Tormach 51136 User manual

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©Tormach® 2022
TECHNICAL DOCUMENT Version 0722A
INSTALLATION GUIDE
24R Z-AXIS BRAKE RETROFIT KIT

PURPOSE
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Before you begin, select the image below to watch a walk-through video of this entire installation
procedure.
PURPOSE
This document gives instructions on installing the 24R Z-Axis Brake Retrofit Kit on machines RA10001 through
RA10096, which do not include a Z-axis brake.
IMPORTANT! This kit is required to use an automatic tool changer (ATC) on machines RA10001 through
RA10096. You must install this kit before you begin to install the ATC.
PRODUCT INFORMATION
Product:24R Z-Axis Brake Retrofit Kit (PN51136)
Quantity Description
1 24R Z-Axis Brake Cable Assembly (PN51138)
1 Z-Axis Motor with Z Brake (PN51133)
Note: If any items are missing, we can help. Create a support ticket with Tormach Technical Support at
tormach.atlassian.net/servicedesk for guidance on how to proceed.
REQUIRED TOOLS
This procedure requires the following tools. Collect them before you begin.
l3 mm hex wrench
l4 mm hex wrench
l6 mm hex wrench
lAn assistant to help you
lFlat-blade screwdriver, small
lWood blocks
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TD10801: Installation Guide: 24R Z-Axis Brake Retrofit Kit (0722A)

BEFORE YOU BEGIN
BEFORE YOU BEGIN
Update PathPilot
If you haven't yet done so, you must update your controller to the latest version of PathPilot.
1. From the PathPilot interface, on the Status tab, select Update.
Installation Procedure
If your 24R router serial number is between RA10001 and RA10096, you must install the Z-axis brake. Some
machines within that serial number range require an additional installation of a Z-axis brake cable.
1. Find your machine's serial number plate on the side of the electrical cabinet.
Figure 1: Serial number plate.
2. Use the following table to determine which procedure to start with, depending on your specific machine.
Serial Number Go to...
RA10001 through RA10084 "Update Wire 487 From the Machine Control Board" (page4)
RA10085 through RA10096 "Remove the Existing Z-Axis Motor" (page10)
RA10097 or higher The Z-axis brake is pre-installed at the factory, and you don't need to
follow any procedures in this document.
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TD10801: Installation Guide: 24R Z-Axis Brake Retrofit Kit (0722A)

INSTALLATION
INSTALLATION
Update Wire 487 From the Machine Control Board 4
Install the Z-Axis Brake Cable 6
Remove the Existing Z-Axis Motor 10
Install the Replacement Z-Axis Motor with Brake 13
Verify the Installation 15
Update Wire 487 From the Machine Control Board
1. Power on the machine and the PathPilot controller.
a. Turn the Main Disconnect switch to ONon the side of the electrical cabinet.
b. Twist out the machine's red Emergency Stop button, which enables movement to the machine axes and
the spindle.
c. Press the Reset button.
d. Bring the machine out of reset and reference it.
2. Jog the X-axis to about the middle point of travel (12 in.).
3. Jog the Y-axis about 24 in. in the positive direction.
4. Jog the Z-axis down to the end of travel.
5. Remove any cutting tools from the spindle.
WARNING! Electrical Shock Hazard: You must power off the machine before making any electrical
connections. If you don't, there's a risk of electrocution or shock.
6. Power off the machine and the PathPilot controller.
a. Push in the machine's red Emergency Stop button, which removes power to motion control.
b. From the PathPilot interface, select Exit.
c. Turn the Main Disconnect switch to OFF on the side of the electrical cabinet.
d. Remove the power plug(s) from the wall outlet. If your system is hardwired, isolate the machine by
opening its circuit breaker(s).
e. Follow correct lockout/tagout procedures.
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TD10801: Installation Guide: 24R Z-Axis Brake Retrofit Kit (0722A)

INSTALLATION
7. In the electrical cabinet, on the top of the machine control board, identify the J10 connector.
Figure 1: Machine control board.
8. Unplug the connector from the board. Remove wire 487 and wire 488 from the connector with a small, flat-
blade screwdriver.
9. Remove the necessary wire trough covers and trace wire 487 and wire 488 back to the terminal block strip.
10. Disconnect wire 488 from the terminal block with a small, flat-blade screwdriver. Discard the wire.
11. Connect the loose end of wire 487 to the +24 Vdc by inserting it into the open port of the terminal block
connected to wire 404.
Figure 2: Wire 487 connected to the open port of wire 404.
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TD10801: Installation Guide: 24R Z-Axis Brake Retrofit Kit (0722A)

INSTALLATION
Install the Z-Axis Brake Cable
IMPORTANT! If your machine's serial number is between RA10085 and RA10096, your machine already
has a Z-axis brake cable installed. Skip this section and go to "Remove the Existing Z-Axis Motor"
(page10).
In this section, you'll remove the vacuum table off of the casting to route the Z-axis cable to the electrical cabinet.
To simplify this procedure, we recommend:
lAsking an assistant to help you.
lSetting up a table or a set of saw horses to temporarily hold the vacuum table while you work on the Z-axis
brake cable routing.
Route the Z-Axis Brake Cable to the Electrical Cabinet
1. Remove the M8 screws securing the vacuum table to the machine with a 6 mm hex wrench. Set the screws
aside.
2. From the end of the machine, slide the vacuum table off of the casting.
3. From the back of the gantry, remove the screws securing the lid to the rear of the Z-axis cover with a 3 mm
hex wrench. Set the cover and screws aside.
Figure 3: Z-axis cover.
4. Remove the five M5 screws on the cable tray cover on the back of the gantry and the five M5 screws from
the cable tray cover on the side of the gantry with a 3 mm hex wrench. Set the screws and covers aside.
5. Find the 24R Z-Axis Brake Cable Assembly (PN51138) provided in this kit.
6. Wrap the ends of the cable together with electrical tape.
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TD10801: Installation Guide: 24R Z-Axis Brake Retrofit Kit (0722A)

INSTALLATION
7. To route the cable through the X-axis energy chain, you must remove every other energy chain cover. Put
small, flat-blade screwdriver into the left rectangle opening and pry up. Then, pry up on the right rectangle
opening. Lift the cover and set it aside.
Figure 4: Removing a cover on the X-axis energy chain.
8. Repeat Step 7 for every other energy chain cover. The top and bottom energy chain covers are different
sizes, so keep them separate for re-installation.
9. Begin routing the brake cable through the X-axis energy chain and then down the side of the gantry.
10. Replace the energy chain covers that you set side earlier by sliding them back into place and snapping both
the top and the bottom to secure them.
11. Route the cable down the side of the gantry, through the cable tray on the bottom of the gantry, and then
into the Y-axis energy chain closest to the electrical cabinet.
12. Remove any necessary energy chain covers on the Y-axis energy chain with a short, small, flat-blade
screwdriver. Set aside the covers.
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TD10801: Installation Guide: 24R Z-Axis Brake Retrofit Kit (0722A)

INSTALLATION
13. Route the cable through the Y-axis energy chain and then toward the hole on the top of the electrical
cabinet.
Figure 5: Cable routing through the hole on the top of the electrical cabinet.
14. Replace any energy chain covers that you set aside earlier.
15. Route the cable through the hole in the top left of the electrical cabinet and then through the wire troughs.
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TD10801: Installation Guide: 24R Z-Axis Brake Retrofit Kit (0722A)

INSTALLATION
Make Electrical Connections
1. Route wire 509 and wire 510 to the machine control board, and then unwrap the electrical tape.
2. Connect wire 509 to pin 2 on the J10 connector with a small, flat-blade screwdriver.
Figure 6: Wire 509 on the J10 connector on the machine control board.
3. Route wire 510 toward the top of the 24 Vdc power supply.
4. Find the security pin on the bottom of the power supply, and release it with a small, flat-blade screwdriver.
You can tsen lift the power supply off of the DIN rail to make the wire connections.
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TD10801: Installation Guide: 24R Z-Axis Brake Retrofit Kit (0722A)

INSTALLATION
5. Connect wire 510 to the empty V- terminal on the power supply with a small, flat-blade screwdriver.
Figure 7: Wire 510 on the V- terminal on the power supply.
6. Re-seat the power supply onto the DINrail, and then re-seat the security pin with a small, flat-blade
screwdriver.
7. Re-install wire troughs into the electrical cabinet.
Remove the Existing Z-Axis Motor
1. If you haven't yet done so, you must first power off the machine and the PathPilot controller.
WARNING! Electrical Shock Hazard: You must power off the machine before making any electrical
connections. If you don't, there's a risk of electrocution or shock.
2. Power off the machine and the PathPilot controller.
a. Push in the machine's red Emergency Stop button, which removes power to motion control.
b. From the PathPilot interface, select Exit.
c. Turn the Main Disconnect switch to OFF on the side of the electrical cabinet.
d. Remove the power plug(s) from the wall outlet. If your system is hardwired, isolate the machine by
opening its circuit breaker(s).
e. Follow correct lockout/tagout procedures.
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TD10801: Installation Guide: 24R Z-Axis Brake Retrofit Kit (0722A)

INSTALLATION
3. Locate the Z-axis motor power connector in the rear of the Z-axis cover and disconnect it.
Figure 8: Z-axis motor power connector.
4. From the Z-axis motor, remove the four M6 screws securing it in place with a 4 mm hex wrench. Set the
screws aside.
Figure 9: Existing Z-axis motor secured to the machine.
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TD10801: Installation Guide: 24R Z-Axis Brake Retrofit Kit (0722A)

INSTALLATION
5. Locate the Z-axis motor coupler. If you can access the screw securing the coupler to the Z-axis motor shaft,
loosen it with a 4 mm hex wrench. If you can't access the screw, go to Step 6.
Figure 10: Existing Z-axis motor coupler.
6. Put a 4 ft wood board under the spindle head. Slowly lift the board up to move the spindle head up and
rotate the coupler. Put a shim under the board to keep it in place while you loosen the screw securing the
coupler to the Z-axis motor shaft with a 4 mm hex wrench.
7. Lift and remove the Z-axis motor and discard it.
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TD10801: Installation Guide: 24R Z-Axis Brake Retrofit Kit (0722A)

INSTALLATION
Install the Replacement Z-Axis Motor with Brake
1. Find the Z-axis motor with Z brake provided in the kit.
2. With the motor's wires facing the back of the machine, slip the motors shaft into the coupler on the ball
screw and set the motor on top of the Z-axis motor mount.
Figure 11: Replacement Z-axis motor installed onto the machine.
3. Tighten the coupler onto the shaft of the motor with a 4 mm hex wrench.
4. Verify that the Z-axis brake's manual override lever is slid to the left (in the engaged position). If it's not,
slide the lever to engage the brake.
5. Secure the Z-axis motor to the motor mount with the four M6 screws from the previous step.
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TD10801: Installation Guide: 24R Z-Axis Brake Retrofit Kit (0722A)

INSTALLATION
6. Identify the Z-axis motor power connector in the rear Z-axis cover and connect it to the motor.
Figure 12: Connecting the Z-axis motor power connector to the motor.
7. Connect the Z-axis brake cable to the Z-axis motor’s brake connector in the rear Z-axis cover.
Figure 13: Connecting the Z-axis brake cable to the Z-axis motor's brake connector.
8. Re-install the following items with the parts that you set aside earlier:
lVacuum table
lRear Z-axis cover
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TD10801: Installation Guide: 24R Z-Axis Brake Retrofit Kit (0722A)

INSTALLATION
Verify the Installation
1. Turn the Main Disconnect switch to ONon the side of the electrical cabinet.
In the electrical cabinet, examine the axis motor drives to determine if the green LEDs are illuminated.
lIf the green LEDs are OFF, continue to the next step.
lIf the green LEDs are ON, power off the machine and go to "Troubleshooting" (page16) >Problem:
The Emergency Stop button doesn't work.
2. Twist out the machine's red Emergency Stop button, which enables movement to the machine axes and the
spindle.
Examine the Reset button to determine if the blue LED is already illuminated.
lIf the blue LED is OFF, continue to the next step.
lIf the blue LEDis ON, power off the machine and go to "Troubleshooting" (page16) >Problem: The
Emergency Stop button doesn't work.
3. Press the Reset button.
4. From the PathPilot interface, bring the machine out of reset.
5. On the keyboard, press the Page Up key to raise the spindle head off of the wooden block.
6. From the PathPilot interface, reference the Z-, X-, and Y-axis.
The Z-axis motor should operate smoothly and sound like the other two axis motors. If the Z-axis motor
sounds different, go to "Troubleshooting" (page16).
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TD10801: Installation Guide: 24R Z-Axis Brake Retrofit Kit (0722A)

TROUBLESHOOTING
TROUBLESHOOTING
Problem:Spindle head falls after installing the new motor with brake when the machine is powered off.
Probability How-To Steps
High 1. Power off the machine.
2. On the top of the Z-axis motor, push the manual break override lever to the
left.
The brake switches into automatic mode, and engages the brake when the
machine is powered off.
Problem:The Z-axis motor makes grinding noises during operation.
Probability How-To Steps
High 1. Verify that the latest version of PathPilot is installed on your controller.
2. In the rear Z-axis cover, check the Z-axis motor connector to verify that it's
properly connected and all wires are seated into the connector.
3. In the electrical cabinet, inspect wires 509 and 510 to verify that they are
properly connected.
For information, see "Electrical Schematics" (page17).
Problem:The Emergency Stop button doesn't work.
Probability How-To Steps
High 1. Verify that any of the following symptoms occur:
lThe blue Reset LED is always on, even when the Emergency Stop button is
pressed in.
lThe green LEDs on the axis drives are always on, even when the Emergency
Stop button is pressed in.
lThe green LED on the K1 relay is always on, even when the Emergency Stop
button is pressed in.
2. In the electrical cabinet, inspect wires 509 and 510. Verify that they are
connected to the correct location inside the electrical cabinet:
lWire 509 connects to Pin 2 on the J10 connector of the ECM1 machine
control board.
lWire 510 connects to -V on the 24 Vdc power supply.
3. If wires 509 and 510 are connected to the correct locations in the electrical
cabinet, refer to the troubleshooting section of the 24R operator’s manual.
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TD10801: Installation Guide: 24R Z-Axis Brake Retrofit Kit (0722A)

ELECTRICAL SCHEMATICS
ELECTRICAL SCHEMATICS
24 Vdc Controls (Sheet 3) 18
Axis Drive Bus (Sheet 4) 19
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TD10801: Installation Guide: 24R Z-Axis Brake Retrofit Kit (0722A)

ELECTRICAL SCHEMATICS
24 Vdc Controls (Sheet 3)
LOCATION:
Document realized with version :
CONTRACT:
1 2 3 4 5 6 7 8 9 10
+L1 Electrical anel
Machine Schematic
2018.0.5.5
Tormach, Inc
1071 Uniek Dr.
Waunakee, WI 53597
SOLIDWORKS Electrical
24V DC Control
24V DC Control
2 - COL9 2 - COL9
24V DC
- S1
2A
NL
+V-V
51138
24V DC ower Supply
100-240V AC
+V-V
4
-X2 6
7
5
410
407
402
409
403
403 409
37526
24V
-FAN1
Electrical Cabinet Fan
-K1
10A
03-8
6
9
GND5
413 411
412411
12 13
-X2 11 422 -X2 8
9
429
421
-K1
10 11
37515
Drive Relay
4 7 1
02-9
5 8 2 6 9 3
03-4
-K1
-K2
A1 A2
37343
VFD Contactor
2 1
02-9
3 4 5 6 13 14
03-7
-K2
-X2 16
17 428
430
430
-D1
37514
415 414
-TS1
37420
Thermal Switch
427 425
-X2 14
15 426
-K2
13 14
37343
VFD Contactor
423
-XS1
1 2 3 4 5
37353
420
6 - COL7
3 2
406 405
6 - COL7
6 - COL7
408
-XS2
1 2 3 4 5
39263
9 - COL6
-X2 1 404
7 - COL6
7 - COL6 7 - COL6
118 115
408
413
424 423
410
GND6 419 418 417 416
489
-S1
5
6
3
4
-S1
Reset
37342
-S2
1
2
Emergency Stop
30462
-XS29
1 2 3 4 5
51163 -XS30
1 2 3 4 5
37927
+L2 - Operator Box
433
431
434
436
435
431 GND7 436 434 432 432
39627
Operator Box Cable, 270cm
508 10
487
401
401
8 - COL3
6 - COL9
6 - COL7
6 - COL7
529
6 - COL9
510
4 - COL10
AGE
03 13
REVISION
Page 18
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TD10801: Installation Guide: 24R Z-Axis Brake Retrofit Kit (0722A)

ELECTRICAL SCHEMATICS
Axis Drive Bus (Sheet 4)
LOCATION:
Document realized with version :
CONTRACT:
1 2 3 4 5 6 7 8 9 10
+L1 Electrical anel
Machine Schematic
2018.0.5.5
Tormach, Inc
1071 Uniek Dr.
Waunakee, WI 53597
SOLIDWORKS Electrical
Axis Drive
Axis Drive
121 116
2 - COL9 2 - COL9
-XFM1
30459
Drive Transformer
0 1
11 13
-F1
5A
1
2
38693
GND8
X FUSE
F1 8A
8AF2
Y FUSE
8AF3
Z FUSE
8AF4
A FUSE
1AF5
BRAKE FUSE
8A 8A
10A
F8 F7 F6
ATC FUSE
DB FUSE
MAIN FUSE
DC BUS BOARD
J1 J2
X+
X-
Y+
Y-
Z+
Z-
A+
A-
TC+
TC-
CA +
CA -
32005
-BUS1
-C1
+ -
30468
212
9 - COL4
122
-DR1
32000X-DRIVE
UL+ UL- DIR+ DIR- ENA+ ENA- GND
VDC
U
V
W
J6\6
-DR2
32000Y-DRIVE
UL+ UL- DIR+ DIR- ENA+ ENA- GND
VDC
U
V
W
Motor
50374
Y-MOTOR
-M2
Motor
51133 Z-MOTOR
-M3
M3B
-DR3
32000Z-DRIVE
UL+ UL- DIR+ DIR- ENA+ ENA- GND
VDC
U
V
W
213 214 215
205 206
229 230 231
216 217 218
J6\18 J6\17 J6\16 J6\15 J6\14 J6\13
J6\12 J6\11 J6\10
J6\9 J6\8 J6\7
J6\24 J6\23 J6\22 J6\21 J6\20 J6\19
209 210
211
6 - COL5 6 - COL5 6 - COL5 6 - COL5 6 - COL5
6 - COL5 6 - COL5 6 - COL5 6 - COL5 6 - COL5 6 - COL5
6 - COL5 6 - COL5 6 - COL5 6 - COL5 6 - COL5 6 - COL5
-DR4
32793A-DRIVE
AC AC A+ A-
B+ B-
DIR- DIR+ UL- UL+ EN- EN+
6 - COL5 6 - COL5 6 - COL5 6 - COL5 6 - COL5 6 - COL5
Motor
-M4
A-MOTOR
-XS10
1 2 4 6 7
30480
-XS9
1 2 4 6 7
30235
235 234 233
219 220 221 222
232
GND9
9 - COL6
-XS3
1 2 3
39264 -XS4
1 3 2
39265
-XS5
1 2 3
39264 -XS6
1 3 2
39265
-XS7
1 2 3
39264 -XS8
1 3 2
39265
201 202
Motor
50374 X-MOTOR
-M1
203 204
205 206
207 208
210 209
219 220 221 222
GND10
228 227 226
225 224 223
238 237 236
116
203 204
8 ON 7 ON 6 OFF 5 ON 4 ON 3 ON 2 OFF 1 ON
IN OSITION
XYZ AXIS
DI SWITCH SETTINGS
4TH AXIS O TION
NOT INCLUDED IN BASE MACHINE
6 - COL5
J6\1 J6\5 J6\4 J6\3 J6\2
38924
GND14
GND15
GND16
9 - COL6
9 - COL6
9 - COL6
512 511
-XS36
1 2
39687 -XS37
1 2
50782
509
6 - COL7
510
3 - COL2
AGE
04 13
REVISION
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TD10801: Installation Guide: 24R Z-Axis Brake Retrofit Kit (0722A)