Tormach ATC User manual

USING THE TORMACH
TOOLING SYSTEM ATC
AUTOMATIC TOOL CHANGER
FOR THE PCNC 1100
Operator’s Manual
© 2013 Tormach®LLC. All rights reserved.
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Tormach TTS ATC Manual:
UM10081_TTS_ATC_PCNC1100_1013A

1. Preface 2
1.1 Manual Overview 2
1.2 Safety 2
1.3 System Requirements 3
2. Preparaon     4
2.1 UnpackingandCheckingShipment  4
2.2 BeforeYouBegin    5
2.3 MounngtheATC    5
3. ElectricalInstallaon    7
4.1 AirLineConneconandRequirements  12
4. AirLines     12
5. SowareInstallaon    14
6. SystemValidaon    15
6.1 AlignToolTrayandSlots   16
7.1 FootPedalKit     20
7.2 FilterRegulatorLubricator(FRL)  20
7. OponalAccessories    20
7.3 PressureSensor    21
8. Operaon     23
8.1 GeneralTheoryofOperaon   23
8.2 Loading/UnloadingTools   23
8.3 AutomacTrayLoad/Unload   24
8.4 ManualTrayLoad/Unload   24
8.5 ToolTouch-oRoune    25
8.6 ATCBypass     25
9. Maintenance&Troubleshoong  26
9.1 Support     26
9.2 Maintenance 26
9.3 Troubleshoong    26
10. ExplodedView&PartsList   33
10.1 ATCCarousel     34
10.2 ATC1100ColumnMount   36
10.3 TTSATCActuator    38
10.4 ATCControlModuleAssembly   40
10.5 TTSATCPneumacSchemac   42
10.6 ATCElectrical     43
TABLE OF CONTENTS
PB 1
UM10081_TTS_ATC_PCNC1100_1013A UM10081_TTS_ATC_PCNC1100_1013A

1.1 Manual Overview
ThismanualisintendedforusersoftheTormachTooling
SystemAutomacToolChanger-anaccessorytothe
TormachPCNC1100mill.Readersareassumedtobe
familiarwiththeoperaonanddocumentaonfortheir
parcularmillingmachine.Forquesonsofageneral
nature(e.g.applyingtoolheightosetcompensaon)
pleaserefertothePCNC1100machinemanual.
TheTTSATCcanbeusedwithallexisngpartprograms
withoutmodicaon,regardlessofexisngtoolnumber
assignments.Forprogramsthatuse10toolsorfewerthe
ATCmaybeusedforalltoolchanges.Forpartprograms
requiringmorethan10tools,orforprogramsrequiring
specialtoolingnotappropriateforanATC,suchasa
reversingtappinghead,itcanbeusedinconjunconwith
manualchanges.Anytoolnumberbetween1and253
maybeassignedtoaposioninthetooltray–youarenot
connedtousingtoolnumbers1-10.Thisisconvenientif
youhaveatoollibraryalreadysetupwithtoolnumbers
andheightsmeasuredinyourtoolosettable.The
toolchangerrememberstoolsassignedtothetray,and
promptsformanualspindleinseronandremovalofnon-
assignedtoolsatappropriatemes.Toolsmaybeassigned
todierenttraynumberssothat,forinstance,onecan
dedicategroupsoftrayassignmentstospecicjobsthat
are run frequently.
AlltoolsarecalledfromGcodewithstandardM6
commands,orfrombuonsontheATCcontrolscreen.
1.2 Safety
Anymachinetoolispotenallydangerous,
especiallyautomatedtoolsundercomputer
control.BecauseTormachdoesnotknow
thedetailsofyourworkshoporotherlocal
condions,noresponsibilitycanbetakenfordamage
orinjurycausedbytheuseofthemillandATC.Itisthe
owner’sandoperatorsresponsibilitytounderstandthe
mill/ATCsystemintegraonandoperaonandtocomply
withanylegislaonandcodesofpracceapplicableto
countryorstate.Ifthereisanydoubt,seekguidancefrom
aprofessionallyqualiedexpertratherthanriskinjury.
ThesafetyofanyapplicaonusingtheATCisulmately
theresponsibilityofthoseperformingthesetupand
operaon.Pleasedonottakethisresponsibilitylightly
-usecommonsenseandreviewallinstruconsonthe
operaonandmaintenanceoftheATC
Operator Safety
• Whenusingelectrictools,machinesorequipment,
basicsafetyprecauonsshouldalwaysbefollowed
toreducetheriskofre,electricshock,andpersonal
injury.
• Readandunderstandthismanual.Donotoperatethe
ATCwithoutknowingthefunconofeverycontrol
key,buon,andalignmentandreferencingprocedure.
RefertothismanualorcontactTormachifanyfuncon
isnotunderstood.
• KeephandsclearoftheATCatallmesduringtool
changesorwhencommandinganyATCmoonfrom
theATCcontrolscreenofthemill’scontrolsoware.
• Avoidcontactwithmovingparts.Beforeoperangthe
millandATC,removealljewelryincludingwatchesand
rings,neckesandanyloose-ngclothing.Tieback
hair.
• Keephairawayfrommovingparts.
• Donotreachforthepart,toolorxturewhilerunning
apartprogram.
• Keepworkareaclean.Clueredareasinviteinjuries.
• WearANSIapprovedeyeproteconatallmes.
• Keepworkareawelllit.
• Keepthecomputerareaclearofcluer.
• Neveruselongerorlargertoolsthannecessary.
• DonotusetheATCorpowertoolsindamp,wetor
poorlylitlocaons.
• Donotusetoolsinthepresenceofammablegasesor
liquids.
• Useonlyidencalreplacementpartswhenservicing.
• TakeoglovesbeforeyouoperatetheATC.Glovesare
easilycaughtinmovingpartsorcungtools.
• Neveroperatewithunbalancedtooling.
• NeveroperatetheATCaerconsumingalcoholic
beveragesortakingstrongmedicaon.
• Protectyourhands.Stopthemachineandensurethat
thecomputercontrolisstoppedbeforeyou:
*Changetools;
*Changepartsoradjusttheworkpiece;
*Makeanadjustment;
• Keepworkareawelllit.Askforaddionallightif
needed.
• Alwaysuseproperfeedsandspeeds,aswellasdepth
andwidthofcut,topreventtoolbreakage.
• Usepropercungtoolsforthejob.
• Donotusedullordamagedcungtools.Theybreak
easilyandbecomedangerousprojecles.
• Becertaineveryoperatorunderstandstheoperaon
andsafetyrequirementsofthemillandATCbefore
operang.Itistheresponsibilityoftheownerof
1. PREFACE
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UM10081_TTS_ATC_PCNC1100_1013A UM10081_TTS_ATC_PCNC1100_1013A

theATCtoprovideandensurepointofoperaon
safeguardingperOSHAstandards.
Electrical Safety
TheTormachToolingSystemATCoperateson
70VDC,fusedat8amps.Itispoweredfrom
theDCBusBoard(PN32005)insidethecontrol
cabinetofthemill.Neveroperatethe
machinetoolwiththecabinetdooropen.Nevermakeor
checktheseconneconswiththemillpoweredon.
PowertotheATCandotherdevicesinsidethecontrol
cabinetmayretaindangerousvoltagesaerexternal
powerhasbeenremoved.Donotmodifythese
conneconsinanyway.Ifunsureabouttheconnecons,
callTormachoraqualiedrepairtechnician.
1.3 System Requirements
TousetheTormachToolingSystemATC,yourmachine
mustmeetthefollowingrequirements:
• Youmustprovideacompressedairsourcecapableof
deliveringclean,dryairat95PSIand2CFM.
• TheTormachPowerDrawBar(PN31706)mustbe
installed
• ForPCNC1100machinesserialnumbers1325and
lower,youmusthavepreviouslyinstalledtheSpindle
DriveUpgradekit(PN31090)
• ForPCNC1100machinesserialnumbers999and
lower,youmusthavepreviouslyinstalledtheSeries3
upgradekit(PN32010)
Required Tools
• MetricAllenwrenchset
• Screwdrivers
• Boxwrenchesandlargecrescentwrench
• Hotgluegun
• 12”longwoodendowelorroundstock
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UM10081_TTS_ATC_PCNC1100_1013A UM10081_TTS_ATC_PCNC1100_1013A

2.1 Unpacking and Checking
Shipment
Uponreceipt,carefullyunpacktheATCandinspectto
ensuredamagedidnotoccurintransitandalsotoaccount
forallparts.Ifanydamageisapparent,orpartsmissing,
pleasecontactTormachimmediately.
Withanassistant,litheATContoasturdysurfaceor
workbenchtoprepareitforuse.
11ATCassembly
24¼”airlines,onew/checkvalveandpushng
31ATCsquaretubemount
4 4hexstandoswithM8andM10studs
5 4angenutsandwashers
620nylonM6x16hexbolts
7 1USBcable
81ATCcommunicaonRJ-11cable(512-515)
91Mainpowercable(503,504)terminatedwith4pin
Molexandspades
10 1PDBpowercable(501,502)terminatedwithPDBcon-
nectorandspades
11 1VFDinterconnectwiringkit(532-535)
12 1coolanthosemounngplatew/fasteners
13 PowerDrawBarpowersupplyboard
14 1R8TTSexpandedcollet
15 Operator’sManual
16 SowareinstallaonCD
17 25X20glassfuses
Thefollowingitemsmayormaynotbeincludedbasedon
theageofyourmachineandpowerdrawbarinstallaon:
1. 1drawbarwith8Bellevillewashers
2. PowerDrawbarcontrolcircuitboard(ifrequiredbased
onageofyourpowerdrawbarinstallaon.)
3. DCBusBoard
Checktheseitems.NofyTormachofanydamageincurred
duringtransitormissingpartssoanyclaimscanbemade
withintheshippingcarrier’sdeadline.
2. PREPARATION
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UM10081_TTS_ATC_PCNC1100_1013A UM10081_TTS_ATC_PCNC1100_1013A

2.2 Before You Begin
TheTormachToolingSystemATCisdesignedformachines
withthepowerdrawbar(PN31706)installed.PCNC1100
millingmachineswithserialnumbers1325andlower
willneedtohavethespindledriveupgrade(PN31090)
installedbeforeinstallingtheATC.PCNC1100machines
withserialnumbers999andlowerwillalsohavetohave
theSeries3upgradekit(PN32010)installedbefore
installingtheATC.
Allmachineswillneedtohavethepowerdrawbarinstalled
beforeinstallingtheATC.Seethepowerdrawbarmanual
(includedwiththepowerdrawbarpackageandontheATC
sowareCD)forpowerdrawbarinstallaoninstrucons.
PCNC1100machinesserialnumbers1999andlowerwill
needtoreplacetheoldDCBusBoard(PN30661)withthe
newbusboard(PN32005).
2.3 Mounting the ATC
MounngandaligningtheATCtothemillisajobthatis
bestdonewithtwopeople.TheATCcarouselassembly,
whichweighsapproximately50pounds,iscumbersometo
liandposionaccuratelyespeciallywhenworkingover
themill’schiptray.Installaongoessmoothlywhenone
personholdstheATCinposionwhileanassistantghtens
thefastenersthatconnectittothesquaretubemount.
Initial Hardware Installation
WARNING! SHUT THE COMPUTER
DOWN, THEN POWER DOWN THE MILL
USING THE ROTARY SHUTOFF SWITCH
ON THE RIGHT HAND SIDE OF THE
CONTROL CABINET.
Youmayndinstallaoneasiestifyourstpullthemill
awayfromthewall.
Ifed,removethecoolanthoseandmountfromthe
spindle head.
Ifed,removethelehandmachinearmfromthemill
column.
45
UM10081_TTS_ATC_PCNC1100_1013A UM10081_TTS_ATC_PCNC1100_1013A

Ifed,removetheuppercoolantsplashguards
(backsplash)fromtheleandrighthandchiptrays.
1. ThreadtheM8sideofhexstandosintomillcolumn
andghtensecurelywithawrench.
2. HangthetoolchangersquaretubemountontheM10
studs.Securewithangenutsandwashers.Theslots
arewiderthanthestudtoallowforminordeviaons
inholelocaons,andtofacilitateasmalldegreeoflt.
3. Withtheassistanceofanotherperson,fastentheATC
tothemountusingthe4M10socketheadcapscrews
andangenuts.
4. Duetostackupofparttolerances,exibility,and
backlashinthelinearbearings,thechangermight
seleslightly,orsagfromhorizontalonitsmounng
system.Thisisnormal.Compensateforminorsagby
lngthemountslightlysothetooltrayappearslevel
usingabubblelevel.
Note: Be sure to adjust the mount so that the mill
spindle cover sheet metal clears the ATC linear rail.




5. Reroutethecoolanthosebymounngthecoolant
hoseclamptotheincludedcoolantplate.Aachthe
platetotheundersideofthespindleheadusingthe
twothreadedholesontheundersideofthespindle
headcasng.
67
UM10081_TTS_ATC_PCNC1100_1013A UM10081_TTS_ATC_PCNC1100_1013A

3. ELECTRICAL INSTALLATION
1. Removethefourcolumncoverplatescrewsfrombase
ofcolumnatthebackofthemill.TheZcolumncover
platewillbereplacedwiththeATCcontrolmodule.
Save the screws.
2. LaytheATCcontrolmoduleplatewithsolenoid
sidedownonthechiptrayortheYaxisbearingbox
temporarily.
3. Removethepowerdrawbarelectricalhousing(Zaxis
motorconneconboxcoverplate).


Bar control circuit board.
CircuitboardslabeledRev1.2willneedtobereplaced.In
thiscaseTormachshouldhaveincludedtheupdatedcircuit
boardwithyourATC.


• Toreplaceanold(Rev1.2orearlier)circuitboard,
disconnectandremovetheoldcircuitboard,taking
noteofthelocaonsoftheconnectors.Whilenot
necessary,youmaynditeasiertoremovetheair
linesandthecablecarrieraswell.
• Replacetheolddrawbarboardwiththenewone.
Itiseasiesttoreplacethesolenoidleads(redand
blackwire)beforere-mounngthecircuitboard.The
solenoidleadsgototheoppositesideofboardfrom
otherconnectors.Thisistheonlyconnectoronthat
side(2pinnylon).
ConnecttheblackVFDinterconnectRJ11cable(withthe
spadeterminalends)totheDB1connectoronthepower
drawbarcontrolboard,andtheATCcommunicaonRJ11
cabletotheDB3connectorasshowninthefollowing
gure.
67
UM10081_TTS_ATC_PCNC1100_1013A UM10081_TTS_ATC_PCNC1100_1013A

4. Removetheold“wallwart”powerconnectorandreplaceitwithwires501,502.Thesewireswillberoutedtothe
newDCBusBoard,andyouwillbeabletothrowoutthewallwartpowersupply.

supply.
5. Routeallwires(thetwoRJ11cables,thebluespindledoorswitchinterfacewires,andthepowerwires503,504)
throughthemillcolumn.


COLUMN. THESE WIRES CARRY 110V AC AND IN RARE CASES CAN CAUSE EMF THAT
DISTURBS USB SIGNAL TRANSMISSION WHEN THEY ARE NOT TWISTED. TWISTING THE
WIRES CANCELS THIS EMF.
89
UM10081_TTS_ATC_PCNC1100_1013A UM10081_TTS_ATC_PCNC1100_1013A

6. Re-securethedrawbarelectricalhousingtotheZaxis
motorconneconboxcoverplate).
7. ConnecttheATCcommunicaonRJ11cable(fromthe
DB3connectoronthepowerdrawbarcircuitboard)
andtheUSBcabletotheATCcontrolboard.
8. DropanyslackwiresfromtheATCcontrolmoduleinto
theZcolumn,andsecuretheATCcontrolmoduleto
thebackofthemillusingthesavedM5screwsand
intoexisngcolumnholes.Besurethatextrawire
slackdoesnotcontacttheYaxisballscrew.
9. RoutetheUSBcablethroughtheboomholeofthe
electriccabinetintoanyPCUSBport.
CAUTION! DO NOT CONNECT THE USB
CABLE TO THE COMPUTER UNTIL AFTER
THE SOFTWARE INSTALLATION IS
COMPLETE.



your electrical cabinet to route the USB cable to your
control computer.
10.RuntheblueATCcontrolboardpowerleads(503,504)
andthepowerdrawbarcircuitboardpowerleads
(501,502)throughthewirechannelsfromtheholeto
thebusboardatthetopofthecabinet.
11.Series31100machinescomewiththecorrectDCBus
BoardforusewiththeATC.Series3ownerscanskip
steps12-13.Domakesuretoinstallthe5x20mmfuses
intheDCBusBoardATCandPDBfuseholders.This
appliestoallmodelmachines.
89
UM10081_TTS_ATC_PCNC1100_1013A UM10081_TTS_ATC_PCNC1100_1013A

12. PCNC 1100 MACHINES SERIAL NUMBERS 1999 AND
LOWER: ReplacetheoldDCbusboard(PN30661)with
thenewbusboard(PN32005).Ensureallfusesare
presentontheDCBusBoardbeforeinstallaon(there
shouldbenoemptyfuses).WhenremovingtheoldDC
busboard,catchthestandosandsavethescrews.
Replacewiththenewboardonthesamestandos.
Itisextremelyhelpfultotackgluethestandosin
placebeforemounngtheboard.Aneasywaytodo
thisistoputadabofhotglueonthefastenersbefore
inserngthemthroughtheboardholesandstandos.


13.Double-checkthepolarityofthecapacitor,stepper
driver,andATCconneconsbeforepoweringupthe
machine.Reversingpolaritywilldestroythestepper
driversandATCcontrolboard.
14.Installthepowerdrawbardaughterboardpower
supply(PN31980)byslidingitontothespade
connectorsonthenewDCbusboard(PN32005).This
boardsuppliesthe12Vneededbythepowerdrawbar,
andwillallowyoutothrowawaythewallwartpower
supplythatcamewiththepowerdrawbar.
15.RoutetheRJ11VFDinterconnectcablealongthe
boomwiretraytotheVFD.RemovetheVFDcover
byunscrewingthePhillipsfasteneronthefaceofthe
coverplate.
10 11
UM10081_TTS_ATC_PCNC1100_1013A UM10081_TTS_ATC_PCNC1100_1013A

32005 DC BUS
Lables and wire numbers
X+ 302
X- 303
Y+ 304
Y- 305
Z+ 306
Z- 307A+ 324
A- 325
BRAKE RLY+ 328
BRK- 327
BRAKE RLY- 329
BRK+ 326
J2-48VAC L15
J1-48VAC L25 CAP- 300
CAP+ 301
8 A
8 A 8 A
8 A 2 A
8 A
15 A
8 A
503 Optional ATC +
504 Optional ATC -
501 Optional PDB -
502 Optional PDB +
DAUGHTERBOARD
FOR OPTIONAL PDB
F1 = X AXIS
F2 = Y AXIS
F3 = Z AXI
F4 = A AXIS
F5 = DC BRAKE
F6 = MAIN
F7 = PDB
F8 = ATC
F7
F6
F1
F2
F3
F4
F5
F8
S
16.InserttheblackandredwiresoftheRJ-11cableinto
posionsT1andB3ontheVFDfor1100machines.To
maketheseconnecons,insertasmallatheadscrew
driverintheholejustabovethewireterminaltoopen
the terminal.
Tidyupthewiresandreplacethecabletraycovers.
Red Wire
to B3
Black Wire
to T1
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UM10081_TTS_ATC_PCNC1100_1013A UM10081_TTS_ATC_PCNC1100_1013A

4. AIR LINES
4.1 Air Line Connection and
Requirements
Itisrecommendedtousealter/dryer/lubricatoronthe
airlineusedtosupplytheATC.Airsupplyrequirements
dependonfrequencyoftoolchanges.Forsuccessful
operaon,yourcompressorwillneedtobeableto
maintain95PSItotheATC.Typicallyconsumponfor
frequenttoolchangesislessthan4CFMat95PSI.
Pleasenotethatnotallregulatorsarecreatedequal.
Inexpensiveregulatorstendtoconstrictairow,which
makesforlongermake-upmesasthepowerdrawbar
res.Whilethisisnotaproblemforthepowerdrawbar
whenoperatedbyhand(theuserjustwaitstheextra
secondortwoforthecylindertofullypressurize),itcan
causeproblemswhenusingtheATC,whichonlypauses
500msbetweenthedrawbarringandthezaxismoving.
Beerregulatorsdonotrestricttheowwhileregulang
pressure.
Connecting the Air Lines
1. Manuallypullthetooltraytotheretractedposion
bypullingonthemotorenclosureoritwillretract
suddenlywhenyoupressurizetheairlines.
2. Routetheairlines.Thelinesarelabeledateachend-
connectthemtothesolenoids/ngswiththesame
labels.
3. Connecttheairlinefromyourcompressortothele
sideinputconnectorlabeled“AIR-IN”.Youcanremove
thepushnganduseaquickconnectagainstthe
rstteeifdesired,butwe’vefounditeasiertorun
tubingtoaquickconnectnginaneasier-to-reach
locaon.
4. Threadthe¼NPTpushngintotheairinputport
ofthepowerdrawbar.Connectthepowerdrawbar
airlinelabeled“D”(withtheaachedcheckvalve)
betweenthe“DRAWBAR”pushngontheright
sideoftheATCsolenoidpanelandthedrawbarinput
pushngonthedrawbarsolenoid.Thecheckvalve
allowsairtopassinonedirecononly–ifyouinstallit
backwardsthepowerdrawbarwillnotoperate.
5. Ifyouhavepurchasedtheoponalpressuresensor(PN
32329),spliceitintoairlineDandinserttheelectrical
connectorintothejackonthecolumncoverplateas
showninthisphoto:
6. UsetheP-clamptosecurethegreyATCcontrolcable
totheboxbeam,allowingenoughslackforthe
carousel’srangeofmoon:
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UM10081_TTS_ATC_PCNC1100_1013A UM10081_TTS_ATC_PCNC1100_1013A

Thetraysolenoidshaveadjustmentscrewsthatallowyou
toadjusttrayinandtrayoutspeeds.Thesolenoidshave
beenpre-adjustedbeforeshipping.Aircushionpinvalves
ateitherendoftheaircylindercanbeadjustedtocontrol
dampingatextremeendsofcylindertravel.Thesearealso
pre-adjusted.Toolchangemeshouldnotbeadjustedto
lessthan8seconds.Conversely,movingtooslowlywill
triggeranerrorcondion.
Tray Solenoids
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UM10081_TTS_ATC_PCNC1100_1013A UM10081_TTS_ATC_PCNC1100_1013A

5. SOFTWARE INSTALLATION
Youmaynowreapplypowertothemillandpoweron
yourcomputer.MakesurethattheUSBcabletotheATC
controllerisunpluggedforthenextsteps.
TheATCsowareinstallaonwilldeletethecontentsof
thePCNC3folderonyourCdrivebeforeinstallingthenew
soware.IfyouhavesavedpersonallesinthePCNC3
folder,copytheselestoafolderonyourdesktopbefore
youinstallthenewsoware.
TobegintheATCsowareinstallaon,makesure
thatMach3isshutdown,andinserttheCDintothe
computer’sCDdrive.Amenuwilldisplaychoicesfor1100
SeriesIIand1100Series3millingmachines.Choosethe
appropriatesowareforyourmachine.Thesoware
installaonshouldpreserveyourtooltable,xture
osets,andMachlicensele.Itwill,however,deleteany
changesyouhavemade(probepolarity,jogincrements,
NewFangledWizardlicensele).Ifyoupreviously
customizedyourversionofMach3usingPCNCCongyou
willneedtorepeatthesecustomizaonsaerinstallingthe
newsoware.

standard Tormach screens. Flash screens are no


14 15
UM10081_TTS_ATC_PCNC1100_1013A UM10081_TTS_ATC_PCNC1100_1013A

6. SYSTEM VALIDATION
ConnecttheUSBcablefromtheATCcontrollertothemill’scontrolcomputer.Startthecontrolsowareusingthe
PCNC1100-ATCicononthedesktop.Whenthesystemcomesup,itshouldndtheATCautomacallyontheUSBports
andcongureitself.YoushouldseeaconrmaonmessageonthemainMachscreenmessagelinethatdisplaysthe
sowareversion:
“ATCStartup–inialized”
AnswerYEStoscreenpromptsrequesngit’s“okaytoresetandreferencez”.WhenusingtheATC,thesepromptsalways
occuratstartup.Ingeneral,youshouldalwaysreferenceZimmediately.Thetoolchangerwillpromptduringexecuonif
youskipitnow.
ClickontheATCSetupbuononthelowerporonofthescreen.Notethattheupperlecornerdisplaysthermware
andpluginversions.ThegreenCONNECTEDlightshouldbeglowingtoindicateUSBcommunicaonisestablished.This
veriesthesowareinstallaonandtheUSBconnecon.
14 15
UM10081_TTS_ATC_PCNC1100_1013A UM10081_TTS_ATC_PCNC1100_1013A




WiththeZaxisinthehomed(highest)posion,perform
thefollowingteststoverifytheoperaonofthetool
changer:
1. ApplyathinlmofwayoiltothelinearrailsoftheATC
slideassembly.Somechaerisexpectedunltheoil
haslubricatedthelinearbearings.
2. OntheATCSetupscreen,click“TrayIn”,“TrayOut”
buonstoverifythatthetrayairlinesarecorrectand
thatthemagnecaircylindersensorsareproperly
working.Message“ATCbuonexecuted”aereach
buonpressveriesoperaoncompleon.
3. Withthetrayinthe“in”posion,clickthe“Refresh”
buonunder“Diagnoscs”ontheATCSetupscreen.
VerifythattheTrayInSensorLEDisilluminatedwhen
the tray is in.
4. RepeatStep3forTrayOutposion.Youwillneedto
clickthe“Refresh”buontoreadthesensors.
• IfeithertheTrayInorTrayOutsensorfailstorespond
asexpected,refertothe“SensorIssue”seconin
Maintenance and Troubleshoong.
5. WiththetrayoutjogtheZaxisdownacoupleof
inches.




square tube mount.
Clickthe“GotoTrayLoadPosion”.Thisshouldmove
theZaxisupandbringthetrayin.
6. Clickthe“ReferenceToolTray”buonontheATC
Setupscreen-itshouldndandcenteronitshome
switch.Itwillturnunlitndsoneendofthesensor,
thenreverseandndtheotherendofthesensor,and
thencenterbetweenthesetwospots.
7. Testthedrawbarpendant.
8. OntheATCSetupscreen,clicktheDrawBarUp,Draw
BarDownbuons.Thedrawbarshouldoperate
accordingly.
9. ClickDrawBarDownbuonontheATCsetupscreen.
Itshouldreandlatch.Nowhitthetop(Lock)buon
onthependant.Itshouldunlatch.
10.ClickBlaston,BlastoontheATCSetupscreen.You
shouldheartheairstartandstopatthenozzlesinthe
tooltray.
11.Withatoolinthespindleandthetrayintheout
posion,startthespindleatlowspeedinmanual
mode.Clickthe“Refresh”buonontheATCSetup
screen,andverifythattheVFDRunningLEDis
illuminated.
12.Oponalpressuresensorvericaon:Ifyouhave
installedthepressuresensoraccessory(PN32329)
youmayverifythatthePressureSensorLEDonthe
ATCSetupscreenisilluminatedunderlowpressure
condionsanddarkundernormalpressurecondions.
Youwillhavetoclickthe“Refresh”buontoseethe
LEDchangecorrespondingtoachangeinstate.
6.1 Align Tool Tray and
Slots
Accuratealignmentofthetooltrayandslots,andthe
drawbarthrow,arethemostimportantfactorsinassur-
ingreliableandrepeatabletoolchangeroperaon.Take
yourme,andtakecaretodothisaccurately.Avideoof
thealignmentprocedurecanbewatchedonourwebsite:
hp://www.tormach.com/upgrades_s_atc.html
1. ItishelpfultogettheATCassemblyapproximately
levelusingabubblelevelbeforebeginningthe
alignmentprocedure.
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UM10081_TTS_ATC_PCNC1100_1013A UM10081_TTS_ATC_PCNC1100_1013A

2. Makesurethespindleisiniallyempty.Thereshould
benotoolholderinthespindleatthispoint.
3. Clickthe“GoToTrayLoadPosion”buonontheATC
Setupscreen.TheZaxiswilljogupandthetraywill
actuatein,openingthetoolaccessdoor,andthedraw
barwillactuate.
4. Verifythatthespindleisroughlyinthecenterofthe
carouseldooropening.Ifnecessary,movetheATC
forwardorbackwardbylooseningthefourangenuts
thatholdthesquaretubemounttothecolumn.
5. Insertalong(12-14”)dowelorpieceofroundstock
intoaTTStoolholder.Insertthetoolholderintothe
forkoftheexposedtrayslot.Usingothervercallines
(edgeofmilcolumn,Tslotsintable)sightalongthe
dowelandcheckwhetherthedowelandthespindle
axisareparallelinbothXandYplanes.
6. Ifthedowelandthespindleaxisarenotparallel,
adjusttheltoftheATCinbothXandYdirecons
unltheyare.
• TiltintheYdireconisfacilitatedbylooseningthe
angenutsthatholdthesquaretubemounttothe
column,thengentlytappingtheATCtrapezoidmount
with a mallet.
• TiltintheXdireconcanbeadjustedbyloosening
thesocketheadcapscrewsthatmounttheATCtothe
squaretube,thenturningtheeccentricadjustment
screws.ThisisbestdonewiththeATCinthe“Tray
In”posion,asthecenterofgravityoftheunitin
the“TrayIn”posionwillallowyoutouseboth
adjustmentscrewstolttheATC.
• Verifythatthetoolholdershankisparalleltothe
spindleaxisinbothXandYbyusinganangleblockor
1-2-3blockwithastraightedge:
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UM10081_TTS_ATC_PCNC1100_1013A UM10081_TTS_ATC_PCNC1100_1013A

7. Onceyouaresasedthattheaxisofthedowelis
paralleltothespindleaxisinbothXandY,jogthe
spindledowntothetopoftheTormachtoolholder
shank.Donotgoallthewaydowntotheshoulderyet.
Verifybyeyethatitisroughlycenteredonthecollet
centeropening.
• Toadjustthealignmentofthetoolholdertothecollet
intheXdirecon,loosenthejamnutattheendofthe
traycylinderrodandmoveittoaroughlycentered
posion.Press“TrayIn”toverifytheadjustment.You
willlikelyhavetorepeatthisprocedureseveralmes
togetthelocaoncorrect.
• Toadjustthealignmentofthetoolholdertothecollet
intheYdirecon,usethe“--“or“++”-buonsonthe
ATCSetupscreenAlignmentsecon.Itisbesttowiggle
theforkwithyourthumbandindexngertofeelthe
extremesofthecarouselbacklashagainstthespindle
withyourngerstoseethatitisroughlycenteredle
andrightofforkwhilemakingthisadjustment.
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UM10081_TTS_ATC_PCNC1100_1013A UM10081_TTS_ATC_PCNC1100_1013A