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Tormach ATC Operator's Manual

Automatic tool changer for pcnc 1100
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USING THE TORMACH
TOOLING SYSTEM ATC
AUTOMATIC TOOL CHANGER
FOR THE PCNC 1100
Operator's Manual
© 2013 Tormach
LLC. All rights reserved.
®
Tormach TTS ATC Manual:
Questions or comments?
UM10081_TTS_ATC_PCNC1100_1013A
Please e-mail us at:
info@tormach.com

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  • Page 1 USING THE TORMACH TOOLING SYSTEM ATC AUTOMATIC TOOL CHANGER FOR THE PCNC 1100 Operator’s Manual © 2013 Tormach LLC. All rights reserved. ® Tormach TTS ATC Manual: Questions or comments? UM10081_TTS_ATC_PCNC1100_1013A Please e-mail us at: info@tormach.com...

  • Page 3: Table Of Contents

    Foot Pedal Kit 7.2 Filter Regulator Lubricator (FRL) Optional Accessories 7.3 Pressure Sensor Operation 8.1 General Theory of Operation 8.2 Loading/Unloading Tools 8.3 Automatic Tray Load/Unload 8.4 Manual Tray Load/Unload 8.5 Tool Touch-off Routine 8.6 ATC Bypass Maintenance & Troubleshooting 9.1 Support Maintenance 9.3 Troubleshooting 10. Exploded View & Parts List 10.1 ATC Carousel 10.2 ATC 1100 Column Mount 10.3 TTS ATC Actuator 10.4 ATC Control Module Assembly 10.5 TTS ATC Pneumatic Schematic 10.6 ATC Electrical UM10081_TTS_ATC_PCNC1100_1013A...

  • Page 4: Preface

    1. PREFACE 1.1 Manual Overview Operator Safety • This manual is intended for users of the Tormach Tooling When using electric tools, machines or equipment, System Automatic Tool Changer - an accessory to the basic safety precautions should always be followed Tormach PCNC 1100 mill. Readers are assumed to be to reduce the risk of fire, electric shock, and personal familiar with the operation and documentation for their injury. • particular milling machine. For questions of a general Read and understand this manual. Do not operate the nature (e.g. applying tool height offset compensation) ATC without knowing the function of every control please refer to the PCNC 1100 machine manual. key, button, and alignment and referencing procedure. Refer to this manual or contact Tormach if any function The TTS ATC can be used with all existing part programs is not understood. • without modification, regardless of existing tool number Keep hands clear of the ATC at all times during tool assignments. For programs that use 10 tools or fewer the changes or when commanding any ATC motion from ATC may be used for all tool changes. For part programs the ATC control screen of the mill’s control software. • requiring more than 10 tools, or for programs requiring Avoid contact with moving parts. Before operating the special tooling not appropriate for an ATC, such as a mill and ATC, remove all jewelry including watches and reversing tapping head, it can be used in conjunction with rings, neckties and any loose-fitting clothing. Tie back manual changes. Any tool number between 1 and 253...

  • Page 5: System Requirements

    Electrical Safety The Tormach Tooling System ATC operates on 70 VDC, fused at 8 amps. It is powered from the DC Bus Board (PN 32005) inside the control cabinet of the mill. Never operate the machine tool with the cabinet door open. Never make or check these connections with the mill powered on. Power to the ATC and other devices inside the control cabinet may retain dangerous voltages after external power has been removed. Do not modify these connections in any way. If unsure about the connections, call Tormach or a qualified repair technician. 1.3 System Requirements To use the Tormach Tooling System ATC, your machine must meet the following requirements: • You must provide a compressed air source capable of delivering clean, dry air at 95 PSI and 2 CFM. • The Tormach Power Draw Bar (PN 31706) must be installed • For PCNC 1100 machines serial numbers 1325 and lower, you must have previously installed the Spindle Drive Upgrade kit (PN 31090) • For PCNC 1100 machines serial numbers 999 and lower, you must have previously installed the Series 3 upgrade kit (PN 32010) Required Tools • Metric Allen wrench set • Screwdrivers •...

  • Page 6: Preparation

    2. PREPARATION 2.1 Unpacking and Checking 1 ATC assembly Shipment 4 ¼” air lines, one w/ check valve and push fitting 1 ATC square tube mount Upon receipt, carefully unpack the ATC and inspect to 4 hex standoffs with M8 and M10 studs ensure damage did not occur in transit and also to account 4 flange nuts and washers for all parts. If any damage is apparent, or parts missing, 20 nylon M6x16 hex bolts please contact Tormach immediately. 1 USB cable With an assistant, lift the ATC onto a sturdy surface or 1 ATC communication RJ-11 cable (512-515) workbench to prepare it for use. 1 Main power cable (503,504) terminated with 4 pin Molex and spades 1 PDB power cable (501,502) terminated with PDB con- nector and spades 1 VFD interconnect wiring kit (532-535) 1 coolant hose mounting plate w/ fasteners Power Draw Bar power supply board 1 R8 TTS expanded collet Operator’s Manual Software installation CD 2 5X20 glass fuses The following items may or may not be included based on the age of your machine and power draw bar installation: 1 draw bar with 8 Belleville washers Power Draw bar control circuit board (if required based on age of your power draw bar installation.) DC Bus Board Check these items. Notify Tormach of any damage incurred during transit or missing parts so any claims can be made within the shipping carrier’s deadline.

  • Page 7: Before You Begin

    All machines will need to have the power drawbar installed before installing the ATC. See the power draw bar manual (included with the power draw bar package and on the ATC software CD) for power draw bar installation instructions. PCNC 1100 machines serial numbers 1999 and lower will need to replace the old DC Bus Board (PN 30661) with the new bus board (PN 32005). 2.3 Mounting the ATC If fitted, remove the left hand machine arm from the mill column. Mounting and aligning the ATC to the mill is a job that is best done with two people. The ATC carousel assembly, which weighs approximately 50 pounds, is cumbersome to lift and position accurately especially when working over the mill’s chip tray. Installation goes smoothly when one person holds the ATC in position while an assistant tightens the fasteners that connect it to the square tube mount. Initial Hardware Installation WARNING! SHUT THE COMPUTER DOWN, THEN POWER DOWN THE MILL USING THE ROTARY SHUTOFF SWITCH ON THE RIGHT HAND SIDE OF THE CONTROL CABINET.
  • Page 8 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. Reroute the coolant hose by mounting the coolant hose clamp to the included coolant plate. Attach the...

  • Page 9: Electrical Installation

    3. ELECTRICAL INSTALLATION Remove the four column cover plate screws from base Circuit boards labeled Rev 1.2 will need to be replaced. In of column at the back of the mill. The Z column cover this case Tormach should have included the updated circuit plate will be replaced with the ATC control module. board with your ATC. Save the screws. Circuit boards labeled Rev 1.3 and higher do not need to be removed from the housing. • To replace an old (Rev 1.2 or earlier) circuit board, disconnect and remove the old circuit board, taking note of the locations of the connectors. While not necessary, you may find it easier to remove the air lines and the cable carrier as well. • Replace the old draw bar board with the new one. It is easiest to replace the solenoid leads (red and black wire) before re-mounting the circuit board. The solenoid leads go to the opposite side of board from other connectors. This is the only connector on that side (2 pin nylon).
  • Page 10 Remove the old “wall wart” power connector and replace it with wires 501, 502. These wires will be routed to the new DC Bus Board, and you will be able to throw out the wall wart power supply. Note: If you purchased a Power Draw Bar and ATC at the same time, you will not have a wall wart power supply. Route all wires (the two RJ11 cables, the blue spindle door switch interface wires, and the power wires 503, 504) through the mill column. IMPORTANT – TWIST THE BLUE SPINDLE DOOR SWITCH INTERFACE WIRES TO THE POWER DRAW BAR CIRCUIT BOARD (105, 105A) AND THE RED WIRES (105A, 106) INSIDE THE COLUMN.
  • Page 11 CAUTION! DO NOT CONNECT THE USB CABLE TO THE COMPUTER UNTIL AFTER THE SOFTWARE INSTALLATION IS COMPLETE. Connect the ATC communication RJ11 cable (from the DB3 connector on the power draw bar circuit board) Note: Series 1 machines were not manufactured and the USB cable to the ATC control board. with this hole. If you have a pre-Series I machine you will need to drill a 5/8” hole in the bottom of your electrical cabinet to route the USB cable to your control computer.
  • Page 12 PCNC 1100 MACHINES SERIAL NUMBERS 1999 AND Note: Refer to the DC bus board layout diagram on LOWER: Replace the old DC bus board (PN 30661) with the following page when transferring wires. the new bus board (PN 32005). Ensure all fuses are present on the DC Bus Board before installation (there 13. Double-check the polarity of the capacitor, stepper should be no empty fuses). When removing the old DC driver, and ATC connections before powering up the bus board, catch the standoffs and save the screws. machine. Reversing polarity will destroy the stepper Replace with the new board on the same standoffs. drivers and ATC control board. It is extremely helpful to tack glue the standoffs in 14. Install the power drawbar daughterboard power place before mounting the board. An easy way to do supply (PN 31980) by sliding it onto the spade this is to put a dab of hot glue on the fasteners before connectors on the new DC bus board (PN 32005). This...
  • Page 13 CAP+ 301 F4 = A AXIS F5 = DC BRAKE BRAKE RLY+ 328 F6 = MAIN F7 = PDB F8 = ATC 503 Optional ATC + 504 Optional ATC - X+ 302 X- 303 BRK- 327 Y+ 304 BRAKE RLY- 329...

  • Page 14: Air Line Connection And Requirements

    4. AIR LINES 4.1 Air Line Connection and side of the ATC solenoid panel and the draw bar input push fitting on the draw bar solenoid. The check valve Requirements allows air to pass in one direction only – if you install it backwards the power drawbar will not operate. It is recommended to use a filter/dryer/lubricator on the air line used to supply the ATC. Air supply requirements depend on frequency of tool changes. For successful operation, your compressor will need to be able to maintain 95 PSI to the ATC. Typically consumption for frequent 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, which makes for longer make-up times as the power draw bar fires. While this is not a problem for the power draw bar when operated by hand (the user just waits the extra second or two for the cylinder to fully pressurize), it can cause problems when using the ATC, which only pauses If you have purchased the optional pressure sensor (PN 500 ms between the draw bar firing and the z axis moving. 32329), splice it into air line D and insert the electrical Better regulators do not restrict the flow while regulating connector into the jack on the column cover plate as pressure. shown in this photo: Connecting the Air Lines Manually pull the tool tray to the retracted position by pulling on the motor enclosure or it will retract suddenly when you pressurize the air lines.
  • Page 15 The tray solenoids have adjustment screws that allow you to adjust tray in and tray out speeds. The solenoids have been pre-adjusted before shipping. Air cushion pin valves at either end of the air cylinder can be adjusted to control damping at extreme ends of cylinder travel. These are also pre-adjusted. Tool change time should not be adjusted to less than 8 seconds. Conversely, moving too slowly will trigger an error condition. Tray Solenoids UM10081_TTS_ATC_PCNC1100_1013A...

  • Page 16: Software Installation

    NewFangled Wizard license file). If you previously customized your version of Mach 3 using PCNCConfig you will need to repeat these customizations after installing the new software. Note: The ATC software is only compatible with the standard Tormach screens. Flash screens are no longer supported by Mach or Tormach and we have made no effort to develop flash screens for the ATC. UM10081_TTS_ATC_PCNC1100_1013A...

  • Page 17: System Validation

    6. SYSTEM VALIDATION Connect the USB cable from the ATC controller to the mill’s control computer. Start the control software using the PCNC1100-ATC icon on the desktop. When the system comes up, it should find the ATC automatically on the USB ports and configure itself. You should see a confirmation message on the main Mach screen message line that displays the software version: “ATC Startup – initialized” Answer YES to screen prompts requesting it’s “okay to reset and reference z”. When using the ATC, these prompts always occur at start up. In general, you should always reference Z immediately. The tool changer will prompt during execution if you skip it now. Click on the ATC Setup button on the lower portion of the screen. Note that the upper left corner displays the firmware and plugin versions. The green CONNECTED light should be glowing to indicate USB communication is established. This verifies the software installation and the USB connection. UM10081_TTS_ATC_PCNC1100_1013A...

  • Page 18: Align Tool Tray And Slots

    Make sure when doing this that the spindle cover sheet metal will not hit the ATC linear rail. If there is interference, adjust the X position of the ATC by loosening the fasteners that attach the ATC to the square tube mount.
  • Page 19 Make sure the spindle is initially empty. There should be no tool holder in the spindle at this point. Click the “Go To Tray Load Position” button on the ATC Setup screen. The Z axis will jog up and the tray will actuate in, opening the tool access door, and the draw bar will actuate. Verify that the spindle is roughly in the center of the carousel door opening. If necessary, move the ATC forward or backward by loosening the four flange nuts that hold the square tube mount to the column. If the dowel and the spindle axis are not parallel, adjust the tilt of the ATC in both X and Y directions until they are. • Tilt in the Y direction is facilitated by loosening the flange nuts that hold the square tube mount to the column, then gently tapping the ATC trapezoid mount with a mallet. • Tilt in the X direction can be adjusted by loosening the socket head cap screws that mount the ATC to the square tube, then turning the eccentric adjustment screws. This is best done with the ATC in the “Tray In” position, as the center of gravity of the unit in the “Tray In” position will allow you to use both adjustment screws to tilt the ATC. Insert a long (12-14”) dowel or piece of round stock into a TTS tool holder. Insert the tool holder into the fork of the exposed tray slot. Using other vertical lines (edge of mil column, T slots in table) sight along the dowel and check whether the dowel and the spindle axis are parallel in both X and Y planes. • Verify that the tool holder shank is parallel to the spindle axis in both X and Y by using an angle block or 1-2-3 block with a straightedge: UM10081_TTS_ATC_PCNC1100_1013A...
  • Page 20 • To adjust the alignment of the tool holder to the collet in the Y direction, use the “--“or “++”- buttons on the ATC Setup screen Alignment section. It is best to wiggle the fork with your thumb and index finger to feel the extremes of the carousel backlash against the spindle with your fingers to see that it is roughly centered left and right of fork while making this adjustment. Once you are satisfied that the axis of the dowel is parallel to the spindle axis in both X and Y, jog the spindle down to the top of the Tormach tool holder shank. Do not go all the way down to the shoulder yet. Verify by eye that it is roughly centered on the collet center opening. • To adjust the alignment of the tool holder to the collet in the X direction, loosen the jam nut at the end of the tray cylinder rod and move it to a roughly centered position. Press “Tray In” to verify the adjustment. You will likely have to repeat this procedure several times to get the location correct. UM10081_TTS_ATC_PCNC1100_1013A...
  • Page 21 7 in the previous section (Align tool Tray and Slots). If the ATC. alignment is off, you might have to jog up and loosen the We’re now ready to verify the alignment. First, verify that nylon bolts a tad first. Jog up and tighten the nylon bolts the power drawbar is adjusted correctly. The drawbar at center until snug but not overly tight. Repeat to align all should be adjusted so that a tool holder will fall out of the slots. the spindle when the drawbar is actuated. Draw bar adjustment is discussed in the power draw bar installation manual, included for reference on the ATC software installation CD. Test the ATC Alignment Click “Go To Tray Load Position” on the ATC Setup screen. Push the TTS tool holder with dowel into the open slot in the tool tray. Slowly jog Z down until the TTS shoulder touches the spindle nose. It should slide smoothly on the TTS shank. If it doesn’t, the tray is miss-aligned (not centered or perpendicular to the spindle), or the collet hasn’t opened far enough to spring out for smooth entry. You should only have to do this once. At this point all the forks will align identically to the spindle and work as SLOT If the tray is not properly aligned there will be 1 did. You may verify this by hitting the “Go To Tray Load...

  • Page 22: Foot Pedal Kit

    7. OPTIONAL ACCESSORIES 7.1 Foot Pedal Kit The Foot Pedal Kit (PN 31728) provides easy foot-activation of Power Draw Bar for hands-free operation. To install: Remove the power draw bar electrical housing. 7.2 Filter Regulator Lubricator (FRL) The Filter Regulator Lubricator (PN 32457) is recommended for proper conditioning of supply air for both the Power Draw Bar and the ATC. Note: See Chapter 4: Air Lines for recommended air supply requirements To install: Plug the foot pedal cable into the Foot Pedal connector port on the power draw bar control board (as shown in Drill two holes into the back of the splash guard (or the figure below). wherever is convenient for mills without a splash guard). Secure the FRL to the mounting bracket with your own equipment.

  • Page 23: Pressure Sensor

    Sight Window Adjustment Knob A droplet of lubricant will form on the bottom of the stem located inside of the sight glass. Open the lube adjustment knob 1/2 turn (towards Open the FRL fill port with a hex key. the +). Fill the port with standard air tool oil (using a small Flush all air bubbles from the system. funnel if necessary). When air bubbles no longer appear in the sight window and a droplet of lubridant forms on the bottom of the stem, close the lube adjustment knob 1/4 turn (so that it is open approximately 1/4 turn from the closed position). 7.3 Pressure Sensor Pressure Sensor (PN 32329) prevents the carousel from actuating during low air supply pressure condition. Splice air line D and insert the Pressure Sensor as shown. 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.
  • Page 24 Note: See Chapter 4: Air Lines for additional information. UM10081_TTS_ATC_PCNC1100_1013A...

  • Page 25: Operation

    PLEASE NOTE – ALWAYS SHUT DOWN THE CONTROL SOFTWARE (MACH3) BEFORE TURNING OFF THE CONTROL COMPUTER. FAILURE TO SHUT MACH DOWN PROPERLY WILL RESULT IN THE ATC NOT REMEMBERING TOOL LOCATIONS. 8.2 Loading/Unloading Tools There are two ways to load and unload the tool tray in preparation for machining using the ATC. In automatic tool load- ing, the ATC will load the tool that is currently in the spindle and store it in the nearest open tray slot. In manual tool loading, the tray will slide in and the tray door will open, allowing the operator to manually place tools into the tray. The following sections detail these two modes of operation.

  • Page 26: Automatic Tray Load/Unload

    8.3 Automatic Tray Load/ 8.4 Manual Tray Load/ Unload Unload The left hand side of the ATC control screen contains the If you want to load or unload multiple tools you may find buttons and DROs used to store and retrieve tools. it faster to open the tool changer door and load or unload them manually. The Manual Load/Unload buttons and DRO To load a tool into the tray: on the right hand side of the ATC Control screen will allow you to bring the tray to a loading position (door open), Load the desired tool into the spindle. manually insert or delete, and assign or un-assign tool Enter the tool number in the tool DRO (next to the numbers to tray positions. “Store” button). Do not forget to press “Enter” after typing in this number. To load tools manually: Note: This DRO is identical to the tool DROs on the Click “Go To Tray Load Position” to move the spindle head up and bring the ATC in to the door open other screens.

  • Page 27: Tool Touch-Off Routine

    8.5 Tool Touch-off Routine Unless you set up the sensor height of your Tool Setter before touching off the tools, the tool lengths entered in your tool table will be relative, not true tool lengths. If you have the optional TTS Tool Setter (PN 31875) the ATC You must set up the Tool Setter sensor height to mix control software can be used to automatically measure ATC tools that have been measured using the Tool the tool height offset for every tool in the tray. To use Setter with tools that have been measured on a granite this feature, plug the Tool Setter into the accessory port black and height gauge. Setting the sensor height and test communication by actuating the Tool Setter is described in detail in the PCNC 1100 operator’s by hand and ensuring that the green Tool Setter LED on manual, section 8.2. the ATC Control screen lights up. Center the Tool Setter directly under the spindle and click the “Touch Off Entire 8.6 ATC Bypass Tray” button on the ATC Control screen. The ATC will cycle through every tool in the tray and enter the measured tool To activate the ATC Bypass, click the ATC Bypass Button on length in the tool table. A few things to note about tool the ATC Control screen. touch-off: When the ATC Bypass is activated, this will prevent the Tools with large diameters (greater than the diameter ATC from executing any tool changes. Instead you will be of the Tool Setter pad) will not be accurately measured prompted by the software to manually complete any tool unless the cutting edge of the tool makes contact with changes that are called within a program. the Tool Setter. For instance, care must be taken when using the “Touch Off Entire Tray” routine with a fly cutter or shell mill in the tray. UM10081_TTS_ATC_PCNC1100_1013A...

  • Page 28: Maintenance & Troubleshooting

    9. MAINTENANCE & TROUBLESHOOTING 9.1 Support 9.3 Troubleshooting Tormach provides free technical support through multiple channels. The methods are listed below, in order of Mechanical Issues preference: Binding This manual (for ATC related issues) or the PCNC manual is always the first place to check! If your ATC has not been properly aligned you may Related documents at http://www.tormach.com/ experience binding as the collet descends over the documents.html tool holder shank. The ATC carousel must be in a plane Our website at www.tormach.com perpendicular to the spindle axis. The best way to check Send an email to: info@tormach.com this is to place a long dowel in a drill chuck or set screw Telephone Tormach at: 608-849-8381 tool holder, then position that toolholder in an open tray Fax Tormach at: 209-885-4534 slot. As you jog the spindle down over the toolholder shank, watch the end of the dowel. If the ATC is properly 9.2 Maintenance aligned, the end of the dowel won’t move as the collet slides over the shank. Aligning the ATC is time consuming to do properly, but once set the alignment should not The Tormach Tooling System Automatic Tool Changer change. requires little maintenance. Periodically inspect the following: Collet Slip Ensure that your air is clean and dry. A filter/regulator...
  • Page 29 Collet slip is more likely to occur if your speeds, feeds, Sensors or fixturing result in machining operations with a lot of high frequency chatter (end mill “squeal”). We have The ATC uses the following sensors: seen even light cuts result in collet slip if the end mill is squealing or chattering excessively. Usually, such noise TRAY IN and vibration should be avoided for other reasons TRAY OUT (poor surface finish, reduced tool life) and tweaking TRAY REFERENCE the spindle RPM or increasing the feedrate will tune (optional) pressure switch the chatter out. The TRAY IN/OUT sensors are normally open reed ATC Tray Chatter switches. TRAY OUT is visible under the band clamp at the end the pneumatic actuator. TRAY IN is hidden in a recess If the 3 linear bearings that support the carousel are in the linear rail behind the pneumatic cylinder and is not not properly aligned with the linear guides, you may visible unless the cylinder has been removed. The piston experience chatter on tool changes. Sometimes this of this pneumatic actuator is magnetic - the reed switches chatter can be eliminated with a light application of way are actuated when the piston inside the cylinder comes oil to the linear guides. If the chatter persists, loosen the within 0.100” of the sensor. 4 M5 Allen head screws that hold the linear bearings on to the carousel assembly. Allow the bearings to self align, When Mach 3 is started the ATC goes through initialization, then retighten. the TRAY IN and TRAY OUT sensors are evaluated. If the ATC software encounters a condition where both sensors Z Height Not Repeatable return HI or both return LO, an error message is generated.
  • Page 30 Sensor is Defective Any magnet can be used to verify whether or not the sensor is working. If you bring a strong magnet near the TRAY IN or TRAY OUT sensors they should return TRUE. If the sensor is working, you can skip to the “Sensor is out of adjustment” section. If the sensor is not working, you will need to determine whether the sensor itself is defective or if there is a short in 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.
  • Page 31 TRAY REFERENCE The TRAY REFERENCE sensor is a normally open reed switch housed in a black plastic enclosure on the underside of the carousel umbrella. It is used to provide a carousel home reference position. It reads a small neodymium magnet embedded in the hub. When a magnet is near the sensor, the sensor should read close to 0 Ohms, otherwise it should read open circuit. If the sensor reads appropriately at the 20 pin connector, then the overwhelming likelihood is that the 20 pin junction (male side – to the control board) has a faulty crimp. To be sure you can repeat the above multimeter tests at the control board (see schematic for appropriate The first tool change after the control software is started, pins.) or any time after the mill is e-stopped and then re- powered, the tray will reference itself. It spins quickly in If the sensor does not read appropriately you should one direction until is the sensor reads the magnet, moves remove the sensor assembly (which requires removal of past the magnet, then it reverses direction and moves the pneumatic actuator). As a final check you can ohm out slowly until it reads the magnet again. If the sensor is not the sensors when they are off of the machine. The sensor working properly the tray will spin for 10 seconds or so, assembly is PN 32138. then time out and give an error message. Sensor is Out of Adjustment The sensor should be positioned as shown in the above photo – a small gap should be present between the If the tray sensors work when you wave a magnet over magnet embedded in the hub and the sensor itself. them, but don’t read the tray position accurately, they are out of adjustment. The magnetic piston must come This sensor can be Ohmed out in the same way as the TRAY within about 0.100” of the sensor to activate the sensor.
  • Page 32 ATC Recovery As you learn to use the tool changer you may experience a tool crash. Thankfully, it is very difficult to damage the Tormach ATC. The software is intelligent and can predict potential crashes, warning the operator with a pop-up window before executing the commanded change. If you are unfortunate enough to experience a crash: Use the “Drawbar Down” button on the ATC Setup screen or the “Release” and “Lock” buttons on the pendant to release the tool. Use the Reference Z button to move the Z axis clear of the ATC. Hub Disassembly Use the “Tray Out” button on the ATC Setup screen to retract the tray. Remove the tool tray by removing the flange nut that Always re-reference the tool tray after a crash. attaches the tray to the hub. Make sure that the tools that are physically in the tray Use an Allen wrench to unscrew the stud that the match the tools shown on the ATC control screen. flange nut was screwed on to If there is a mismatch between the software and the Behind the stud is a small (M4?) socket head cap actual tools that are present in the tray, click the “Go screw. Remove this To Tray Load Position” button and then use the “Insert” Loosen the two set screws and remove the hub from and “Delete” buttons to correct the error. the shaft. Broken Fork Fasteners Software The hex bolts that hold the tool forks to the tray are The ATC requires the latest Tormach release of Mach3 nylon shear bolts that have been engineered to fail under greater-than-normal loads. These bolts will snap in the...
  • Page 33 The control software records the positions of the tools in the carousel and spindle in a configuration file when you shut the software down. If you fail to shut the software down before turning off the computer, or if you have a power failure during operation, the software may restart with incorrect tool positions shown on the ATC screen. This is an easy condition to recover from. Perform the following steps to correct this problem: If there is a tool in the spindle, remove it before proceeding with an ATC recovery. Click the “Tray Load Position” button on the ATC screen. Using the “Tray FWD” or “Tray REV” buttons, index through the tray. Use the “Insert” and “Delete” buttons on the Manual Load/Unload section of the ATC control screen until the tools that are physically in the tray match up with the tools shown on the ATC control screen. UM10081_TTS_ATC_PCNC1100_1013A...
  • Page 34 Notes UM10081_TTS_ATC_PCNC1100_1013A...

  • Page 35: Exploded View & Parts List

    EXPLODED VIEW & PARTS LIST UM10081_TTS_ATC_PCNC1100_1013A...

  • Page 36: Atc Carousel

    10.1 ATC Carousel ITEM NO. PART NUMBER DESCRIPTION QTY. 32149 Tool Tray Door 32133 Tray Arm Pin - Front 32150 Tray Door Thrust Bearing - Lower 32148 Door Thrust Bearing - Upper 32195 M6 x 5 Flat Head Screw 32131 Tray Door Arm 32132 Tray Arm Pin - Rear 32192 M3 x 12 SHCS 32136 12mm C-Clip 32135 Tray Lever Washer - Rear 32134 Lever Washer - Front 32151 Spring Washer 32153 Cowling Standoff 32160 Tool Tray Sensor Housing 32162 Tray Sensor Housing - Top...
  • Page 37 UM10081_TTS_ATC_PCNC1100_1013A...

  • Page 38: Atc 1100 Column Mount

    10.2 ATC 1100 Column Mount ITEM NO. PART NUMBER DESCRIPTION 32120 1100 Box Beam 32244 Cam Tilt Adjuster 32121 Column Standoff 32248 Cable Retainer Clip 32177 M8 x 10 SHCS 32187 M10 Flange Nut 32233 Fender Washer 42246 UM10081_TTS_ATC_PCNC1100_1013A...
  • Page 39 UM10081_TTS_ATC_PCNC1100_1013A...

  • Page 40: Tts Atc Actuator

    10.3 TTS ATC Actuator ITEM NO. PART NUMBER DESCRIPTION 32187 M10 Flange Nut 32186 M10 x 25 SHCS 32122 Interface Mount 32123 Rail 32124 Linear Bearing 32183 M8 x 16 Low Head SHCS 32125 Bearing Spacer Block 32126 Front Cylinder Bracket 32188 M6 x 25 SHCS 32190 M6 Flange Nut 32145 Motor Chassis Cover 32130 Cylinder 3/4 x 16 Jam Nut 32142 1/8 NPT x 1/4 Push Connector 32137 Band Clamp 32172 7/16 Jam Nut...
  • Page 41 UM10081_TTS_ATC_PCNC1100_1013A...

  • Page 42: Atc Control Module Assembly

    10.4 ATC Control Module Assembly ITEM NO. PART NUMBER DESCRIPTION QTY. 32206 Column Access Plate 32210 2 Port Solenoid 32207 1/4 NPT x 1/4 Elbow 32212 1/4 NPT x 1/4 Straight 32209 5 Port Solenoid 32213 1/4 NPT x 1/4 Extended Elbow 32211 Speed Muffler 32215 1/4 Run Tee 32232 1/4 PUR Air Line 32238 1/8 NPT X 1/4 Straight Female 32238 Pressure switch boot 32237 Pressure Plug 32793 Stepper Driver 32230...
  • Page 43 Reed Reed UM10081_TTS_ATC_PCNC1100_1013A...

  • Page 44: Tts Atc Pneumatic Schematic

    10.5 TTS ATC Pneumatic Schematic UM10081_TTS_ATC_PCNC1100_1013A...

  • Page 45: Atc Electrical

    ATC J2 Tool Tray Solenoid +12V ATC J2 Estop (not used) ATC J2 Solenoid 5 - Gnd ATC J2 Solenoid 4 - Gnd ATC J2 Solenoid 3 - Gnd ATC J2 Air Blast Solenoid - Gnd ATC J2 Tool Tray Solenoid - Gnd ATC J2 Estop (not used) ATC J3 - Switches and Sensors (Molex Micro 12) ATC J3 unused ATC J3 unused ATC J3 Cylinder In Switch/ +5V ATC J3 Tool Tray Homing Switch /+5V ATC J3 Cylinder Out Switch /+5V ATC J3 Extra Switch / +5V ATC J3 unused ATC J3...
  • Page 46 ATC J4 - Tormach Stepper Ribbon (IDC 10) ATC J4 unused ATC J4 unused ATC J4 +5V common ATC J4 Step ATC J4 Direction ATC J4 unused ATC J4 unused ATC J4 unused ATC J4 unused ATC J4 unused ATC J5 - ATC (RJ-11) ATC J5 Draw Bar Board Input Signal (VFD, Solenoid Status via PWM) ATC J5 Draw Bar Output - UP ATC J5 Draw Bar Output - DN ATC J5...

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