Tormach 1500MX Manuals

Tormach 1500MX Manuals

Manuals and User Guides for Tormach 1500MX. We have 1 Tormach 1500MX manual available for free PDF download: Operator's Manual

Tormach 1500MX Operator's Manual

Tormach 1500MX Operator's Manual (288 pages)

Brand: Tormach | Category: Industrial Equipment | Size: 13 MB

Table of Contents

Table of Contents
5
Safety

19
- Intended Use
  20
- Machine Standards
  20
  - American National Safety Institute (ANSI)
    20
  - Occupational Safety and Health Administration (OSHA)
    20
- Safety Overview
  20
  - Safety Messages
    20
    
    Personal Injury
    20
    
    Property Damage
    21
  - Safety Decals
    21
    
    On the Electrical Cabinet Door
    21
    
    Next to the Main Disconnect
    22
    
    On the Spindle Nose
    22
  - Information Decals
    23
    
    Serial Number Plate
    23
- Machine Safety
  23
  - General Shop Safety
    23
  - Operational Safety
    24
    
    General
    24
    
    Tooling
    24
    
    Workholding
    25
  - Electrical Safety
    25
- Noise Exposure
  25
- Operating Modes Reference
  25
  - Run Mode (Mode 1)
    25
  - Setup Mode (Mode 2)
    26
  - Mode Constraints
    26
  - Automatic Tool Changer (ATC) Constraints
    27
About Your Machine

29
- Machine Specifications
  30
Site Requirements

33
- General Site and Space Requirements
  34
  - Site Requirements
    34
  - Space Requirements
    34
  - Operator Workstation Reference
    34
- Electrical and Power Requirements
  34
  - Electrical Requirements
    34
  - Power Requirements
    34
- Space Planning Drawing - 1500MX
  36
- Electrical Site Plan - 1500MX
  37
Installation

39
- Before You Begin
  40
  - Inspect the Items Delivered
    40
  - Machine Configuration
    40
- Installation Tools and Items
  40
- Move the Pallet
  40
- Unpack the Machine Crate
  41
- Self-Assembled Installation
  42
  - Install the Enclosure
    42
    
    Before You Begin
    43
    
    Helpful Tips for Installation
    43
    
    Install the Chip Trays
    43
    
    Required Tools and Items
    43
    
    Install the Enclosure Panels
    46
    
    Assemble the Door
    52
    
    Install the Door Latch
    55
    
    Secure Panel and Door Screws
    55
    
    Install the Door Latch Push Button
    56
    
    Install the Components
    57
    
    Install the Lights
    57
    
    Install the Air Gun
    58
    
    Install the Windows
    59
    
    Assemble the Console
    60
  - Set up the Pathpilot Controller
    61
    
    Specify the Date and Time
    61
    
    Specify the Keyboard Language
    61
    
    Update Pathpilot
    61
- Factory-Assembled Machine Setup
  62
  - Set up the Pathpilot Controller
    62
    
    Specify the Date and Time
    62
    
    Specify the Keyboard Language
    62
    
    Update Pathpilot
    62
  - Set up the Flood Coolant Kit
    63
    
    Install the Flood Coolant Pump
    63
    
    Required Tools
    63
    
    Unpack the Coolant Tank Crate
    63
    
    Install the Flood Coolant Filter
    64
    
    Make Coolant Connections
    64
- Verify the Installation
  65
  - Power on the Machine
    65
  - Verify Axes Function
    67
  - Verify Spindle Function
    67
  - Power off the Machine
    67
- Install Accessory Components
  68
  - Install the Automatic Tool Changer
    68
    
    Prepare the Machine
    68
    
    Required Tools
    68
    
    Unpack the ATC Box
    68
    
    Assemble the ATC
    70
    
    Install the ATC Electrical Cabinet
    72
    
    Level the ATC
    75
    
    Adjust the Tool Alignment and Set the Tool Tray Height and Encoder Position
    77
  - Install the Flood Coolant Kit
    78
    
    Required Tools
    78
    
    Unpack the Coolant Tank Crate
    78
    
    Install the Flood Coolant Filter
    79
    
    Install the Flood Coolant Pump
    79
    
    Install the Coolant Manifold
    80
    
    Install the Y-Axis Washdown Nozzle
    80
    
    Install the Flood Coolant Ring
    82
    
    Install the Manual Sprayer
    83
    
    Make Coolant Connections
    86
  - Install the Automatic Chip Tray Washdown Kit
    86
    
    Before You Begin
    86
    
    Install the Coolant Hoses and Fittings
    87
    
    Install the Washdown Coolant Filter
    87
    
    Install the Washdown Pump
    87
    
    Required Tools
    87
    
    Install the Washdown Bars
    88
    
    Make Connections
    88
  - Install the MQL Kit
    89
    
    Remove the Tubing from the Pump
    89
    
    Required Tools
    89
    
    Route the Tubing
    90
    
    Mount the Pump
    91
  - Install the Microarc
    93
    
    Install the A-Axis Driver Install the Microarc 6 in the Machine
    93
  - Install the Probe and Tool Setter
    98
    
    Before You Begin
    98
    
    Notes
    98
    
    Required Tools
    98
    
    Wireless Receiver Installation
    98
    
    Wireless Probe Installation and Setup
    99
    
    Adjust Probe Tip Concentricity
    100
    
    Set Probe Length and Diameter
    100
    
    Probe Status Lights Reference
    102
    
    Tool Setter Installation and Setup
    102
    
    Align the Tool Setter's Stylus
    103
    
    Reference the Tool Setter
    104
    
    Set G37 Position
    104
System Basics

105
- System Reference
  106
  - Machine Table
    106
  - Spindle
    106
    
    About the Spindle
    106
  - Axes
    106
- Basic Controls Reference
  106
  - Machine Controls
    106
  - Pathpilot Interface
    107
  - Tormach® 2024
    107
Pathpilot Interface Overview

109
- About Pathpilot
  110
- Notebook Section
  110
  - Main Tab
    110
  - File Tab
    110
  - Settings Tab
    111
  - Offsets Tab
    111
  - Conversational Tab
    111
  - Probe Tab
    111
  - Status Tab
    112
- Persistent Controls
  112
  - Program Control Area
    112
  - Position Status Area
    112
  - Manual Control Area
    113
- Keyboard Shortcuts
  113
- Manage Pathpilot Versions
  113
Pathpilot Tools and Features

117
- Create and Load G-Code Files
  118
  - Load G-Code
    118
    
    About System Files
    118
    
    Preview G-Code Files
    118
    
    Transfer Files to and from the Controller
    118
    
    Access Recent G-Code Files
    119
    
    Close the Current Program
    119
  - Edit G-Code
    119
    
    Edit G-Code with a Text Editor
    119
    
    Edit G-Code with Conversational Programming
    119
    
    Change the Step Order
    120
    
    Create a New Job Assignment
    120
    
    Edit a Job Assignment
    120
    
    Load an Existing G-Code File
    120
  - Read G-Code
    120
    
    About the G-Code Tab
    120
    
    Expand the G-Code Tab
    120
    
    Search in the Code
    120
    
    Lead-In Moves
    121
    
    Set a New Start Line
    121
    
    About the Tool Path Display
    122
    
    Change the View of the Tool Path Display
    122
  - Use Conversational Programming
    123
    
    About Conversational Programming
    123
    
    Create a Face on a Part
    123
    
    About Facing
    124
    
    Create a Profile on a Part
    124
    
    Facing in Pathpilot
    124
    
    Facing Reference
    124
    
    About Profiling
    125
    
    Profiling in Pathpilot
    125
    
    Create a Pocket on a Part
    126
    
    Profiling Reference
    126
    
    About Circular Pockets
    127
    
    About Pockets
    127
    
    About Rectangular Pockets
    127
    
    Creating Pockets in Pathpilot
    127
    
    Create Hole Locations on a Part (Drill/Tap)
    128
    
    About Drilling and Tapping
    129
    
    Create a Drilling Sequence
    129
    
    Drilling and Tapping in Pathpilot
    129
    
    Create a Tapping Sequence
    130
    
    Create Threads on a Part
    130
    
    Drilling and Tapping Reference
    130
    
    About Thread Milling
    131
    
    Thread Milling in Pathpilot
    131
    
    Thread Milling Reference
    131
    
    About Engraving
    132
    
    Create Text to Engrave on a Part
    132
    
    Import a DXF File
    132
    
    Adjust the Tree View Window
    133
    
    Change the Layer or Shape Cut Order
    133
    
    Working in the Preview Window
    133
    
    Working with Layers and Shapes
    133
- Machine Settings and Accessories
  133
  - Change the Network Name
    134
  - Select the Spindle Type
    134
  - Specify the Tool Change Method
    134
    
    About Automatic Tool Changes
    134
    
    About Manual Tool Changes
    134
  - Enable Accessories
    134
    
    Specify Probing and Tool Measuring Options
    134
    
    Enable the USB M-Code I/O Interface Kit
    135
  - Enable an Internet Connection
    135
    
    Connect to Dropbox
    135
    
    Enable Automatic Updates
    137
- Set up G-Code Programs
  137
  - Use a Probe with Pathpilot
    137
    
    Set the X and y Work Offset Zero on the Corner of a Feature
    137
    
    Set up the Probe
    137
    
    Use a Probe to Find a Feature's Location
    137
    
    Use a Probe to Set Work Offset Zeroes
    137
    
    Find the Center of a Pocket
    138
    
    Find the Center of a Rectangular Boss
    138
    
    Find the Center of a Slot
    138
    
    Set the Work Offset Zeroes on a Feature
    138
    
    Use a Probe to Find the Center of a Feature
    138
    
    Find the Center of a Circular Boss
    139
    
    Find the Center Rotation of an A-Axis
    139
  - Set Tool Length Offsets
    139
    
    About Tool Offsets
    140
    
    Measure Tools Using a Known Reference Height
    140
    
    Set a Known Reference Height
    140
    
    Touch off the Tool Length Offsets
    140
    
    Use an Electronic Tool Setter (ETS) to Measure Tools
    141
    
    Measure Tools Using a Known Reference Height
    142
    
    Set a Known Reference Height
    142
    
    Use a Tool Height Setter to Measure Tools
    142
    
    Verify the Calibration of the Tool Height Setter
    142
  - Set Work Offsets
    143
    
    About Work Offsets
    143
  - View Work Offsets
    144
  - View Available G-Code Modes
    144
- Run G-Code Programs
  144
  - Bring the Machine out of Reset
    144
    
    About Reset Mode
    144
  - View the Active Axis to Jog
    145
  - Jog the Machine
    145
    
    Jog in Continuous Velocity Mode
    145
    
    Jog in Step Mode
    145
  - View the Current Machine Position
    146
  - Reference the Machine
    146
    
    About Referencing
    146
  - Start a Program
    146
    
    About Cycle Start
    146
    
    Cycle Start Reference
    146
  - Stop Machine Motion
    147
  - View the Active G-Code Modes
    147
  - View the Distance to Go
    147
    
    About Distance to Go
    147
- Control G-Code Programs
  147
  - Use the Feed Hold Function
    147
    
    About Feed Hold
    147
  - Use the Feed Rate Override Function
    148
    
    About Feed Rate Override
    148
  - Use M01 Break Mode
    148
    
    About M01 Break
    148
  - Use the Maxvel Override Function
    148
    
    About Maxvel Override
    149
  - Use Single Block Mode
    149
    
    About Single Block
    149
  - Use the Spindle Override Function
    149
    
    About Spindle Override
    149
  - Change the Feed Rate
    149
    
    About Feed Rates
    150
  - Change the Spindle Speed
    150
    
    About Spindle Controls
    150
  - Change the Tool Number
    150
    
    About M6 G43
    150
  - Use a G30 Position
    150
    
    About G30
    151
  - View the Tool Length
    151
  - Manually Enter Commands
    151
    
    About the MDI Line DRO Field
    151
    
    Admin Commands Reference
    151
  - Copy Recently Entered Commands
    152
  - Limit G30 Moves
    152
    
    About G30
    152
  - Use Feeds and Speeds Suggestions
    152
    
    Refresh DRO Field Values
    153
    
    Use Additional Provided Information
    153
    
    Create Tool Descriptions
    154
    
    Enable Feeds and Speeds Suggestions in Conversational Routines
    154
    
    Manually Enter Tool Descriptions
    154
    
    Automatically Generate Tool Descriptions
    155
    
    Tool Keywords Reference
    155
- System File Management
  156
  - Manage System Files
    156
    
    About System Files
    156
  - Create Backup Files
    156
    
    About Backup Files
    157
  - Restore Backup Files
    157
  - Import and Export the Tool Table
    158
    
    Export the Tool Table as a .Csv File
    158
    
    Import a .Csv File
    158
Basic Operations

161
- Start the Machine
  162
- Reference the Machine
  162
  - About Referencing
    162
- Jog the Machine
  162
  - About Jogging
    163
    
    About Continuous Velocity Jogging
    163
    
    About Step Jogging
    163
  - Jog Controls Reference
    163
    
    Jogging in Pathpilot
    163
    
    Jogging with the (Optional) Jog Shuttle
    163
    
    Jogging with the Keyboard
    163
- Manually Control the Spindle
  164
  - About the Spindle
    164
- Load G-Code
  164
- Set up Tooling
  164
- Set Tool Length Offsets
  165
- Set Work Offsets
  169
  - About Work Offsets
    170
- Operate the Coolant Pump
  170
  - About Coolant
    170
Programming

171
- Programming Overview
  172
  - About G-Code Programming Language
    172
  - G-Code Formatting Reference
    172
    
    Line Numbers
    172
    
    Words
    172
    
    Letters
    173
    
    Values
    173
    
    Order of Execution
    174
    
    Modal Groups
    175
    
    Comments
    176
  - Supported G-Codes Reference
    176
- Programming G-Code
  177
  - About the Examples Used
    177
  - Rapid Linear Motion (G00)
    177
  - Linear Motion at Feed Rate (G01)
    178
  - Arc at Feed Rate (G02 and G03)
    178
    
    Radius Format Arc
    178
    
    Arc in XY Plane
    179
    
    Arc in XZ Plane
    179
    
    Arc in YZ Plane
    179
    
    Center Format Arc
    179
  - Dwell (G04)
    180
  - Set Offsets (G10)
    180
    
    Set Tool Table (G10 L1)
    180
    
    Set Coordinate System (G10 L2)
    181
    
    Set Coordinate System (G10 L20)
    181
    
    Set Tool Table (G10 L10)
    181
    
    Set Tool Table (G10 L11)
    181
  - Plane Selection (G17, G18, G19)
    182
  - Length Units (G20 and G21)
    182
  - Return to Predefined Position (G28 and G28.1)
    182
  - Return to Predefined Position (G30 and G30.1)
    182
  - Automatically Measure Tool Lengths with an ETS (G37 and G37.1)
    182
    
    Move to G37 Position over ETS (G37.1)
    182
    
    Move and Measure Tool Length (G37)
    183
  - Straight Probe (G38.X)
    183
    
    Use the Straight Probe Command
    184
  - Cutter Compensation (G40, G41, G42)
    185
  - Dynamic Cutter Compensation (G41.1 and G42.1)
    185
  - Apply Tool Length Offset (G43)
    185
  - Engrave Sequential Serial Number (G47)
    185
  - Cancel Tool Length Compensation (G49)
    186
  - Absolute Coordinates (G53)
    186
  - Select Work Offset Coordinate System (G54 to G54.1 P500)
    186
  - Set Exact Path Control Mode (G61)
    186
  - Set Blended Path Control Mode (G64)
    186
  - Distance Mode (G90 and G91)
    187
  - Arc Distance Mode (G90.1 and G91.1)
    187
  - Temporary Work Offsets (G92, G92.1, G92.2, and G92.3)
    187
  - Feed Rate Mode (G93, G94, and G95)
    187
  - Spindle Control Mode (G96 and G97)
    188
- Programming Canned Cycles
  188
  - Canned Cycles Reference Supported Canned Cycles
    188
  - High Speed Peck Drill (G73)
    190
  - Cancel Canned Cycles (G80)
    190
  - Drilling Cycle (G81)
    190
  - Simple Drilling Cycle (G82)
    191
  - Peck Drilling Cycle (G83)
    191
  - Boring Cycle (G85)
    191
  - Boring Cycle (G86)
    192
  - Boring Cycle (G88)
    192
  - Boring Cycle (G89)
    192
- Programming M-Code
  192
  - Supported M-Codes Reference
    192
  - Program Stop and Program End (M00, M01, M02, and M30)
    193
  - Spindle Control (M03, M04, and M05)
    193
  - Tool Change (M06)
    193
  - Coolant Control (M07, M08, and M09)
    193
  - Override Control (M48 and M49)
    194
  - Feed Override Control (M50)
    194
  - Spindle Speed Override Control (M51)
    194
  - Set Current Tool Number (M61)
    194
  - Set Output State (M64 and M65)
    194
  - Wait on Input (M66)
    194
  - Chip Conveyor Control (M231 and M233)
    195
- Programming Input Codes
  195
  - Feed Rate (F)
    195
  - Spindle Speed (S)
    195
  - Change Tool Number (T)
    195
- Advanced Programming
  195
  - Parameters
    195
    
    Parameters Reference
    195
    
    Behavior of Uninitialized Parameters
    196
    
    Intended Use
    196
    
    Numbered Parameters Reference
    196
    
    Parameter Mode
    196
    
    Parameter Scope
    196
    
    Parameter Syntax
    196
    
    Persistence and Volatility
    196
    
    Read-Only Parameters
    196
    
    Named Parameters Reference
    197
    
    Subroutine Parameters Reference
    197
  - Expressions
    197
    
    Binary Operators Reference
    198
    
    Functions Reference
    198
  - Subroutines
    198
    
    Subroutines Reference
    198
    
    Conditional Subroutines Reference
    199
    
    If/Endif
    199
    
    Do/While
    200
    
    If/Elseif/Else/Endif
    200
    
    Looping Subroutines Reference
    200
    
    Repeating Subroutines Reference
    200
    
    While/Endwhile
    200
Machine Maintenance

203
- Maintenance Safety
  204
  - All Maintenance Procedures
    204
  - Swarf Maintenance Procedures
    204
  - Coolant Maintenance Procedures
    204
- Maintenance Schedules
  204
  - Daily
    204
  - Weekly
    204
  - Monthly
    204
  - Semi-Annually
    204
  - Annually
    204
  - Clean the Way Covers
    205
  - Clean the Coolant System
    205
    
    About Cutting Fluid
    205
    
    Cutting Fluid Reference
    205
  - Examine the Enclosure Windows
    206
  - Lubricate the Machine
    206
    
    About the Automatic Oiler
    206
  - Examine the Spindle Belt
    206
  - Prevent Rust
    206
    
    Remove Rust
    206
Troubleshooting

209
- Troubleshooting Safety
  210
- Getting Help
  210
- Required Tools
  210
- Frequently Found Problems
  211
- Electrical Service
  212
  - LED Identification
    212
  - Overview
    214
- Power Distribution Subsystem
  214
  - The Machine Won't Power on
    214
  - The Pathpilot Operator Console Won't Power on
    215
- Control Power Subsystem
  215
  - The Machine Won't Power on
    216
- Servo Drive Subsystem
  217
- Spindle Drive Subsystem
  221
- Servo IO Breakout Board Subsystem
  227
  - Groups of Inputs and Outputs Aren't Functioning
    227
    
    Servo Drive Inputs and Outputs
    227
Diagrams and Parts Lists

229
Electrical Schematics

275
- Vac Power (Sheet 2)
  276
- VDC Controls (Sheet 3)
  277
- Safety Systems
  278
- Spindle Drive (Page 5)
  279
- Y-, and Z-Axis Drives (Page 6)
  280
- A- and B-Axis Drives (Page 7)
  281
- Ethercat IO Board
  282
- Accessory / Auxiliary (Page 9)
  283
- X1 AC Terminal Strip (Pages 11-13)
  284
- X2 Control Terminal Strip (Page 14)
  287
- X3 Grounds Terminal Strip (Page 15)
  288

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