Tormach 1100MX Manuals

Manuals and User Guides for Tormach 1100MX. We have 4 Tormach 1100MX manuals available for free PDF download: Operator's Manual, Installation Manual, Owner's Manual

Tormach 1100MX Operator's Manual (270 pages)

Brand: Tormach | Category: Industrial Equipment | Size: 21 MB

Table of Contents
5
Safety
21
Intended Use
22
Machine Standards
22
American National Safety Institute (ANSI)
22
Occupational Safety and Health Administration (OSHA)
22
Safety Overview
22
Safety Messages
22
Personal Injury
22
Property Damage
23
Safety Decals
23
On the Electrical Cabinet Door
23
Next to the Main Disconnect
23
On the Spindle Nose
24
Information Decals
24
Serial Number Plate
24
Machine Safety
24
General Shop Safety
24
Operational Safety
25
General
25
Tooling
26
Workholding
26
Electrical Safety
26
Noise Exposure
26
About Your Machine
29
Performance Expectations Reference
30
Cutting Performance Reference
30
Resolution and Accuracy Reference
30
Specifications Reference
31
Machine Specifications
31
Site Requirements
33
General Site and Space Requirements
34
Site Requirements
34
Space Requirements
34
Operator Workstation Reference
34
Electrical and Power Requirements
35
Electrical Requirements
35
Power Requirements
35
Options for Non-Conforming Sites
35
Installation
37
Visual Installation Guide
38
Before You Begin
39
Installation Tools and Items
39
Move the Pallet
39
Assemble the Machine Stand
39
Unpack the Machine Crate
41
Install Core Components
42
Install the Y-Axis
42
Lift and Move the Machine
43
Required Tools
43
Before You Begin
43
Assemble the Lifting Bar Kit
43
Connect the Machine for Lifting
44
Lift the Machine
44
Install the Drip Guard
45
Install the X-Axis Motor Cover
45
Install the Controller
46
Install the Controller Arm
46
Install the Monitor
47
Make Monitor Connections
47
Install the Pathpilot Controller
48
Set up the Pathpilot Operator Console
48
Install the Oiler
49
Make Automatic Oiler Connections
50
Make Manual Oiler Connections
50
Set up the Manual Oiler
50
Verify the Installation
50
Power on the Machine
50
Power off the Machine
52
Verify Spindle Function
52
Verify Axes Function
52
Install Accessory Components
53
Set up the Automatic Oiler
53
Look for Leaks and Clear the Lines
53
Specify the Interval Time
53
Specify the Actuation Time
54
Install the FRL Filter-Regulator-Lubricator
54
Install the FRL
54
Set up the FRL
55
Make Air Connections
55
Set up the Coolant Kit
55
Install the Automatic Tool Changer (ATC)
56
Required Tools
57
Required Tools for Installation
57
Required Tools for Verification
57
Air Requirements
57
Prepare the Machine
57
Disassemble the Power Drawbar Button
57
Install the Air Cylinder
58
Mount the Automatic Tool Changer (ATC) Bracket
58
Install the Main Assembly
59
Level the Automatic Tool Changer (ATC)
59
Prepare the Machine
59
Examine Perpendicularity in the y Direction
60
Examine Perpendicularity in the X Direction
60
Examine the Alignment of the Carousel Door Opening
60
Make Air Connections
61
Make Electrical Connections
62
Verify the Installation
62
Adjust the Tool Alignment and Set the Tool Tray Height and Encoder Position
63
Install the 4Th Axis
64
Required Tools
65
Unpack the 4Th Axis
65
Lubricate the Rotary Table
65
Adjust the Backlash
66
To Set the Backlash by Positioning the Backlash Adjustment Screw
66
To Set the Backlash by the Numbers
66
Mount the Rotary Table
67
Install the A-Axis Motor Driver
67
Verify the Installation
67
Install the Chip Pans
68
Install the Backsplash and Splash Guard
69
Install the Enclosure
69
Before You Begin
70
Required Tools
70
Install the Enclosure Panels
70
Install the Left Rear Panel
70
Install the Left Side Panel
71
Install the Left Side Window Retainers
71
Install the Left Front Panel
71
Install the Right Rear Side Panel
72
Install the Right Rear Top Panel
72
Install the Right Side Panel
72
Install the Right Side Window Retainers
72
Install the Right Front Panel
72
Install the Left Top Panel
73
Install the Right Top Panel
73
Install the Front Upper Panel
74
Install the Front Lower Panel
74
Install the Rear Splash Shield
74
Assemble the Linear Rails
74
Install the Linear Assemblies
75
Assemble the Front Doors
76
Install the Front Door Assemblies
76
Install the Door Latch
77
Install the Floodlights
77
Install the Side Windows
78
Install the Access Panel
79
Install the Stainless Steel Wear Guard
80
Use the Maintenance Labels
80
About the Maintenance Labels
80
Write the Date on the Maintenance Labels
80
Replace the Windows
80
Set up the Door Lock Switch Kit
80
Install the Door Lock Switch Kit
80
Update Pathpilot
82
Download and Install an Update File from the Controller
82
Install an Update File from a USB Drive
83
Enable the Door Lock Switch Kit
83
Install the Pathpilot Operator Console
84
Required Tools
84
Prepare the Machine
84
Remove the Right Side Window
84
Remove the Operator Box
84
Install the Mount Arm
84
Mount the Console
86
Assemble the Controller and Keyboard Tray
86
Lift and Secure the Controller Assembly
87
Make Electrical Connections
88
Reassemble the Machine
90
Set up the Pathpilot Controller
90
Specify the Date and Time
90
Specify the Keyboard Language
90
Configure the Optional Touch Screen Kit
90
System Basics
91
System Reference
92
Machine Table
92
Spindle
92
About the Spindle
92
Axes
92
Basic Controls Reference
92
Machine Controls
92
Pathpilot Interface
93
Pathpilot Interface Overview
95
About Pathpilot
96
Notebook Section Reference
96
Main Tab Reference
96
File Tab Reference
96
Settings Tab Reference
97
Offsets Tab Reference
97
Conversational Tab Reference
97
Probe Tab Reference
97
Status Tab Reference
98
Persistent Controls Section Reference
98
Program Control Area Reference
98
Position Status Area Reference
98
Manual Control Area Reference
99
Keyboard Shortcuts Reference
99
Manage Pathpilot Versions
99
Download and Install an Update File from the Controller
99
Install an Update File from a USB Drive
100
Install a Previous Version of an Update File
100
Pathpilot Tools and Features
103
Create and Load G-Code Files
104
Load G-Code
104
Transfer Files to and from the Controller
104
About System Files
104
Preview G-Code Files
104
Access Recent G-Code Files
105
Close the Current Program
105
Edit G-Code
105
Edit G-Code with a Text Editor
105
Edit G-Code with Conversational Programming
105
Change the Step Order
106
Create a New Job Assignment
106
Load an Existing G-Code File
106
Edit a Job Assignment
106
Read G-Code
106
Expand the G-Code Tab
106
About the G-Code Tab
106
Search in the Code
107
Set a New Start Line
107
Lead-In Moves
108
Change the View of the Tool Path Display
108
About the Tool Path Display
109
Use Conversational Programming
109
About Conversational Programming
109
Create a Face on a Part
109
About Facing
110
Facing in Pathpilot
110
Facing Reference
111
Create a Profile on a Part
111
About Profiling
111
Profiling in Pathpilot
111
Profiling Reference
112
Create a Pocket on a Part
112
About Pockets
113
Creating Pockets in Pathpilot
113
About Circular Pockets
113
About Rectangular Pockets
114
Create Hole Locations on a Part (Drill/Tap)
114
About Drilling and Tapping
115
Drilling and Tapping in Pathpilot
115
Create a Drilling Sequence
115
Create a Tapping Sequence
116
Drilling and Tapping Reference
116
Create Threads on a Part
117
About Thread Milling
117
Thread Milling in Pathpilot
117
Thread Milling Reference
118
Create Text to Engrave on a Part
118
About Engraving
119
Import a DXF File
119
Working with Layers and Shapes
119
Change the Layer or Shape Cut Order
119
Adjust the Tree View Window
120
Working in the Preview Window
120
Machine Settings and Accessories
120
Change the Network Name
120
Select the Spindle Type
120
Specify the Tool Change Method
120
About Automatic Tool Changes
121
About Manual Tool Changes
121
Enable Accessories
121
Enable the 4Th Axis Homing Kit
121
Enable the Door Lock Switch Kit
121
Enable Probing and Tool Measuring Options
122
Enable the Rapidturn
122
Enable the Touch Screen Kit
122
About Soft Keyboards
122
Enable the USB M-Code I/O Interface Kit
122
Enable an Internet Connection
122
Connect to Dropbox
123
Enable Automatic Updates
124
Set up G-Code Programs
125
Use a Probe with Pathpilot
125
Before You Begin
125
Use a Probe to Find a Feature's Location
125
Use a Probe to Set Work Offset Zeroes
125
Set the X and y Work Offset Zero on the Corner of a Feature
125
Set the Work Offset Zeroes on a Feature
125
Use a Probe to Find the Center of a Feature
126
Find the Center of a Pocket
126
Find the Center of a Slot
126
Find the Center of a Rectangular Boss
126
Find the Center of a Circular Boss
126
Find the Center Rotation of an A-Axis
127
Set Tool Length Offsets
127
Touch off the Tool Length Offsets
127
Set a Known Reference Height
127
Measure Tools Using a Known Reference Height
128
Use an Electronic Tool Setter (ETS) to Measure Tools
128
Use a Zero Setting Gauge to Measure Tools
129
Set a Known Reference Height
129
Verify the Calibration of the Zero Setting Gauge
129
Measure Tools Using a Known Reference Height
129
About Tool Offsets
130
Set Work Offsets
130
About Work Offsets
130
View Work Offsets
131
View Available G-Code Modes
131
Run G-Code Programs
131
Bring the Machine out of Reset
131
About Reset Mode
131
Disable Hard Stop Referencing
132
View the Active Axis to Jog
132
Jog the Machine
132
Jog in Continuous Velocity Mode
133
Jog in Step Mode
133
View the Current Machine Position
133
Reference the Machine
133
About Referencing
133
Start a Program
134
About Cycle Start
134
Cycle Start Reference
134
Stop Machine Motion
134
Operate the Coolant Pump
134
About Coolant
134
View the Active G-Code Modes
134
View the Distance to Go
134
About Distance to Go
135
Control G-Code Programs
135
Use the Feed Hold Function
135
About Feed Hold
135
Use the Feed Rate Override Function
135
About Feed Rate Override
135
Use M01 Break Mode
136
About M01 Break
136
Use the Maxvel Override Function
136
About Maxvel Override
136
Use Single Block Mode
136
About Single Block
136
Use the Spindle Override Function
137
About Spindle Override
137
Change the Feed Rate
137
About Feed Rates
137
Change the Spindle Speed
137
About Spindle Controls
138
Spindle Controls Reference
138
Change the Tool Number
138
About M6 G43
138
Use a G30 Position
138
About G30
139
View the Tool Length
139
Manually Enter Commands
139
About the MDI Line DRO Field
139
Admin Commands Reference
139
Copy Recently Entered Commands
140
Limit a G30 Move
140
About G30
140
Use Feeds and Speeds Suggestions
140
Refresh DRO Field Values
141
Use Additional Provided Information
141
Enable Feeds and Speeds Suggestions in Conversational Routines
141
Create Tool Descriptions
142
Manually Enter Tool Descriptions
142
Automatically Generate Tool Descriptions
142
Tool Keywords Reference
143
System File Management
143
Manage System Files
143
About System Files
144
Create Backup Files
144
About Backup Files
145
Restore Backup Files
145
Import and Export the Tool Table
146
Import a .Csv File
146
Export the Tool Table as a .Csv File
146
Basic Operations
147
Start the Machine
148
Reference the Machine
148
About Referencing
148
Jog the Machine
148
About Jogging
149
About Continuous Velocity Jogging
149
About Step Jogging
149
Jog Controls Reference
149
Jogging in Pathpilot
149
Jogging with the Keyboard
149
Jogging with the (Optional) Jog Shuttle
149
Manually Control the Spindle
150
Change the Spindle Speed Range
150
About the Spindle
150
Spindle Controls Reference
151
Load G-Code
151
Set up Tooling
151
Install a Tool in a Set Screw Tool Holder
151
Install a Tool in an er Collet Tool Holder
151
Install a Drill Chuck in a Jacobs Taper Arbor
152
Set Tool Length Offsets
152
Touch off the Tool Length Offsets
152
Set a Known Reference Height
152
Measure Tools Using a Known Reference Height
153
Use an Electronic Tool Setter (ETS) to Measure Tools
153
Use a Zero Setting Gauge to Measure Tools
154
Set a Known Reference Height
154
Verify the Calibration of the Zero Setting Gauge
154
Measure Tools Using a Known Reference Height
154
About Tool Offsets
155
Set Work Offsets
155
About Work Offsets
155
Operate the Coolant Pump
156
About Coolant
156
First Part Tutorial
157
About this Tutorial
158
Before You Begin
158
Required Items and Tools
158
Set up the Machine
158
About Referencing
158
Mount the Workpiece
159
Set the Work Offsets
159
Set the Z Zero
159
Set the X/Y Zeroes
159
About Work Offsets
159
About True Positive Tool Length
160
About X/Y Part Zeroes
160
Set Tool Offsets
160
Touch off the Tool Offsets
160
Measure Tools Using a Known Reference Height
160
Complete the Milling Operations
161
Create a Pocket
161
Load the Tool
161
Write the G-Code with Conversational
161
Run the Program
162
Engrave the Text
162
Write the G-Code with Conversational
162
Run the Program
163
Programming
165
Programming Overview
166
About G-Code Programming Language
166
Comments and Messages
166
G-Code Formatting Reference
166
Line Numbers
167
Words
167
Letters
167
Values
167
Order of Execution
168
Modal Groups
169
Supported G-Codes Reference
170
Programming G-Code
171
About the Examples Used
171
Rapid Linear Motion (G00)
171
Linear Motion at Feed Rate (G01)
172
Arc at Feed Rate (G02 and G03)
172
Radius Format Arc
172
Center Format Arc
173
Arc in XY Plane
173
Arc in XZ Plane
173
Arc in YZ Plane
173
Dwell (G04)
174
Set Offsets (G10)
174
Set Tool Table (G10 L1)
174
Set Coordinate System (G10 L2)
175
Set Tool Table (G10 L10)
175
Set Tool Table (G10 L11)
175
Set Coordinate System (G10 L20)
175
Plane Selection (G17, G18, G19)
175
Length Units (G20 and G21)
176
Return to Predefined Position (G28 and G28.1)
176
Return to Predefined Position (G30 and G30.1)
176
Automatically Measure Tool Lengths with an ETS (G37 and G37.1)
176
Move to G37 Position over ETS (G37.1)
176
Move and Measure Tool Length (G37)
177
Straight Probe (G38.X)
177
Use the Straight Probe Command
178
Cutter Compensation (G40, G41, G42)
178
Dynamic Cutter Compensation (G41.1 and G42.1)
179
Apply Tool Length Offset (G43)
179
Engrave Sequential Serial Number (G47)
179
Cancel Tool Length Compensation (G49)
180
Absolute Coordinates (G53)
180
Select Work Offset Coordinate System (G54 to G59.3)
180
Set Exact Path Control Mode (G61)
180
Set Blended Path Control Mode (G64)
180
Distance Mode (G90 and G91)
180
Arc Distance Mode (G90.1 and G91.1)
180
Temporary Work Offsets (G92, G92.1, G92.2, and G92.3)
181
Feed Rate Mode (G93, G94, and G95)
181
Spindle Control Mode (G96 and G97)
182
Programming Canned Cycles
182
Canned Cycles Reference
182
Supported Canned Cycles
182
High Speed Peck Drill (G73)
183
Cancel Canned Cycles (G80)
184
Drilling Cycle (G81)
184
Simple Drilling Cycle (G82)
185
Peck Drilling Cycle (G83)
185
Tapping Cycle (G84)
185
Boring Cycle (G85)
185
Boring Cycle (G86)
186
Boring Cycle (G88)
186
Boring Cycle (G89)
186
Programming M-Code
186
Supported M-Codes Reference
186
Program Stop and Program End (M00, M01, M02, and M30)
187
Spindle Control (M03, M04, and M05)
187
Tool Change (M06)
187
Coolant Control (M07, M08, and M09)
187
Override Control (M48 and M49)
188
Feed Override Control (M50)
188
Spindle Speed Override Control (M51)
188
Set Current Tool Number (M61)
188
Set Output State (M64 and M65)
188
Wait on Input (M66)
188
Programming Input Codes
189
Feed Rate (F)
189
Spindle Speed (S)
189
Change Tool Number (T)
189
Advanced Programming
189
Parameters
189
Parameters Reference
189
Parameter Syntax
189
Parameter Scope
190
Behavior of Uninitialized Parameters
190
Parameter Mode
190
Persistence and Volatility
190
Intended Use
190
Numbered Parameters Reference
190
Read-Only Parameters
190
Subroutine Parameters Reference
191
Named Parameters Reference
191
Expressions
191
Binary Operators Reference
191
Functions Reference
192
Subroutines
192
Subroutines Reference
192
Conditional Subroutines Reference
193
If/Endif
193
If/Elseif/Else/Endif
193
Repeating Subroutines Reference
194
Looping Subroutines Reference
194
Do/While
194
While/Endwhile
194
Machine Maintenance
195
Maintenance Safety
196
All Maintenance Procedures
196
Swarf Maintenance Procedures
196
Coolant Maintenance Procedures
196
Maintenance Schedules
196
Daily
196
Weekly
196
Monthly
196
Semi-Annually
196
Annually
197
Regularly Maintaining the Machine
197
Clean the Way Covers
197
Clean the Coolant System
197
About Cutting Fluid
197
Cutting Fluid Reference
197
Examine the Drawbar
198
Examine the Enclosure Windows
198
Lubricate the Machine
198
About the Manual Oiler
198
About the Automatic Oiler
198
Lubrication System Reference
199
Examine the Spindle Belt
199
Examine the Pull Stud Clamp
199
Prevent Rust
199
Remove Rust
199
Troubleshooting
201
Troubleshooting Safety
202
Getting Help
202
Required Tools
203
Frequently Found Problems
203
Electrical Service
204
Power Distribution Subsystem
204
The Controller Won't Power on
204
The Coolant Pump Won't Run
205
Control Power Subsystem
206
The Machine Won't Power on
206
Axes Drive Subsystem
207
All Axes Won't Move When Commanded
208
One Axis Won't Move (or Only Moves in One Direction), and Other Axes Move
208
DC-BUS Power Distribution Reference
211
Axis Movement Is Noisy
211
Can't Reference All Axes
212
Limit Switch Function Reference
214
Lost Motion on Axis Travel
215
Spindle Drive Subsystem
217
The Spindle Won't Turn
218
Run and Direction Commands Reference
221
Spindle VFD Trip Reference
221
Machining Operations Are Loud ("Chattery")
222
Can't Load or Unload a Tool, or the Spindle's Drawbar Drags against the Power Drawbar Cylinder's Piston Bolt
224
Spindle Rotates on Contact, or Spindle Isn't Rigidly Clamped
225
Diagrams and Parts Lists
227
Base Machine Exploded View
228
Base Machine Parts List
229
Spindle Cartridge Exploded View
230
Spindle Cartridge Parts List
231
Spindle Head Exploded View
232
Spindle Head Parts List
233
BT30 Power Drawbar Cylinder Exploded View
234
BT30 Power Drawbar Cylinder Assembly Parts List
235
Power Drawbar Push Button Exploded View
236
Power Drawbar Push Button Parts List
237
Spindle Motor Cover Exploded View
238
Spindle Motor Cover Parts List
239
X-Axis Assembly Exploded View
240
X-Axis Assembly Parts List
241
Y-Axis Assembly Exploded View
243
Y-Axis Assembly Parts List
244
Y-Axis Saddle Exploded View
246
Y-Axis Saddle Parts List
247
X-Y Axis Assembly Exploded View
248
X-Y Axis Assembly Parts List
249
Z-Axis Assembly Exploded View
250
Z-Axis Assembly Parts List
251
Lubrication System Diagram
253
Pneumatic Schematics
255
Power Drawbar Pneumatics
256
Automatic Tool Changer (ATC) Pneumatics
257
Electrical Schematics
259
Vac Power (Sheet 1)
260
VDC Controls (Sheet 2)
261
Axis Drive Bus (Sheet 3)
262
Spindle Drive (Sheet 4)
263
Machine Control Board (Sheet 5)
264
Limit/Door Switches (Sheet 6)
265
Accessory and Auxiliary Power (Sheet 7)
266
Grounds (Sheet 8)
267
Electrical Panel Layout and Fuse Table (Sheet 9)
268
Operator Box Layout (Sheet 10)
269
Wiring Table (Sheet 11)
270

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