Tormach 770MX User manual

TECHNICAL DOCUMENT Version 1019A
OWNER'S GUIDE
770MX AUTOMATIC TOOL CHANGER (ATC)
Page 1

1.1 PURPOSE
This document gives instructions on installing and using an
Automatic Tool Changer (ATC)for 770MX.
1.2 PRODUCT INFORMATION
Product: Automatic Tool Changer (ATC)for 770MX (PN 39290)
The Automatic Tool Changer (ATC) holds up to 10 tools in a single
tray. If your program requires more tools, the ATC changes tools
automatically for all tools assigned to the tray, and pauses for a
manual tool change for all tools not assigned to the tray.
Note: If any of these items are missing, we can help. Email
[e-mail] to contact Tormach Technical
Support for guidance on how to proceed.
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2.1 SETUP
Complete the following steps in the order listed:
2.1.1 Required Tools 3
2.1.2 Air Requirements 3
2.1.3 Prepare the Machine 3
2.1.4 Install the Automatic Tool Changer (ATC) 3
2.1.5 Make Final Alignments to the Automatic Tool Changer
(ATC) 9
2.1.1 Required Tools
This procedure requires the following tools. Collect them before you
begin.
Required Tools for Installation
l1-1/2 in. adjustable wrench
l16 mm and 19 mm open-ended wrench
lMarker
lMetric hex wrench set
lPhillips screwdriver
lSmall, flat-head screwdriver
lSnips
lSocket wrench, 13 mm socket, and (optionally) an extender
Required Tools for Verification
lBT30 tool holder (for alignment rod)
lMachinist's square, between 6 in. and 9 in. (152 mm and 229
mm)
lStraight rod (for BT30 tool holder), between 8 in. and 12 in.
(203 mm and 305 mm)
2.1.2 Air Requirements
You must verify that the site conforms to the following air supply
requirements.
lAir Pressure Between 90 psi and 120 psi (620 kPa to 825
kPa).
If the air supply is more than 120 psi (825 kPa), you must use
a regulator.
lDry Air We recommend using a compressed air dryer,
desiccator, or filter between the air compressor and the
machine.
lLubricated Air You must lubricate the air with air tool oil.
Use the FRLFilter-Regulator-Lubricator (PN 32457) or similar
for this purpose.
2.1.3 Prepare the Machine
1. If there's a tool holder in the spindle, remove it.
2. Remove any accessories or fixtures from the machine table.
3. Center the machine table: from the PathPilot interface, in the
MDILine DRO field, type the command for your machine's
center position, as detailed in the following table. Then select
the Enter key.
Machine Command
1100M and
1100MX
G20 G53 G1 X9 Y-5.5 Z0 F20
770M, 770MX,
and PCNC770
G20 G53 G1 X7 Y-3.75 Z0 F20
PCNC440 G20 G53 G1 X5 Y-3.125 Z0 F20
PCNC1100 G20 G53 G1 X9 Y-4.75 Z0 F20
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.
4. Power off the machine and the PathPilot controller.
a. Push in the Emergency Stop button on the operator box,
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.
2.1.4 Install the Automatic Tool Changer (ATC)
Complete the following steps in the order listed:
Disassemble the Power Drawbar Button 3
Install the Air Cylinder 4
Mount the Automatic Tool Changer (ATC) Bracket 4
Install the Main Assembly 5
Level the Automatic Tool Changer (ATC) 5
Make Air Connections 8
Make Electrical Connections 8
Verify the Installation 8
Disassemble the Power Drawbar Button
1. Disconnect the shop air supply from the machine.
2. Remove four M5 × 0.8 - 10 mm button head cap screws that
secure the Power Drawbar button cover.
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3. Disconnect the air lines from the Retract and Extend ports on
the Power Drawbar.
Figure 2-1: Power Drawbar air line routing.
4. Disconnect the air line from the Air Supply port on the Power
Drawbar button.
5. Remove two M4 × 0.7 - 50 mm socket head cap screws that
secure the Power Drawbar button to the spindle head. Then,
cut the cable ties that secure the air lines together.
6. Remove the Power Drawbar button from the spindle head.
Install the Air Cylinder
1. Attach the air cylinder on to the ATC main assembly.
Figure 2-2: Putting the air cylinder into the ATC main
assembly.
2. Secure the air cylinder to the ATC main assembly with a 12
mm hex wrench (provided) and two M14 × 20 mm socket
head cap screws.
Figure 2-3: Putting the air cylinder hardware into the air
cylinder.
3. Connect the air lines from the ATC main assembly to the air
cylinder as follows:
lConnect the short air line to the front of the cylinder.
lConnect the long air line to the back of the cylinder.
Mount the Automatic Tool Changer (ATC) Bracket
1. Identify the four provided standoffs that are used to mount
the ATC to the Z-column:
lThree fixed standoffs
lOne tilt standoff
2. Remove the flange nuts and the washers from the standoffs,
and then set them aside.
3. Identify and remove the four set screws on the Z-column with
a flat-blade screwdriver.
4. Install the four standoffs on the Z-column as shown in the
following image.
Figure 2-4: Four standoffs installed on the Z-column.
5. Securely tighten the standoffs on the Z-column with a 1-1/2
in. adjustable wrench.
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6. Put the ATC mounting bracket on the standoff's threaded
studs as shown in the following image.
Figure 2-5: ATC mounting bracket moving on to the four
standoffs.
Note: Make sure that the tilt standoff's eccentric
cam fits into the large slot on the ATC mounting
bracket.
7. Secure the bracket by reinstalling the washers and flange nuts
that you removed in Step 2 with a 13 mm socket.
8. Pull the bracket toward the front of the machine. You'll make
adjustments to the location of the bracket later in this
procedure, but we recommend starting with it moved
forward.
Install the Main Assembly
1. Remove the four provided M8 × 1.25 - 16 mm socket head cap
screws and washers from the bottom of the ATC electrical
cabinet. Then, set all aside for later use.
CAUTION! Team Lift Required:You must have the
aid of more than one person to lift and move the
object. The object is heavy, and lifting it by yourself
can cause serious injury.
2. Lift the ATC main assembly on to the mounting bracket.
Figure 2-6: ATC main assembly positioned above the
mounting bracket.
3. Align the locating pin on the ATC main assembly with the
matching hole in the mounting bracket.
4. Secure the ATC main assembly to the mounting bracket with
the four M8 × 1.25 - 16 mm socket head cap screws and
washers that you set aside in Step 1.
Level the Automatic Tool Changer (ATC)
This section gives instructions to roughly level the ATC on the
machine by using a long, straight rod. More adjustments are made
later in the installation procedure.
NOTICE! After the initial installation, you must level the ATC. If
you don't, there's a risk of machine damage.
Complete the following steps in the order listed:
Prepare the Machine 5
Examine Perpendicularity in the Y Direction 6
Examine Perpendicularity in the X Direction 6
Examine the Alignment of the Carousel Door Opening 7
Prepare the Machine
1. Push the tool tray toward the spindle.
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Figure 2-7: Tool tray moved in toward the spindle.
2. Make sure that the linear bearing on the ATC is flush with the
ATC main assembly.
Figure 2-8: Linear bearing flush with the ATC main
assembly.
3. Find a straight rod between 8 in. and 12 in. (203 mm and 305
mm) long. Verify that it's straight: roll it on a known flat
surface (like a granite surface plate).
Note: You'll use the rod to verify that the ATC is
correctly installed on the mill, so it must be straight.
4. Put the alignment rod into a tool holder.
5. Put the tool holder into the fork so that the groove in the tool
holder slides into the fork, and so that the drive slot aligns
with the dog. Don't rest the tool holder on top of the fork.
6. Put a machinist's square on the machine table.
Examine Perpendicularity in the Y Direction
1. Make sure that the rod is perpendicular to the machine table
in the Y direction: compare the rod's position to the vertical
edge of the machinist's square.
lIf the rod is perpendicular to the vertical edge of the
machinist's square, go to "Examine Perpendicularity in the
X Direction" (below).
lIf the rod must be adjusted, go to Step 2.
2. Loosen the flange nuts on the standoffs.
3. Turn the tilt standoff with an adjustable wrench, and slowly
pivot the ATC until the rod is perpendicular to the vertical
edge of the machinist's square.
Figure 2-9: Tilt standoff.
4. Tighten the flange nuts with a 13 mm socket.
5. Reexamine the alignment of the ATC in the Y direction. If the
rod isn't perpendicular to the vertical edge of the machinist's
square, repeat Steps 2 through 5.
Examine Perpendicularity in the X Direction
1. Make sure that the rod is perpendicular to the machine table
in the X direction: compare the rod's position to the vertical
edge of the machinist's square.
lIf the rod is perpendicular to the vertical edge of the
machinist's square, go to "Examine the Alignment of the
Carousel Door Opening" (on the next page).
lIf the rod must be adjusted, go to Step 2.
2. Loosen the two socket head cap screws on the linear rails.
Figure 2-10: Socket head cap screws on the linear rails.
3. Slowly pivot the linear rails up or down until the rod is
perpendicular to the vertical edge of the machinist's square.
4. Tighten the socket head cap screws.
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5. Reexamine the alignment of the ATC in the X direction. If the
rod isn't perpendicular to the vertical edge of the machinist's
square, repeat Steps 2 through 5.
Examine the Alignment of the Carousel Door Opening
1. Remove the tool holder from the fork, and then set it aside.
Note: You'll need this tool later in the installation
procedure to make further alignments.
2. 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 Emergency Stop button on the operator box,
which enables movement to the machine axes and the
spindle.
c. Press the Reset button on the operator box.
d. Bring the machine out of reset and reference it.
3. Verify that the ATC is all the way forward (toward the
spindle), and then slowly move the Z-axis down (-Z) to
examine the clearance of the carousel door opening.
4. Make sure that the carousel door opening is approximately
equal to the front back and left of the spindle mounting
flange:
lIf it is, go to Step 8.
Figure 2-11: Distance between the carousel door
opening and the spindle mounting flange.
lIf it's not, go to Step 5.
5. Loosen the four socket head cap screws that secure the ATC
main assembly to the mounting bracket with a 6 mm hex
wrench.
Figure 2-12: Socket head cap screws securing the ATC main
assembly to the mounting bracket.
6. Adjust the carousel door opening as required:
lIf the Carousel Door Opening is Contacting the Front
Pivot the ATC around the locating pin on the bottom of the
mounting bracket toward the front of the machine (closer
to you).
lIf the Carousel Door Opening is Contacting the Back
Pivot the ATC around the locating pin on the bottom of the
mounting bracket toward the back of the machine (closer
to the machine column).
lIf the Carousel Door Opening is Contacting the Left
Loosen the four flange nuts that attach the mounting
bracket to the column to move the bracket forward or
backward.
Note: Moving the ATC mounting bracket could
change the position of the tilt standoff (on the Z-
column). If you move it, you must verify that the
ATC is still correctly installed; go to "Examine
Perpendicularity in the Y Direction" (on the
previous page).
Repeat this step as needed.
7. Tighten the socket head cap screws and the flange nuts (if you
loosened them in Step 5).
8. Move the tool tray to its retracted position.
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9. Center the machine table: from the PathPilot interface, in the
MDILine DRO field, type the command for your machine's
center position, as detailed in the following table. Then select
the Enter key.
Machine Command
1100M and
1100MX
G20 G53 G1 X9 Y-5.5 Z0 F20
770M, 770MX,
and PCNC770
G20 G53 G1 X7 Y-3.75 Z0 F20
PCNC440 G20 G53 G1 X5 Y-3.125 Z0 F20
PCNC1100 G20 G53 G1 X9 Y-4.75 Z0 F20
10. Power off the machine and the PathPilot controller.
a. Push in the Emergency Stop button on the operator box,
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.
Make Air Connections
1. Cut the cable tie that secures the ATC cables and plastic tubes
together with snips.
2. Route the loose ends of the two 1/4 in. plastic tubes
connected to the ATC main assembly through the enclosure
knockout, up the energy chain, and toward the Power
Drawbar. Then, pull the air line from the FRLback through the
energy chain.
WARNING! Crush Hazard: If the ATC isn't completely
retracted, it could move once the air is reconnected.
When you reconnect the air, you must keep your
hands away from the ATC.
3. Trim and connect the loose ends of the 1/4 in. plastic tubes in
the following order:
a. Connect the Retract (PDBBottom) airline to the bottom
push-to-connect elbow on the Power Drawbar.
b. Connect the Advance (PDBTop) airline to the top push-to-
connect elbow on the Power Drawbar
c. Connect the air supply line from the FRL to the air in port in
the ATC main assembly, as shown in the following image.
Figure 2-13: Air in port in the ATC main assembly.
d. If you haven't already done so, connect your shop's air
supply to the FRL.
Make Electrical Connections
1. Route the ATC power cable and the USB cable toward the rear
of the machine and out of one of the enclosure knockouts.
2. Put the USB cable in the access hole in the rear of the stand
toward the controller.
3. Put the USB cable into any open USB port on the PathPilot
controller.
4. Connect the ATC power cable to the ATC Power connector on
the side of the electrical cabinet (below the Enclosure Lights
Power connectors).
Verify the Installation
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 Emergency Stop button on the operator box,
which enables movement to the machine axes and the
spindle.
c. Press the Reset button on the operator box.
d. Bring the machine out of reset and reference it.
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2. If you have not yet done so, you must make sure that the
PathPilot controller is updated to the latest version of
PathPilot.
3. From the PathPilot interface, on the Settings tab, select the
ATC radio button.
Figure 2-14: ATC radio button on the Settings tab.
The ATC tab appears in the PathPilot interface.
Note: If prompted, you may need to update the
firmware for the ATC. Follow the on-screen
instructions.
4. Load an empty tool holder into the spindle:
a. Push and hold the collet open button on the side of the
ATC.
The collet opens.
b. Load a tool into the spindle.
c. Release the button.
The collet closes.
5. From the PathPilot interface, on the Main tab, in the RPM
DRO field, type 1000. Then select the Enter key.
6. Select FWD.
The spindle starts.
7. From the Status tab, make sure that the VFD Running green
light comes on.
Figure 2-15: VFDRunning light on the Status tab.
Note: If the VFDRunning light did not come on in
Step 8, we can help. Email [e-mail] to
contact Tormach Technical Support for guidance on
how to proceed.
8. Select Stop.
The spindle stops.
2.1.5 Make Final Alignments to the Automatic Tool
Changer (ATC)
Complete the following steps in the order listed:
Adjust the Tool Alignment and Set the Tool Tray Height and
Encoder Position 9
Adjust the Tool Alignment and Set the Tool Tray Height and
Encoder Position
1. From the PathPilot interface, on the ATC tab, select Ref Tool
Tray.
Figure 2-16: Ref Tool Tray button on the ATCtab.
The tool tray spins.
Note: You're only required to reference the tool tray
once, unlike the mill axes’ referencing procedure.
2. If you haven't already done so, load a tool into the spindle.
3. Manually rotate the spindle two revolutions by hand.
The encoder has now been oriented.
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4. Disconnect the air from the machine.
5. While manually advancing the tool tray toward the spindle,
align the fork with the tool. Complete the following steps in
the order listed:
a. Slowly jog the Z-axis up or down until the groove in the
fork aligns with the groove in the tool holder.
b. Determine if the tray must move clockwise or
counterclockwise to align the fork with the tool holder.
From the PathPilot interface, in the ATC tab, either select -
-to step the tool tray counterclockwise or ++ to step the
tool tray clockwise.
c. Fully seat the ATC to its tray load position, verifying that
the tool and its drive dog slots are fully inserted into the
fork.
6. Verify that, from the Status tab, the ATC Tray In LEDis still
illuminated.
If the LEDisn't illuminated, examine the tool tray. It may have
exceeded the Tray In sensor during adjustments in the
previous step.
7. On the ATC tab, select Set TCPOS.
Figure 2-17: Set TCPOS button on the ATC tab.
The tool change position has now been set.
8. Select Set TC M19. Then, in the dialog box that displays, select
OK.
Figure 2-18: Confirmation dialog box to change the
spindle's alignment position.
9. Follow the on-screen instructions to set the spindle's tool
change rotation position:
a. Rotate the spindle clockwise in the fork by hand, and hold
it in place. Then, select OK.
b. Rotate the spindle counterclockwise in the fork by hand,
and hold in place. Then, select OK.
The tool change rotation position has now been set. In the
dialog box that displays, select OK.
10. Manually move the ATC back to the retracted position.
WARNING! Crush Hazard: If the ATC isn't completely
retracted, it could move once the air is reconnected.
When you reconnect the air, you must keep your
hands away from the ATC.
11. Reconnect the air.
12. Remove the tool from the spindle.
13. Move the Z-axis up: in the MDILine DROfield, type G20 G53
G1 Z0 F20. Then select the Enter key.
14. On the ATC tab, select Go To Tray Load Position. Then,
manually load a tool into the fork.
15. Orient the spindle:from the PathPilot interface, in the MDI
Line DRO field, type M19 R0 Q10. Then select the Enter key.
16. Open the collet: on the ATC tab, select Collet, and wait until
the LED toggles from Closed to Open.
Note: You must verify that the collet is open (and not
just that the brake is engaged) before you continue.
17. Verify that the spindle is concentric with the tool: slowly jog
the Z-axis down and, depending on the result, do one of the
following:
lIf the Spindle is Concentric with the Tool You've
completed the alignments.
lIf Adjustments are Required Go to Step 18.
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18. Determine if the tray must move left or right. Use two
wrenches to loosen the jam nut on the end of the cylinder rod,
making sure that you don't spin the rod end when adjusting
the jam nut. Then, either turn the rod end one-half turn
further on to the cylinder rod to move the tool tray to the left,
or turn it one-half turn off of the cylinder rod to move the tool
tray to the right. Once finished, tighten the jam nut.
Figure 2-19: Moving the tool tray left or right.
Note: Don't move the tool tray more than 0.100 in. in
either direction (left or right). If you do, the tool tray
will exceed the Tray In sensor, which affects how
ATC operations are communicated to PathPilot.
19. Adjust for the ATC's backlash: apply light pressure forward
and backward on the carousel; then, from the PathPilot
interface, on the ATC tab, select ++ or -- until there's equal
space on the front and the back of the BT30 taper.
20. Verify that, from the Status tab, the ATC Tray In LEDis still
illuminated.
If the LEDisn't illuminated, examine the tool tray. It may have
exceeded the Tray In sensor during adjustments in the
previous step.
21. Repeat adjustments until the tool's shank is concentric with
the collet in the spindle.
22. Move the Z-axis up: in the MDILine DROfield, type G20 G53
G1 Z0 F20. Then select the Enter key.
23. Remove the tool from the ATC. Then, select Retract.
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3.1 OPERATION
Note: Make sure that there's always a tool holder in the
collet while the machine is not in use. Retracting the
Power Drawbar to the clamped position with no tool holder
in the collet will eventually fatigue the collet, and may
shorten its service life. For more information, refer to the
Power Drawbar documentation.
Read the following sections to understand how to operate the ATC:
3.1.1 Assign Tool Numbers 12
3.1.2 Automatically Load a Tool into the Tool Tray 12
3.1.3 Automatically Unload a Tool From the Tool Tray 12
3.1.4 Load a Tool into the Spindle 12
3.1.5 Manually Unload a Tool From the Tool Tray 13
3.1.6 Retrieve a Tool From the Tool Tray 13
3.1.7 Switch to Manual Tool Changes 13
3.1.1 Assign Tool Numbers
Use any tool number, from 1-1000, to assign a position in the
tool tray.
3.1.2 Automatically Load a Tool into the Tool Tray
1. Load a tool into the spindle.
2. From the PathPilot interface, on the ATC tab, type the tool
number in the Tool DRO field. Then select the Enter key.
3. Select Store Current Tool.
Figure 3-1: Store Current Tool button on the ATC tab.
The tool is assigned to the nearest open slot. The ATC fetches
the tool from the spindle and stores the tool in the tray. When
stored, the tool number displays on the tray image in the
center of the screen.
4. Click Retract.
Figure 3-2: Retract button on the ATC tab.
The tray returns to the machining position.
3.1.3 Automatically Unload a Tool From the Tool Tray
Note: Typing a new tool number in the Tool DRO field
doesn't remove the tool from its tray assignment.
1. From the PathPilot interface, on the ATC tab, type the tool
number in the Remove DRO field. Then select the Enter key.
Figure 3-3: Remove DROfield on the ATC tab.
2. Select Remove.
The ATC fetches the tool from the tray.
3. Unload the tool from the spindle.
4. From the ATC tab, select ATC FWD or ATC REV.
Figure 3-4: ATCREV and ATCFWD buttons on the ATC tab.
The tray moves to the next location and fetches another tool.
5. Select Retract.
The tray returns to the machining position.
3.1.4 Load a Tool into the Spindle
Load a tool into the spindle:
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1. Push and hold the collet open button on the side of the ATC.
The collet opens.
2. Load a tool into the spindle.
3. Release the button.
The collet closes.
3.1.5 Manually Unload a Tool From the Tool Tray
1. From the PathPilot interface, on the ATC tab, in the Insert
DRO field, type the tool number. Then select the Enter key.
2. Select Go To Tray Load Position.
The spindle head moves up and the ATC moves into the door
open position.
3. Select Delete.
Figure 3-5: Delete button on the ATCtab.
The tool is unassigned from the tray and the tray moves to
that tool.
4. Select Tray FWD or Tray REV.
The tray moves to the next slot location.
5. Select Retract.
The tray returns to the machining position.
3.1.6 Retrieve a Tool From the Tool Tray
Depending on your workflow, do one of the following from the
PathPilot interface:
oType the command directly into the MDILine DROfield
using the following format:T[TOOL NUMBER] M06
For example, T1 M06
oType the tool number in the Tool DRO field. Then select the
Enter key.
3.1.7 Switch to Manual Tool Changes
From the PathPilot interface, on the Settings tab, select the
Manual Tool Change radio button.
The Automatic Tool Changer (ATC) is prevented from making
tool changes.
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TD10627: Owner's Guide: 770MX Automatic Tool Changer (ATC) (1019A)
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