Tormach SmartCool Technical manual

TECHNICAL DOCUMENT
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TD10422_SmartCool_Install_0417A
SmartCool™Install
Product Idencaon: SmartCool Starter Kit (PN 37167)
Purpose: This document details installaon and use of the SmartCool programmable coolant system on a
PCNC 1100™, PCNC 770™, or PCNC 440™ mill with PathPilot®.
This document has 10 secons:
1. Install SmartCool Head Unit 6. Make Control Module Connecons
2. Route Cables on a PCNC 1100 or PCNC 770 7. Calibrate with PathPilot
3. Route Cables on a PCNC 440 8. SmartCool MulCoolant Module (PN 37168)
4. Relocate Flood Coolant Mounng Bracket 9. Programming
5. Make Coolant Connecons 10. Troubleshoong
Qty.SmartCool Starter Kit PN
1 SmartCool Head Unit —
1 Control Module —
1 USB Cable —
1 Tube —
1AC/DC Power Adapter —
1 Mounting Bracket —
2 M6 x 16 mm Socket Head Cap Screw —
2 M6 x 10 mm Button Head Cap Screw —
2 M6 Small Flat Washer —
2 M6 Large Flat Washer —
4Zip Tie Mount 31460
4Zip Tie 32791
1 M5 x 12 mm Socket Head Cap Screw 31353
1 Sheet Metal Screw 31718
NOTE: If any of these items are missing, contact Tormach
Customer Service at (608) 849-8381 for a replacement.
Required Tools:
• Phillips screwdriver • Metric hex wrench set • Adjustable wrench • Wire cutter • M6 x 1 tap1
1PCNC 440 mills serial number 80075 and below require holes to be drilled and tapped to complete assembly.

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TD10422_SmartCool_Install_0417A
NOTE: If mill is not equipped with an automac tool changer (ATC), an addional mounng bracket is required
for SmartCool install. Refer to the table below for more details.
PN Description
37258 PCNC Coolant 1100 Relocation Bracket
37259 PCNC Coolant 770 Relocation Bracket
37260 PCNC Coolant 440 Relocation Bracket
IMPORTANT! Download and install the latest version of PathPilot before proceeding. PathPilot v1.9.7 or later is
required to use these instrucons. For more informaon, refer to www.tormach.com/updates.
Install SmartCool Head Unit
1. Idenfy two pre-exisng mounng holes behind spindle on head casng (see Figure 1).
NOTE: Holes may need to be cleaned of paint prior to use.
PCNC 440 mills serial number 80075 and below require two mounng holes to be drilled and tapped:
• Temporarily place Mounng Bracket behind spindle on head casng
• Mark hole locaons (see Figure 2)
• Drill and tap marks for a M6 x 1 mm screw
Figure 1 Figure 2
Mounting
Bracket
PCNC 440

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TD10422_SmartCool_Install_0417A
2. Using two M6 x 1 mm Buon Head Cap Screws
and two M6 Small Flat Washers, loosely aach
SmartCool Head Unit to Mounng Bracket as
shown in Figure 3.
3. Posion SmartCool Head Unit roughly in
center of slots on Mounng Bracket (see
Figure 4). Final adjustments will be made
aer installaon is complete to ensure coolant
stream is correctly posioned.
4. Using two M6 x 1 mm Socket Head Cap Screws
and two M6 Large Flat Washers, loosely aach
Mounng Bracket to two mounng holes (see
Figure 5).
5. Weave control cable from SmartCool Head Unit
through Mounng Bracket and underneath
head casng (see Figure 6).
NOTE: Cable roung for PCNC 1100/PCNC 770 and
PCNC 440 varies; see related secon.
Figure 6
Figure 4Figure 3
Figure 5

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TD10422_SmartCool_Install_0417A
Route Cables on a PCNC 1100 or PCNC 770
NOTE: This secon shows SmartCool install on a PCNC
1100 mill; installaon on a PCNC 770 mill is similar.
1. Open spindle motor cabinet door.
2. Route control cable from SmartCool Head
Unit up spindle column and through inside of
spindle motor cabinet (see Figure 7).
3. Using two zip es and two zip e mounts,
secure control cable from SmartCool Head
Unit to mill in locaons A and B as shown in
Figure 8.
4. Route control cable from SmartCool Head
Unit to back of mill based your specic mill
conguraon:
• If power drawbar (oponal) is installed:
Route through power drawbar’s cable
carrier and out to back of mill (see Figure 9).
• If no power drawbar is installed: Holding control cable from SmartCool Head Unit in locaon Cas
shown in Figure 10, slowly run spindle head up and down to ensure clearance through full range of
moon in Z direcon. Loosen center screw on Z-axis motor mount plate; using one zip e and one zip
e mount, aach control cable from SmartCool Head Unit (see Figure 10).
5. Slowly run spindle head up and down to ensure control cable cannot get caught in any part of mill.
Figure 7
Figure 9
Power Drawbar Installed
Figure 8
B
A
Figure 10
No Power Drawbar Installed
C

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TD10422_SmartCool_Install_0417A
Route Cables on a PCNC 440
1. Route control cable from SmartCool Head Unit up spindle column; secure using two cable mounts and two
zip es as shown in Figure 11 and Figure 12.
2. Slowly run spindle head up and down to ensure control cable cannot get caught in any part of mill.
Relocate Flood Coolant Mounting Bracket
If your mill is equipped with an oponal ATC, Coolant
Hose Mount Bracket is already relocated. Skip to Step
5 later in this secon.
1. If mill is equipped with ood coolant kit,
remove 1/4” Coolant Hose and Coolant Hose
Mount Bracket (see Figure 13); set aside.
Figure 11 Figure 12
Figure 13
1/4” Coolant
Hose
Coolant Hose
Adapter
Coolant Hose
Mount Bracket

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TD10422_SmartCool_Install_0417A
2. Idenfy mill-specic locaon for mounng
bracket (see Figure 14 and Figure 15).
NOTE: PCNC 440 mills serial number 80075 and
below require one hole to be drilled and tapped
behind SmartCool’s Mounng Bracket. Temporarily
place Relocaon Bracket on spindle column ush
with right edge of spindle head casng as shown in
Figure 15; mark hole locaons. Drill and tap these
marks for a 6 mm screw.
3. Using two screws from Coolant Hose Mount
Bracket, aach Coolant Hose Mount Bracket
and Coolant Hose Adapter to Relocaon
Bracket (see Figure 16). Figure 16
Relocation
Bracket
Push-to-connect
Fitting
Coolant Hose
Adapter
Figure 15
PCNC 440
Figure 14
PCNC 1100 / PCNC 770

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TD10422_SmartCool_Install_0417A
4. Aach Relocaon Bracket to head casng in
locaon idened in step 2.
5. Remove Push-to-connect Fing from Tube
(see Figure 17); install on Coolant Hose Adapter
using adjustable wrench (see Figure 16).
Make Coolant Connections
SmartCool units are pre-congured for use with ood
coolant, but can be congured to use mist coolant as
the primary coolant source.
NOTE: An oponal MulCoolant Module (PN 37168)
allows the SmartCool to use ood coolant and mist
coolant simultaneously – along with several other
conguraons. For more informaon, refer to
SmartCool MulCoolant Module secon later in this
document.
Flood Coolant
Connect Tube to Push-to-connect Fing on
Relocaon Bracket and route to SmartCool Head Unit
(see Figure 18).
Mist Coolant
1. Idenfy Hub on SmartCool Head Unit (see
Figure 19).
Figure 18
Push-to-connect
Fitting
Figure 17
Push-to-connect
Fitting
Figure 19
Hub

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TD10422_SmartCool_Install_0417A
2. Remove cap from Hub; idenfy two slots for
ood and mist coolant (see Figure 20) and set
aside.
3. Remove Hub’s mounng plate from front of
SmartCool Head Unit (see Figure 21); idenfy
two slots for ood and mist coolant. Hub
mounng plate follows same paern as hub
cap.
4. Re-install hub mounng plate with mist slot on
boom; ghten screws nger-ght.
5. Re-install hub cap set aside earlier with mist
slot on boom. Insert two hoses into slots as
shown in Figure 22; ghten screws nger-ght.
Figure 20
Flood
Mist
Figure 21
Figure 22

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TD10422_SmartCool_Install_0417A
Make Control Module Connections
1. Connect the Control Module as follows:
• Connect AC/DC Power Adapter to Power
port (see Figure 23)
• Connect USB Cable to USB port
(see Figure 23)
• Connect Control Cable from SmartCool
Head Unit (see Figure 23)
NOTE: If equipped with oponal MulCoolant Module
(PN 37168), wait to make M07 Auxiliary Solenoid
connecon unl SmartCool MulCoolant Module
secon later in this document.
2. Control Module is magnec; aach to back of
mill as shown in Figure 24.
3. Route USB Cable to controller; connect to any
available USB connector.
4. Route AC/DC Power Adapter to power outlet.
NOTE: SmartCool can be plugged in and used at any
me; mill does not need to power cycle for PathPilot
to recognize SmartCool.
Figure 24
Figure 23
Power USB
Control
Cable
M07 Auxiliary Solenoid (for use
with MultiCoolant Module)
Control Module

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TD10422_SmartCool_Install_0417A
Calibrate with PathPilot
Using a tool of a known length, calibrate the height of the coolant ow from SmartCool by issuing a M08 or M07
command in PathPilot and mechanically adjusng assembly installaon on spindle head casng.
1. To calibrate SmartCool, insert a measured tool
into spindle and acvate length oset. For more
informaon, refer to mill Operator Manual.
2. In MDI line, type M8 P0 to turn on ood
coolant and aim stream at p of tool (for more
informaon, refer to Programming Guide
secon later in this document).
3. Observe coolant stream; if necessary, adjust
SmartCool Head Unit within Mounng Bracket
(see Figure 25) to visually correct for uneven
mounng. Adjust unl coolant stream is in line
with tool p.
4. Tighten down screws securing SmartCool Head
Unit to Mounng Bracket.
5. If necessary, coolant stream can be further
adjusted in PathPilot to posion on tool p as
shown in Figure 26. Type ADMIN SMARTCOOL_
OFFSET to raise or lower the coolant stream;
posive values move the coolant stream up,
negave values move the coolant stream down
(for more informaon, refer to Programming
Guide secon later in this document).
Figure 25
Figure 26

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TD10422_SmartCool_Install_0417A
SmartCool MultiCoolant Module
The oponal MulCoolant Module (PN 37168) allows you to add a second source of coolant to your SmartCool
Head Unit using an auxiliary solenoid.
The SmartCool Head Unit has two slots for coolant
sources (see Figure 27):
• Primary coolant source (like ood coolant)
is controlled with an M08 command in
PathPilot, and aims the boom slot of the
hub.
• Secondary coolant source (like air or
mist coolant) is controlled with an M07
command in PathPilot, and aims the top
slot of the hub.
Typical system conguraons are:
• Flood (M08) and air (M07)
• Flood (M08) and Fog Buster (M07)
• Fog Buster (M08) and air (M07)
Installation
1. Determine your primary and secondary
coolant sources.
NOTE: If you are using a Fog Buster as the secondary
coolant source, skip to Other Conguraons secon
later in this document.
2. MulCoolant Module’s plate is magnec. Place
on mill near Control Module (see Figure 28).
3. Connect MulCoolant Module to middle 3.5
mm jack on Control Module (see Figure 28).
4. Ensure primary coolant source is installed in
boom slot of SmartCool Head Unit’s hub (see
Figure 27).
5. Route secondary coolant source to SmartCool Head Unit; install in top slot of hub.
6. Route 1/4” Black Tube from MulCoolant Module to air line; splice into the T-connector.
Figure 28
MultiCoolant
Module
Control Module
Figure 27
M07 (secondary)
M08 (primary)

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TD10422_SmartCool_Install_0417A
Other Congurations
Using a Fog Buster as a secondary coolant source requires removing the auxiliary solenoid from the MulCoolant
Module and installing it on the Fog Buster. In this conguraon, power is supplied to the Fog Buster through the
SmartCool’s Control Module.
1. Unplug Fog Buster.
2. Remove solenoid and power cord from Fog
Buster (see Figure 29) and set aside; keep for
future use.
3. Remove auxiliary solenoid from MulCoolant Module (see Figure 30); set aside remaining parts from
MulCoolant Module and keep for future use.
4. Install MulCoolant’s auxiliary solenoid in place of solenoid and power cord removed from Fog Buster in
Step 2 (see Figure 31).
5. Connect MulCoolant Module to middle 3.5 mm jack on Control Module (see Figure 28).
Figure 29
Remove
Figure 31
MultiCoolant
Auxiliary
Solenoid
Figure 30
MultiCoolant
Module

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TD10422_SmartCool_Install_0417A
Programming
SmartCool has three programming modes:
1. Z0 Mode (default): Aims coolant stream at a Z0 plane or programmed distance from the Z0 plane.
2. Tool Tip Mode (M08 P~): Aims coolant stream at the tool p or a programmed distance from the tool p.
3. Wiggle Mode (M08 R~): Oscillates coolant stream between two programmed posions.
Program SmartCool using P~, R~, or E~ words to modify the standard coolant M-codes:
M-code Description
M07 Mist coolant or air on (secondary)
M08 Flood coolant on (primary)
M09 Coolant off
Word Denition
E~ Adjusts the Z position when using Z0 mode to aim target point of coolant stream.
P~ Denes the target point of coolant stream. The P word is optional; if the P word is omitted, the target point
of the coolant stream is the Z0.
R~ Enables oscillating coolant stream (wiggle mode).
Q~ Enables pulsing of M07 or M08 solenoid in seconds. Requires SmartCool MultiCoolant Module (PN 37168).
• To turn on ood coolant, program M08 P~ R~ E~
• To turn on mist coolant or air, program M07 P~ R~ E~
• To turn all coolant o, program M09
• P, R, and E are always oponal
If the top of the workpiece is not at Z0, use an E word argument to maintain the coolant stream at the desired
Z locaon.
When using an E or P word argument, units are dened by the acve unit length as specied by G20 (inches) or
G21 (millimeters).
To specify the me period between air blasts using the MulCoolant Module, use a Q word argument. Q is
always in whole seconds. The Q word aects aiming; during the blast period, only M07 aiming is in eect.
The SmartCool Head Unit aims coolant using the top slot on the hub when only M07 is in eect; when M08 is
in eect, aiming priority is switched to the boom slot on the hub. M07 and M08 may be used simultaneously.

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TD10422_SmartCool_Install_0417A
Examples
Description Example Code
Turn on ood coolant, maintain stream at Z0 M08
Turn on ood coolant, maintain stream at 1 unit above Z0 M08 E1
Turn on ood coolant, aim stream at tool tip M08 P0
Turn on ood coolant, aim stream at 1 unit above tool tip M08 P1
Turn on ood coolant, aim stream at 3 units below tool tip M08 P-3
Turn on ood coolant, aim stream at tool tip and oscillate between tool tip and 3 units above tool tip M08 P0 R3
Turn on ood coolant, maintain stream at Z0 and oscillate between Z0 and 3 units above Z0 M08 R3
Turn on mist coolant or air, aim stream at Z0 M07
Turn off all coolant M09
Keyboard Shortcuts
Key Code Description
Alt + U Manually override PathPilot coolant control to point nozzle up1
Alt + D Manually override PathPilot coolant control to point nozzle down1
Alt + C Cancel manual override of PathPilot coolant control; reverts to automatic control
Alt + M Toggle auxiliary solenoid on and off (requires SmartCool MultiCoolant Module, PN 37168)
1Cancel manual override with Alt + C or any subsequent M-code command.
ADMIN Commands
The aiming of the SmartCool Head Unit can be ne-tuned to compensate for installaon variance or a sagging
coolant stream (non-linear).
ADMIN Command Description
ADMIN SMARTCOOL_OFFSET Offset SmartCool Head Unit up or down as appropriate. Positive values move the
stream up, negative values move the stream down.
For example, ADMIN SMARTCOOL_OFFSET 1.0 moves the coolant stream one unit higher.
NOTE: This oset applies to every poinng operaon, and is retained by the controller; it is not aected by
PathPilot soware upgrades.

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TD10422_SmartCool_Install_0417A
Troubleshooting
Problem: SmartCool does not respond to commands
Possible Cause Probability Action to Identify Cause of Problem Discussion
Unplugged or
defective USB
cable
High Verify that USB device is detected on
PathPilot’s Status tab.
Check USB cable connections; if plugged
in to the controller, switch to any other
open USB port. If PathPilot does not
detect a USB device on the Status tab,
replace the USB cable.
Loose pins on
control cable High Check that all three pins at control
module end of control cable are seated.
If any pins are not seated, click into place.
If pins do not hold, replace control cable.
Over-tightened
hub High
Listen for a sound from the SmartCool
Head Unit that indicates it is working.
Verify that the SmartCool Head Unit
does not move.
Remove the cap from the hub on the
front of the SmartCool Head Unit.
Loosen the mounting screws on the hub
(see Figure 21) and replace the cap.
Power supply is
defective Medium Remove cover from control module and
inspect LEDs on control board.
If LEDs are not illuminated, replace 12V
power supply. If new 12V power supply
does not illuminate LEDs, replace control
module.
Loose wires from
SmartCool Head
Unit to control
cable
Medium
Remove back cover from SmartCool
Head Unit and inspect wiring to control
cable.
Check connections and ensure they are
rmly seated.
Control cable is
defective Low Inspect connection at control module
end of control cable
Check all three pins at control module
end of control cable. If pins are damaged,
replace control cable.
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