgettopress“Enter”aftertypinginthisnumber.

3. Click the “Store Current Tool” button. The ATC willassign the tool to the nearest open slot and store the toolinthatslotinthetray.Thetoolnumberwillnowbedisplayed on the tray image in the center of the screen. Thespindleisnowreadyforthenexttooltobestored.

Toretrieveatoolfromthetraytherearetwooptions.YoucantypeTxxM6attheMDIline(wherexxisthedesiredtoolnumber)orenterthetoolnumberinthetoolDROandpresstheEnterkey.Thiswillretrievethattoolfromthetrayandleave it in the spindle. It also leaves it assigned to the tray.

Toremoveatoolfromthetray,typeinthetoolnumberintheDROnexttothe“Remove”button(remembertopressenteraftertypinginthetoolnumber),thenclick“Remove.”After the ATC fetches the tool you will be prompted toremove the tool from the spindle.

Toremoveatoolfromthespindle,anddeleteitsassignmentfrom the tray, click “Remove.” You will be prompted toremove the spindle tool.

NOTE: Simply typing a new tool number into the tool DRO does not remove the tray assignment. You must use the “Remove”buttontodeletethetool’strayassignment.

“ATCFWD”and“ATCREV”willreturnthespindletooltothetray,thenfetchthenext/previoustoolinthetray.

7.4 Manual Tray Load/Unload

Ifyouwantto loadorunloadmultipletoolsyoumayfindit faster to open the tool changer door and load or unload themmanually.TheManualLoad/UnloadbuttonsandDROontherighthandsideoftheATCscreenwillallowyoutobringthetraytoa loadingposition(dooropen),manuallyinsert or delete, and assignor un-assign tool numbers totraypositions.

Toloadtoolsmanually:

1. Click “Go To Tray Load Position” tomove the spindleheadupandbringtheATCintothedooropenposition.

2. Insert a tool into an open fork.

3. TypethetoolnumberintotheDROnexttothe“Insert”button. Remember to press enter after typing in thenumber.

4. Click“Insert”toassignthetooltotheexposedtrayslot.5. Click“TrayFWD”or“TrayREV”toadvancetothenext

locationifyouwanttoloadanothertool.

Tounloadtoolsmanually:

1. Click “Go To Tray Load Position” tomove the spindleheadupandbringtheATCintothedooropenposition.

2. If the exposed tool is the one you want to remove,simplyclick“Delete”toun-assignthetoolfromthetray.

3. Ifthetoolyouwanttoremoveisnottheexposedtool,typethetoolnumberintotheDROnexttothe“Insert”button. Remember to press enter after typing in thenumber.

4. Click“Delete”toun-assignthetool.Thetraywillmovetothetooltoberemoved.

5. Click“TrayFWD”or“TrayREV”toadvancetothenextlocationifyouwanttounloadthenextorprevioustool.

6. Whenyouarefinishedloadingorunloadingtools,callany tool (using the tool DRO or with an M6 command attheMDIline)orclick“Retract”toreturnthetraytomachiningposition.

NOTE: If you click “Delete” or “Insert” and the ATC is not in tray load position, it will move to tray load position automatically.

7.5 Tool Touch-off Routine

IfyouhavetheoptionalTTSToolSetter(PN31875)theATCcontrol software can be used to automatically measurethetoolheightoffsetforeverytoolinthetray.Tousethisfeature,plugtheToolSetterintotheaccessoryportandtestcommunication by actuating the Tool Setter by hand andensuringthatthegreenToolSetterLEDontheATCControlscreen lightsup.CentertheToolSetterdirectlyunderthespindleandclickthe“TouchOffEntireTray”buttonontheATCControl screen.TheATCwill cycle throughevery toolin the tray and enter the measured tool length in the tool table.Afewthingstonoteabouttooltouch-off:


• Tools with large diameters (greater than thediameter of the Tool Setter pad) will not beaccurately measured unless the cutting edge ofthe tool makes contact with the Tool Setter. Forinstance,caremustbetakenwhenusingthe“TouchOffEntireTray”routinewithaflycutterorshellmillin the tray.

• Unless you set up the sensor height of your ToolSetterbeforetouchingoffthetools,thetoollengthsenteredinyourtooltablewillberelative,nottruetoollengths.YoumustsetuptheToolSettersensorheight tomixATC tools thathavebeenmeasuredusing the Tool Setter with tools that have beenmeasured on a granite black and height gauge.Setting the sensor height is described in detail inthePCNC1100operatormanual.

7.6 ATC Bypass

To bypass the ATC, click the Manual Tool Change checkbuttonontheSettingsscreen.

WhentheManualToolChangeoptionisselected,theATCispreventedfromexecutinganytoolchanges.Insteadyouwillbepromptedbythesoftwaretomanuallycompleteanytool changes that are called within a program.


8. MAINTENANCE & TROUBLESHOOTING8.1 SupportTormachprovides freetechnical support throughmultiplechannels. The methods are listed below, in order ofpreference:

1. Thismanual(forATCrelatedissues)orthePCNCmanualisalwaysthefirstplacetocheck.

2. Viewrelateddocumentsatwww.tormach.com/documents.html

3. OurWebsiteatwww.tormach.com4. Sendanemailto:[email protected]. CallTormachat:608-849-8381x20016. FaxTormachat:209-885-4534

8.2 Maintenance

TheTormachToolingSystemAutomaticToolChangerrequireslittlemaintenance.Periodicallyinspectthefollowing:

• Ensure that your air is clean and dry. A filter/regulator unit should be sufficient for supplyingdry air, as long as you periodically drain yourcompressor.

• The linear guides should be periodically wipedclean and given a light coat of way oil.

• TheDelrinbearingonthecarouseldoorshouldbeperiodically oiled with way oil.

• Ifchipsaccumulateinsidethecarousel,itisadvisedto blow chips clear of the carousel and tray toprevent them from obstructing tool changes.(Alwaysweareyeprotection).

Additionally,afterinstallingtheATCyoumayfindthatyouare using your power drawbar more frequently. Powerdrawbarmaintenanceitemstoconsiderare:

• Periodically tighten the set screw on the spindleflange.

• Periodicallyensurethatmountinghardwareissnugandfastenersaretight.

• Spring washers are wear items that have a service life of ~30,000 tool changes. If you experiencecollet slip or notice deterioration of the springwashers,replacethemaccordingtotheprocedureoutlinedinthepowerdrawbarinstallationtechnicaldocument.

• For more information, refer to Troubleshooting section in TD10039, PCNC 1100 Power Drawbar Installation.

8.3 Troubleshooting

Mechanical Issues

Binding

IfyourATChasnotbeenproperlyalignedyoumayexperiencebindingasthecolletdescendsoverthetoolholdershank.TheATCcarouselmustbe inaplaneperpendiculartothespindleaxis.Thebestwaytocheckthis is toplacea longdowelinadrillchuckorsetscrewtoolholder,thenpositionthattoolholderinanopentrayslot.Asyoujogthespindledown over the tool holder shank, watch the end of thedowel.IftheATCisproperlyaligned,theendofthedowelwon’t move as the collet slides over the shank. AligningtheATCistimeconsumingtodoproperly,butoncesetthealignment should not change.

ColletSlip

Colletslipcanresultfromavarietyofcauses.Thebestwayto prevent collet slip is to make sure that your tool holders andtheboreoftheTTSR8colletarecleananddry.Wipingthem down with alcohol or acetone is a good way to remove wayoilorcuttingfluidthatmaycausecolletslip.

The procedure for adjusting the preload on the springwashers is outlined in the power drawbar installationguide.Becausethespringwasherpreloadalsoaffectstheoperation of the ATC, certain parts of this procedure areworthrepeatinghere:

1. Whenadjustingthepreload,makesureregulatoronyourairlinesettoatorbelowthecutinpressureonyouraircompressor.Forinstance,ifyourregulatorswitchesonat90PSI,andyourregulatorissetto95PSI,theactualairpressureatthedrawbarcouldbeanywherebetween90and95PSI,dependingonthetankpressure.Thisisbad:ifyousetspringwasherpreloadwhenyouhave95PSItoworkwith,thedrawbarwillnotproperlyreleasewhenPSIdecreasesto90,increasingcrashrisk.

2. The higher theworking air pressure, themore preloadyou can get on the spring washers. If compressor can be adjusted to maintain 100 PSI, you can run withhigher preload than you would at 90 PSI. Minimumrecommended air pressure is 95 PSI, but if collet slips,increase supply pressure to get preload up. Do not exceed 120PSI,theworkinglimit for thepowerdrawbarcylinder.


http://www.tormach.com/documents.html

http://www.tormach.com/documents.html

www.tormach.com

3. Notallairregulatorsarecreatedequal.Wehavefoundthat inexpensive regulators tend to constrict air flow,whichmakes for longermake-up times as the powerdrawbarfires.Whilethisisnotaproblemforthepowerdrawbarwhenoperatedbyhand(theuserjustwaitstheextrasecondortwoforthecylindertofullypressurize),itcancauseproblemswhenusingtheATC,whichonlypauses500msbetween thedrawbarfiringand theZaxismoving.Betterregulatorsdonotrestricttheflowwhileregulatingpressure.

4. Colletslipismorelikelytooccurifyourspeeds,feeds,orfixturingresultinmachiningoperationswithalotofhighfrequencychatter(endmill“squeal”).Wehaveseen even light cuts result in collet slip if the end mill is squealingorchatteringexcessively.Usually,suchnoiseandvibrationshouldbeavoidedforotherreasons(poorsurfacefinish,reducedtoollife)andtweakingthe spindle RPM or increasing the feed rate will tune thechatterout.

ATCTrayChatter

If the3 linearbearings that support the carousel arenotproperlyalignedwiththelinearguides,youmayexperiencechatter on tool changes. Sometimes this chatter can beeliminatedwitha lightapplicationofwayoil tothe linearguides.Ifthechatterpersists,loosenthe4M5Allenheadscrews that hold the linear bearings on to the carouselassembly.Allowthebearingstoselfalign,thenretighten.

ZHeightNotRepeatable

If tool change Z height is set incorrectly the toolwill notbeproperlyseatedagainstthespindlenose.Thisproblemmanifests itself in poor repeatability of tool lengthcompensation. This is a condition that can be hard todiagnose, because a small gap between the tool holdershoulder and spindle nose can be difficult to see. If yoususpect that the tools are not seating properly, backlightthe tool holder with a flashlight – any gap will becomeapparent. During tool changes, the spindle should comedown and make contact with the shoulder of the tool. If the spindletravelsdowntoofarornotenough,therewillbeavisiblegapbetweenthetoolholderandthespindlenose.AdjustmentoftoolchangeZheightisdiscussedinsection2.2.6 of this manual.

It is alsopossible theR8 collet isprotruding too far fromthespindlenose,thiscanbethecase ifthedrawbar isn’ttighteneddown sufficiently or if the gapbetween the air

cylinderboltheadand the topof thedrawbarbolt isnotlarge enough. Adjusting the spring washer tension iscoveredintheInitialSetupsectionneartheendofthePDBinstallationdocument. If thegapbetweentheaircylinderboltandthedrawbaristoolittle,thiswillover-traveltheR8colletallowingittohitinthebottomofthepocketoftheTTSholders. Remove washers as required to allow full release of theTTSyetstillnotpushthecolletastobecontactingtheTTSholder.Formoreinformation,refertoTD10039,PCNC 1100 Power Drawbar Installation.

Sensors

TheATCusesthefollowingsensors:

1. TRAYIN2. TRAYOUT3. TRAYREFERENCE4. Pressureswitch(optional)

TheTRAYIN/OUTsensorsarenormallyopenreedswitches.TRAYOUT isvisibleunder thebandclampat theend thepneumatic actuator. TRAY IN is hidden in a recess in thelinearrailbehindthepneumaticcylinderandisnotvisibleunless the cylinder has been removed. Thepistonof thispneumatic actuator is magnetic – the reed switches areactuated when the piston inside the cylinder comes within 0.100”ofthesensor.

WhenPathPilotisstartedtheATCgoesthroughinitialization,theTRAYINandTRAYOUTsensorsareevaluated.IftheATCsoftwareencountersaconditionwherebothsensorsreturnHIorbothreturnLO,anerrormessageisgenerated.Otherchecksinthesoftwareuserthetraysensorstotrytopreventcrashes–forinstanceiftheTRAYINsensorisactivetheATCwillstopyoufromjoggingpastthetoolchangeposition(asoftlimitistriggered).

DiagnosticLEDsarevisibleontheStatusscreen.Thesecanbe used to verify the sensors. If a sensor is not workingas expected, the following possible causes should beinvestigated:

DefectiveSensor

Anymagnetcanbeusedtoverifywhetherornotthesensorisworking.IfyoubringastrongmagnetneartheTRAYINorTRAYOUTsensorstheyshouldreturnTRUE.Ifthesensorisworking,youcanskiptothe“Sensorisoutofadjustment”section.


If the sensor is not working, youwill need to determinewhetherthesensoritself isdefectiveor ifthereisashortin the wiring.

NOTE: The TRAY OUT sensor is held in place by a band clamp – if this clamp is over tightened it will prevent the sensor from working. You might try loosening the band clamp as a first step in diagnosing a bad TRAY OUT sensor.

To distinguish between a wiring problem and a sensorproblem, you will need to Ohm out the sensor with amultimeter:

1. Removethemotorcover, thenremovethetopof thesteppermotor’selectricaljunctionbox:

2. Disconnectthe20pinMolexconnector.Thefemalesidegoestothemotorandsensors:

3. Touchyourprobeleadstothepinscorrespondingtothesensorofinterest:

20-pin connector to motor and sensors

Tray in sensor

Tray out sensor


4. Whenamagnet isnearthesensor, thesensorshouldread close to 0Ohms, otherwise it should readopencircuit.

If thesensor readsappropriatelyat the20pinconnector,thentheoverwhelminglikelihoodisthatthe20pinjunction(male side – to the control board) has a faulty crimp. Tobesureyoucanrepeattheabovemultimetertestsatthecontrolboard(seeschematicforappropriatepins).

If the sensor does not read appropriately you should remove the sensor assembly (which requires removal ofthepneumaticactuator).Asafinalcheckyoucanohmoutthesensorswhentheyareoffofthemachine.ThesensorassemblyisPN32138.

SensorOutofAdjustment

If the tray sensors work when you wave a magnet over them,butdon’treadthetraypositionaccurately,theyareoutofadjustment.Themagneticpistonmustcomewithinabout0.100”ofthesensortoactivatethesensor.Sprinklingironfilingsontheoutsideofthecylinderisagoodwaytoverifythepositionofthemagneticpiston.Youshouldverifythatthesensorispositionedsuchthatthemagneticpistonis directly over the sensor when in the tray out or tray in positions.Also,checkthattheaircushionadjustment(smallbrasssetscrew)hasn’tbeenover-adjustedtoahardstop,which will prevent the piston from traveling all the way to eitherposition.

TrayReference

TheTRAYREFERENCEsensorisanormallyopenreedswitchhousedinablackplasticenclosureontheundersideofthecarousel umbrella. It is used to provide a carousel homereference position. It reads a small neodymium magnetembeddedinthehub.

Thefirsttoolchangeafterthecontrolsoftwareisstarted,oranytimeafterthemill ise-stoppedandthenre-powered,thetraywillreferenceitself.Itspinsquicklyinonedirectionuntilisthesensorreadsthemagnet,movespastthemagnet,thenitreversesdirectionandmovesslowlyuntilitreadsthemagnet again. If the sensor is not working properly the tray will spin for10 secondsor so, thentimeout andgiveanerror message.

The sensor should be positioned as shown in the abovephoto–asmallgapshouldbepresentbetweenthemagnetembeddedinthehubandthesensoritself.

ThissensorcanbeOhmedoutinthesamewayastheTRAYINandTRAYOUTsensors:

Sensor Housing

Magnet

Gap should be 0.010”-0.020” between sensor and magnet face

Tray reference sensor


HubDisassembly

1. Removethetooltraybyremovingtheflangenutthatattachesthetraytothehub.

2. UseanAllenwrenchtounscrewthestudthattheflangenut was screwed on to.

3. Behindthestudisasmall(M4)socketheadcapscrew;remove this.

4. Loosen the two set screwsand remove thehub fromtheshaft.

ATC Recovery

Asyou learn touse the toolchangeryoumayexperiencea tool crash. Thankfully, it is very difficult to damage theTormach ATC. The software is intelligent and can predictpotential crashes, warning the operator with a pop-upwindowbefore executing the commanded change. If youareunfortunateenoughtoexperienceacrash:

1. Use“DrawbarDown”buttonontheATCSetupscreenorthe“Release”and“Lock”buttonsonthependanttorelease the tool.

2. UseReferenceZbuttontomoveZaxisclearoftheATC.3. Usethe“TrayOut”buttonontheATCSetupscreento

retract the tray.4. Alwaysre-referencethetooltrayafteracrash.5. Make sure that the tools that are physically in the tray

matchthetoolsshownontheATCcontrolscreen.6. If there is amismatchbetween the software and the

actual tools thatarepresent in thetray,click the“GoToTrayLoadPosition”buttonandthenusethe“Insert”and“Delete”buttonstocorrecttheerror.

BrokenForkFasteners

Thehexboltsthatholdthetoolforkstothetrayarenylon

shearboltsthathavebeenengineeredtofailundergreater-than-normal loads.Theseboltswillsnapintheeventofatoolcrash,preventingdamagetotheATC.NEVERREPLACETHESE BOLTSWITHMETAL FASTENERS! Doing so will put yourATCatrisktomoreseriousdamageintheeventofatoolcrash.Ifyouexperienceacrashthatbreakstheseshearbolts,replacethemwiththeextraboltsprovidedwiththeATCandrealignthetoolforkusingtheproceduredescribedinsection2.3.3.NotethattheforkhasaU-shapedrabbetononeside.Thisrabbetmust facedownasshowninthefollowingphotos:

Correct

Incorrect

Rabbet should face down


Thecontrol software records thepositionsof the tools inthe carousel and spindle in a configurationfilewhen youshut the software down. If you fail to shut the softwaredown before turning off the controller, or if you have apower failure during operation, the softwaremay restartwithincorrecttoolpositionsshownontheATCscreen.Thisisaneasyconditiontorecoverfrom.Performthefollowingstepstocorrectthisproblem:

1. If there is a tool in the spindle, remove it beforeproceedingwithanATCrecovery.

2. Clickthe“TrayLoadPosition”buttonontheATCscreen.3. Using the “Tray FWD” or “Tray REV” buttons, index

throughthetray.Usethe“Insert”and“Delete”buttonsontheManualLoad/UnloadsectionoftheATCcontrolscreen until the tools that are physically in the traymatch up with the tools shown on the ATC controlscreen.


Notes


9. DIAGRAMS & PARTS LIST


9.1 ATC Carousel

ITEM NO. PN DESCRIPTION QTY.

1 32149 ToolTrayDoor 12 32133 TrayArmPin–Front 13 32150 TrayDoorThrustBearing–Lower 14 32148 DoorThrustBearing–Upper 15 32195 M6x5FlatHeadScrew 16 32131 TrayDoorArm 17 32132 TrayArmPin–Rear 18 32192 M3x12SHCS 29 32136 12mmC-Clip 310 32135 TrayLeverWasher–Rear 111 32134 LeverWasher–Front 112 32151 Spring Washer 113 32153 CowlingStandoff 414 32160 ToolTraySensorHousing 115 32162 TraySensorHousing–Top 116 32166 6PinMolexHeader 117 32164 TraySensorAssembly 118 21205 M6x30SHCS 419 32155 ToolTrayCowling 120 32169 10-32x1/4PushConnector 521 32141 Blast Union Block 122 32180 1/4RollPin 123 32152 ToolTrayHub 124 32159 ToolClaw 1025 32156 ToolTrayPlate 126 32158 ToolClawSpring 1027 32173 M6X16NylonHexBolt 2028 32174 M14FlangeNut 129 32176 M14x30Stud 130 32157 TrayStiffenerWasher 131 32179 M5 x 12 Set Screw 232 32177 M8x10HubRetentionBolt 133 32178 Magnet 134 32236 LidScrew 435 32243 Blastnozzle 236 32232 PUR1/4AirLine 2


9.2 ATC 1100 Column Mount

ITEM NO. PN DESCRIPTION

1 32120 1100BoxBeam2 32244 CamTiltAdjuster3 32121 ColumnStandoff4 32248 CableRetainerClip5 32177 M8x10SHCS6 32187 M10FlangeNut7 32233 Fender Washer8 42246 Nut


9.3 TTS ATC Actuator

ITEM NO. PN DESCRIPTION

1 32187 M10FlangeNut2 32186 M10x25SHCS3 32122 Interface Mount4 32123 Rail5 32124 LinearBearing6 32183 M8x16LowHeadSHCS7 32125 Bearing Spacer Block8 32126 Front Cylinder Bracket9 32188 M6x25SHCS10 32190 M6FlangeNut11 32145 Motor Chassis Cover12 32130 Cylinder3/4x16JamNut13 32142 1/8NPTx1/4PushConnector14 32137 Band Clamp15 32172 7/16JamNut16 32127 Cylinder Rod Bracket17 32143 Motor Chassis18 32182 M8x35SHCS19 32189 M6x16SHCS20 32147 GearHead21 32146 NEMA34Motor22 32191 M6x24SHCS23 32200 Molex20PinHeade24 32199 20PinMolexPlug25 32249 ConnectionBoxLid26 32250 M3x5PanHead27 42249 CableChafeGuard28 32129 Rail Cover Plate29 32140 FlexCableRetainer1/2NPT30 32139 FlexCableRetainer–1/4NPT31 32193 M3x5SHCS32 32203 4PinMolexHeader33 32138 Cylinder Sensor Module34 32128 AirCylinder35 32201 M4x25PHScrew


9.4 ATC Control Module Assembly

ITEM NO. PN DESCRIPTION QTY.

1 32206 ColumnAccessPlate 12 32210 2 Port Solenoid 13 32207 1/4NPTx1/4Elbow 24 32212 1/4NPTx1/4Straight 25 32209 5 Port Solenoid 16 32213 1/4NPTx1/4ExtendedElbow 17 32211 SpeedMuffler 28 32215 1/4RunTee 39 32232 1/4PURAirLine 110 32238 1/8NPTX1/4StraightFemale 111 32238 Pressureswitchboot 112 32237 Pressure Plug 113 32793 Stepper Driver 114 32230 ControlBoxStandoff 115 32228 1/2NPTCableClamp 116 32227 Control Box 117 32231 ControlBoxLid 118 32239 MolexMicroMini10pin 119 32238 4pinmolexjr 120 32240 Molex Micro 12 Pin 121 32208 M5x10PanHead 422 32214 2 Port Solenoid Mount Block 123 32223 RunTeeStandoff 124 21205 M6x30SHCS 425 32190 M6FlangeNut 426 32218 M3x25SHCS 427 32217 M4x30SHCS 628 32221 M4 Washer 1029 32222 M4LockWasher 1030 32219 M4HexNut 631 32220 M3HexNut 432 32225 M4x16SHCS 233 32235 3.5mmjack 134 32236 LidScrew 435 32241 Pressure Switch 136 32270 ATCControlPCB 137 32226 CheckValveInLine 1(notshown) 32860 ATCtoAxisDriverRibbonCable 1(notshown) 35433 503/504ATCPowertoDCBusWireHarness 1(notshown) 35434 501/502DCBustopowerdrawbarPCBWireHarness 1


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(RJ11

, DB3

p1-4)

(ATC

)

(Pend

ant)

3200

5

3197

9

3198

0

Gree

n Red

Oran

ge

Gree

nBlack

Red

Whit

e

Blue

Flex 1

Flex 2

Flex 3

Flex g

/y

Black Bla

ck

Black

Black

3227

0

(Foot

Peda

l)

DB3

Ribbo

n P1-1

0

5A 5A

1

6

1

4

501

502

501

502

503

504

506

-+

509

510

511

508

509

510

511

512-5

15 (4

pin)

512-5

15 (4

pin)

516

517

518

519

520-5

29 (1

0 pin)

503

504

Tray

530

531

(RJ11

, DB1

p1-4)

(VFD

)

3221

032

209

3216

432

138

Black

Red

532-5

35

+ -

+ -

(Cylin

der S

enso

r Mod

ule)

dip sw

506

508

507

Stepp

er Dr

iver

TTS

ATC

Elec

tric

al S

chem

atic

Feb,

201

2

PN 3

2793

12345678

offon onononon offon

To GreenTo White

To Re

d

To Ye

llow


9.5 TTS ATC Pneumatic SchematicDecember, 2012TTS ATC PNEUMATIC SCHEMATIC

BA

MAIN AIR IN

Tray In Speed

Tray Out Speed

Tool Tray Air Blast Assembly

Power Draw

bar Check Valve

C

AB

C

PressureSensor

Carousel Cylinder

VFD

(Optional)


9.6 ATC Electrical

ATC J1 – Power (Molex Mini Jr 4)

ATCJ1 P1 +70VinATCJ1 P2 +70VinATCJ1 P3 GndATCJ1 P4 Gnd

ATC J2 – Solenoids/Estop (Molex Mini Jr 12)

ATCJ2 P1 Solenoid5+12VATCJ2 P2 Solenoid4+12VATCJ2 P3 Solenoid3+12VATCJ2 P4 AirBlastSolenoid+12VATCJ2 P5 ToolTraySolenoid+12VATCJ2 P6 Estop(notused)ATCJ2 P7 Solenoid5–GndATCJ2 P8 Solenoid4–GndATCJ2 P9 Solenoid3–GndATCJ2 P10 AirBlastSolenoid–GndATCJ2 P11 ToolTraySolenoid–GndATCJ2 P12 Estop(notused)

ATC J3 – Switches and Sensors (Molex Micro 12)

ATCJ3 P1 unusedATCJ3 P2 unused

ATCJ3 P3 CylinderInSwitch/+5VATCJ3 P4 ToolTrayHomingSwitch/+5VATCJ3 P5 CylinderOutSwitch/+5VATCJ3 P6 ExtraSwitch/+5VATCJ3 P7 unusedATCJ3 P8 unusedATCJ3 P9 CylinderInSwitch/GndATCJ3 P10 ToolTrayHomingSwitch/GndATCJ3 P11 CylinderOutSwitch/GndATCJ3 P12 ExtraSwitch/Gnd


ATC J4 – Tormach Stepper Ribbon (IDC 10)

ATCJ4 P1 unusedATCJ4 P2 unused

ATCJ4 P3 +5VcommonATCJ4 P4 Step ATCJ4 P5 DirectionATCJ4 P6 unusedATCJ4 P7 unusedATCJ4 P8 unusedATCJ4 P9 unusedATCJ4 P10 unused

ATC J5 – ATC (RJ-11)

ATCJ5 P1 DrawbarBoardInputSignal(VFD,SolenoidStatusviaPWM)ATCJ5 P2 DrawbarOutput–UP

ATCJ5 P3 DrawbarOutput–DNATCJ5 P4 Drawbar/Gnd

Stepper Driver Dip

Sw 1 OnSw 2 Off

Sw 3 OnSw 4 OnSw 5 OnSw 6 OffSw 7 OnSw 8 On

42 PBUM10354_PCNC1100_ATC_0916A UM10354_PCNC1100_ATC_0916A

tormach pcnc 1100 atc - microsoft · 2019. 4. 2. · atc before operating.it is the responsibility...

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