Tormach PCNC 440 Technical manual

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TD10487_PCNC440_ATC_Install_1220A
PCNC 440 AUTOMATIC TOOL CHANGER
Product Idencaon: Automac Tool Changer for PCNC 440 (PN 35900)
Purpose: This document details the installaon and use of the Automac Tool Changer on a PCNC 440 mill.
Qty.PCNC 440 Automatic Tool Changer PN
2Adjustable Stando Assembly 35833
1ATC Assembly —
1Fixed Stando Assembly 35832
1PCNC 440 Coolant Relocaon Bracket Kit 37260
10 Plasc Screw 32173
1Tilt Stando Assembly 35911
NOTE: If any of these items are missing, contact Tormach
Customer Service at [phone] for a replacement.
IMPORTANT! Please read this secon before you begin installing your Automac Tool Changer (ATC).
• Power Drawbar You must install the PCNC 440 Power Drawbar on your machine before installing the
PCNC 440 Automac Tool Changer (ATC). Do not install the power drawbar buon; tool changes are
completed with the ATC.
• PathPilot You must update your controller to the latest version of PathPilot before installing and
operang the ATC. If you don’t, there’s a risk that the ATC could become inoperable. Follow the
instrucons detailed in “Before You Begin” on page 3.

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TD10487_PCNC440_ATC_Install_1220A
Required Items and Tools
• 1-2-3 Block Set (PN 31950)
• 8 inch dowel for Tormach Tooling System (TTS)® tool holder
NOTE: The dowel cannot be longer than 8 inches.
• Adjustable wrench
• FRL Filter-Regulator-Lubricator (PN 32457) or similar
• Metric hex wrench set
• Phillips screwdriver
• PCNC 440 Power Drawbar (PN 35927)
NOTE: You must install the PCNC 440 Power Drawbar on your machine before installing the PCNC 440
Automac Tool Changer (ATC). Do not install the power drawbar buon; tool changes are completed
with the ATC.
• Small, at-head screwdriver
• Snips
• Socket wrench and a 13 mm socket
• TTS® tool holder
Air Requirements
Use a FRL Filter-Regulator-Lubricator (PN 32457) or similar to make sure your setup meets the following air
requirements:
• Air Supply. The required operang range is 90-120 psi. If the air supply exceeds 120 psi, you must use
a regulator.
• Dry Air. To make sure the air is dry, we recommend you use a lter, desiccator, or compressed air dryer
between the air compressor and the ATC.
• Lubricated Air. You must lubricate the air with air tool oil.

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TD10487_PCNC440_ATC_Install_1220A
Before You Begin
1. From the PathPilot® interface, reference the mill by clicking Ref Z, Ref X, and Ref Y.
2. Slowly jog the Z-axis down 1-1/2 inches.
IMPORTANT! You must update your controller to the latest version of PathPilot before installing and
operang the ATC. If you don’t, there’s a risk that the ATC could become inoperable.
3. Update your controller: From the Status tab, select Update. Then, follow the on-screen instrucons. Once
the controller is updated to the latest version of PathPilot, go to Step 4.
4. Power o the mill. Refer to the Power O/On Procedure detailed below.
WARNING! Electrical Shock Hazard: Be sure to power o the machine before making any electrical
modicaons. Failure to do so could result in serious injury or death.
Power Off/On Procedure
Power Off
1. Push in the red Emergency Stop buon
2. From the PathPilot® interface, click Exit; when prompted, click OK to power o
3. Turn the PathPilot controller power strip o
4. Turn the Main Disconnect to the O posion
Power On
1. Turn the PathPilot controller power strip on
2. Aer PathPilot loads, turn the Main Disconnect to the On posion
3. Turn the red E-stop buon clockwise to release
4. Press the green Start buon
5. From the PathPilot interface, click Reset
Partially Disassemble
Before installaon, the following items require relocaon, disassembly, or paral disassembly:
• Coolant Hose. If your mill has a coolant hose installed on the side of the spindle head, you must
relocate it: go to the Coolant Hose secon.
• Power Drawbar Buon. If your mill has a power drawbar buon installed on the spindle head, you
must disassemble it: go to the Power Drawbar Buon secon.
• Enclosure. If your mill has a full enclosure, you must parally disassemble it: go to the Enclosure
secon.
If you do not have the previous (oponal) accessories, go to the Mill secon.

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TD10487_PCNC440_ATC_Install_1220A
Coolant Hose
To relocate the coolant hose, use the included PCNC
440 Coolant Relocaon Bracket Kit.
1. If your mill’s serial number is 80075 or below,
you must rst drill and tap one hole; go to Step
2. If your mill’s serial number is above 80075,
go to Step 4.
2. Behind the spindle, ush with the right edge
of the spindle head casng, use the relocaon
bracket as a template to mark the mounng
locaon (see Figure 1).
3. On the marked mounng locaon, drill and
tap for a 6 mm screw.
4. Uninstall the coolant hose from the mill’s spindle head.
5. Aach the coolant hose to the relocaon bracket.
6. On the spindle head casng, in the locaon idened in Step 2, use the hardware included with the PCNC
440 Coolant Relocaon Bracket Kit to aach the relocaon bracket.
Power Drawbar Button
1. Power o the air compressor and disconnect
all air lines from the power drawbar buon.
Set the air lines to the power drawbar cylinder
and the air compressor aside. Air lines to the
ATC are installed later in this document.
2. From the power drawbar buon assembly, on
the bracket, remove the M6 x 12 mm socket
head cap screw securing the buon to the
spindle motor cover (see Figure 2).
Set the screw aside. Figure 2
Figure 1

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TD10487_PCNC440_ATC_Install_1220A
3. Uninstall the power drawbar buon from the mill’s spindle head.
4. On the spindle motor cover, replace the M6 x 12 mm socket head cap screw set aside in Step 2.
Enclosure
1. From the enclosure’s Le Back Panel, use a
Phillips screwdriver to remove nine 10-32 x
3/8” Phillips screws. The screws secure the
Le Back Panel to the machine column and
the le side panel of the enclosure (see Figure
3).
Set aside the screws and the Le Back Panel.
2. From the enclosure’s top panel, on the three
gibs, loosen nine 10-32 x 3/8” Phillips screws.
3. Slide the Top Window out of the three gibs.
Set aside the window.
Mill
1. From the back of the mill, on the electrical
cabinet, use a 3 mm hex wrench to remove 10
socket head cap screws (see Figure 4).
Set aside the screws and the electrical cabinet
cove r.
2. On the Z-column, use a 3 mm hex wrench to
remove eight buon head cap screws (see
Figure 4).
Set aside the screws and the Z-column cover.
3. Use a 4 mm hex wrench to remove four set
screws from the side of the Z-column (see
Figure 4).
Figure 4
Figure 3
Le Back Panel
Top Window

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TD10487_PCNC440_ATC_Install_1220A
Mount the Automatic Tool Changer
1. Idenfy four standos included with this kit
(see Figure 5):
• One xed stando
NOTE: The xed stando uses a
threadlocker to hold the nut in place.
• One lt stando
• Two adjustable standos
The standos mount the ATC to the mill’s
Z-column.
2. Arrange the four standos next to each other
(see Figure 5).
3. Loosen or ghten the nut on the two adjustable
standos unl they are the same length as the
xed stando (see Figure 5).
4. On the mill’s Z-column, use an adjustable wrench to install the four standos in the order shown in Figure 6.
Securely ghten the standos to the mill’s Z-column.
5. From each stando, remove the ange nut and the washer (see Figure 7).
Set aside all ange nuts and washers.
Figure 6
Tilt
Adjustable
Adjustable
Fixed
Figure 5
Tilt
Adjustable
Adjustable
Fixed
Figure 7

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TD10487_PCNC440_ATC_Install_1220A
6. From the ATC’s motor enclosure, on the access
plate, use a Phillips screwdriver to remove
four M4 x 6 mm screws (see Figure 8).
Set aside the screws and the access plate.
7. On the ATC’s wires, use a snips to cut the cable
es.
CAUTION! Heavy Object: Use two people to
li and install the ATC on the mill’s Z-column. Failure
to do so could result in serious injury and/or machine
damage.
8. On the mill’s Z-column, hold the oil line above
the four standos and put all ATC wires
through the Z-column’s access slot.
Connue to hold the oil line above the four standos.
9. Temporarily rest the ATC on the standos (see Figure 9) and release the oil line.
The oil line is clear of interference.
10. On the top right stando, re-install the washer and ange nut removed in Step 5 (see Figure 10).
NOTE: Tighten the washers and ange nuts nger-ght. Adjustments are made later in this document.
11. On the remaining three standos, re-install the washers and ange nuts set aside in Step 5.
Figure 9 Figure 10
Figure 8

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TD10487_PCNC440_ATC_Install_1220A
Make Air Connections
1. Manually slide the tool tray toward the spindle.
2. On the le side of the motor enclosure, idenfy
the Boom Solenoid (see Figure 11).
3. On the Boom Solenoid (see Figure 11), use
a small, at-head screwdriver to push in the
screw and turn it clockwise.
The screw locks in place to hold the ATC in the
tray load posion.
4. From the power drawbar cylinder, idenfy two
5/32” plasc tubes and connect the loose ends
to the ATC as follows:
a. From the boom push-to-connect elbow
on the power drawbar cylinder, connect
the Retract airline to the le push-to-
connect elbow on the ATC’s top solenoid
(see Figure 12).
b. From the T-connector on the power
drawbar cylinder, connect the Advance
airline to the right push-to-connect elbow
on the ATC’s top solenoid (see Figure 12).
Figure 12
Advance
Retract
Figure 11
Boom Solenoid

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TD10487_PCNC440_ATC_Install_1220A
5. From the air compressor, idenfy the 1/4”
plasc tube and connect the loose end to the
Air In valve on the underside of the motor
enclosure (see Figure 13).
6. If you have an (oponal) pressure sensor, go to
Install the Oponal Pressure Sensor.
If you have an (oponal) lter-regulator-
lubricator, go to Install the Oponal FRL Filter-
Regulator-Lubricator.
If you do not have either a pressure sensor or
a lter-regulator-lubricator, power on the air
compressor.
Install the Optional Pressure Sensor
The ATC Pressure Sensor (PN 32329) is an oponal accessory for the ATC that stops the carousel from starng
during a condion of low air supply pressure.
1. Splice the 1/4 inch main air supply line from the ATC.
2. Insert the spliced air lines into either end of the Pressure Sensor.
3. Plug the electrical connector into the jack on the boom of the ATC.
4. Power on the air compressor.
Install the Optional FRL Filter-Regulator-Lubricator
The FRL Filter-Regulator-Lubricator (PN 32457) is an oponal accessory for the ATC that lubricates the air with air
tool oil. Refer to the documentaon that ships with the FRL for informaon on installaon and use.
Level the Automatic Tool Changer
This secon details the procedure required to roughly align the ATC on the mill. More adjustments are made
later in this document.
1. From the right side of the machine, make sure the ATC’s carousel door opening is approximately equal in
distance on all sides of the spindle. If it is not:
a. On the adjustable standos, use an adjustable wrench to loosen or ghten the nut.
b. Move the ATC assembly in the Y direcon.
Figure 13
Air In

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TD10487_PCNC440_ATC_Install_1220A
2. From the front of the machine, make sure the motor enclosure is approximately 1/8 inch from the mill’s
spindle head (see Figure 14). If it is not:
a. On the adjustable standos, use an adjustable wrench to loosen or ghten the nut.
b. Move the ATC assembly in the X direcon.
3. On the lt stando, use an adjustable wrench to turn the nut unl the front side of the motor enclosure
is approximately parallel with the mill’s spindle head (see Figure 15).
4. From the four standos, securely ghten four
ange nuts.
5. From inside the motor enclosure, ghten the
plasc wire plug against the mill’s Z-column
(see Figure 16).
6. From the le side of the motor enclosure, on
the Boom Solenoid (see Figure 11), use a
small at-head screwdriver to turn the screw
on counterclockwise.
The tool tray retracts.
Figure 15
Figure 16
Figure 14

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TD10487_PCNC440_ATC_Install_1220A
Make Electrical Connections
An illustraon of ATC wire roung is shown in Figure 17. The steps to follow detail the connecons shown below.
1. Put wire V+ and V- (red and black power wires) through the Z-column toward the power supply (see Figure 17).
Fuse
3
Wire Trough
Wire Trough
Fuse
1
Fuse
6
Coolant
Fuse
C1
Contactor
V- (power)
V+ (power)
(colors do not represent wire colors)
VFD
Control
Module
Coolant
Power
Supply
Coolant
Relay
Terminal Block
Ground
VFD-8
VFD-1
Power Supply
+5V VFD-1
VFD-8
HA
V+
V+
VFD-1 and VFD-8
V-
V-
Figure 17
Remove Cover
Remove Cover

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2. On the power supply, use a Phillips screwdriver to make the following power connecons (see Figure 17):
• Insert wire V+ (red) to V+
• Insert wire V- (black) to V-
3. Put wire VFD-1 and VFD-8 (yellow and white spindle wires) through the access hole in the boom of the
Z-column toward the electrical cabinet (see Figure 17).
4. From the electrical cabinet, remove two wire trough covers as shown in Figure 17.
5. Put wire VFD-1 and VFD-8 (yellow and white spindle wires) through the wire troughs together toward the
variable frequency drive (VFD) as shown in Figure 17.
6. On the VFD, use a small, at-head screwdriver to make the following spindle connecons (as shown in
Figure 17:
• Insert wire VFD-1 (yellow) to +5v
• Insert wire VFD-8 (white) to 2/HA
7. Replace the wire trough covers inside the electrical cabinet.
8. Re-install the electrical cabinet cover to the back of the mill using 10 socket head cap screws set aside
earlier.
9. Put the USB cable through the access hole in the boom of the Z-column toward the back of the stand.
Put the USB cable through the access hole in the back of the stand toward the controller.
10. On the controller, insert the USB cable into any open USB port.
11. Re-install the Z-column cover to the back of the mill using eight buon head cap screws set aside earlier.
12. Re-install the motor enclosure’s access plate using four M4 x 6 mm screws set aside earlier.
Validate the Installation
1. Power on the mill following Power O/On
Procedure detailed earlier in this document.
2. From the PathPilot interface, on the Sengs
tab, select the ATC radio buon (see Figure
18).
The ATC tab appears in the PathPilot interface.
Figure 18

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TD10487_PCNC440_ATC_Install_1220A
3. From the Main tab, reference the machine by clicking Ref Z, Ref X, and Ref Y.
4. On the ATC, insert a tool into the spindle as follows:
a. Push and hold the buon (see Figure 19).
The collet opens.
b. Insert a tool into the spindle.
c. Release the buon.
The collet closes.
5. From the PathPilot interface, on the Main tab, type 1000 into the RPM DRO eld and click the FWD buon.
The spindle starts.
6. From the Status tab, make sure that the VFD Running green light comes on (see Figure 20). If the green
light doesn’t come on, there may be a wiring issue. To check the wiring:
a. Remove the tool from the spindle.
b. Power o the mill following the Power O/On Procedure detailed earlier in this document.
c. From the electrical cabinet, on the VFD, examine wire VFD-8, and conrm that it’s connected to 2/HA
on the VFD. If it’s not, make this connecon (for more informaon, refer to the Electrical Schemac
later in this document).
d. Conrm that all wires on the VFD are rmly seated.
e. Repeat the Validate the Installaon procedure.
7. Click Stop.
The spindle stops.
8. Use the buon on the ATC to remove the tool from the spindle.
Figure 20Figure 19

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TD10487_PCNC440_ATC_Install_1220A
Align Tool Tray and Tool Slots
1. Make sure there is no tool in the spindle.
2. From the PathPilot interface, on the ATC tab, click the Ref Tool Tray buon (see Figure 21).
The tool tray spins.
NOTE: You are only required to reference the tool tray once — unlike the mill axes’ referencing procedure.
3. Click the Go to Tray Load Posion buon (see Figure 21).
4. When prompted, click OK (see Figure 22).
The tool tray moves forward.
5. Make sure the spindle is centered over the
ATC’s fork (see Figure 23).
Figure 22
Figure 21
Figure 23

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TD10487_PCNC440_ATC_Install_1220A
Adjusting the Tool Tray Load Position
If the spindle is not centered over the fork in the X
direcon, you must manually adjust the posion of
the ATC assembly on the linear rails.
1. From the ATC’s linear rail, loosen the jam nut
(see Figure 24).
2. Slide the coupler to bring the ATC assembly
closer to the spindle head or further away
from the spindle head (see Figure 24).
3. Aer the ATC’s carousel door opening
is posioned correctly with the spindle,
re-ghten the jam nut.
Adjusting the Tilt of the ATC
1. Insert a dowel — no more than 8 inches long — into a TTS tool holder.
2. Insert the tool holder into the fork (see Figure 25). Make sure the groove in the tool holder slides along
the shoulder on the fork.
NOTE: Do not rest the tool holder on top of the fork.
3. From the PathPilot interface, on the ATC tab, type 1 in the Tool Number DRO eld (see Figure 26).
4. Click the Insert buon (see Figure 26).
The tool number entered appears on the diagram of the ATC’S carousel.
Figure 26
Figure 24
Figure 25

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5. Place a 1-2-3 block on the machine
table (see Figure 27). Make sure the
dowel is parallel with the 1-2-3 block
in both the Y and X direcon.
If the dowel is not parallel, do one of
the following:
a. From the ATC’s linear rail, loosen
two 5 mm socket head cap screws
(see Figure 28) and slowly pivot
the ATC assembly unl the dowel
is parallel with the 1-2-3 block;
re-ghten 5 mm socket head cap
screws.
b. Re-check the alignment of the
dowel in both the Y and X direcon.
or
a. From the lt stando, use an adjustable wrench to turn the nut and slowly pivot the ATC assembly
unl the dowel is parallel with the 1-2-3 block (see Figure 29).
b. Re-check the alignment of dowel in both the Y and X direcon.
Repeat Step 5 unl the dowel is parallel with the 1-2-3 block.
6. Remove the 1-2-3 block from the machine table.
Figure 29Figure 28
Figure 27

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Adjusting the Tool Tray Rotation
1. From the PathPilot interface, slowly jog the Z-axis down to bring the spindle nose toward the tool in the
ATC’s tool tray.
2. Make sure the tool’s shank is in line with the collet in the spindle.
3. Examine the alignment of the spindle’s centerline to the tool slot’s centerline (see Figure 30). Determine
if the tray must move clockwise or counterclockwise.
4. From the PathPilot interface, in the ATC tab, do one of the following (see Figure 31):
• Click the -- buon to step the tool tray counterclockwise
• Click the ++ buon to step the tool tray clockwise
Validate the Automatic Tool Changer Alignment
1. From the PathPilot interface, slowly jog the Z-axis down over the tool’s shank.
2. Make sure the tool’s shank moves freely in the collet.
If it does not, this indicates that the ATC is misaligned and you must repeat the steps in the Align Tool Tray
and Tool Slots secon.
Setting Tool Change Height
1. From the PathPilot interface, slowly jog the Z-axis down over the tool; stop jogging when the spindle nose
just makes contact with the shoulder of the tool holder.
Figure 31
Figure 30
-- ++

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2. On the ATC tab, click the Set TC POS buon
(see Figure 32).
The tool change posion is set.
Adjust for Rotational Play
There is a small amount of rotaonal play built
into the ATC carousel. This play allows for some
misalignment during tool changes, and must be
adjusted for in both direcons. The taper on the tool
shank also helps align the tool during a tool change.
1. From the PathPilot interface, on the ATC tab,
click the Tray FWD buon to rotate the tray
clockwise (forward) one full tool slot.
2. Click the Tray REV buon to rotate the tray
counterclockwise (backward) one full tool slot.
3. Make sure the tool’s shank is in line with the
collet in the spindle. If it is not, repeat Adjusng
the Tool Tray Rotaon secon.
Re-assemble
1. From the enclosure’s le back panel, remove
the ATC Cover (see Figure 33).
2. Use nine 10-32 x 3/8” Phillips screws set
aside earlier in this document to re-install the
enclosure’s le back panel to both the machine
column and the enclosure’s le side panel.
3. Slide the top window back in place on the
enclosure’s top panel and ghten nine 10-32 x
3/8” Phillips screws.
Figure 33
ATC Cover
Figure 32

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TD10487_PCNC440_ATC_Install_1220A
Operate the Automatic Tool Changer
The PCNC 440 Automac Tool Changer holds up to eight tools in a single tray. If your program requires nine or
more tools, the ATC changes tools automacally for all tools assigned to the tray, and pauses for a manual tool
change for all tools not assigned to the tray.
NOTE: Make sure there is always a TTS tool holder in the collet while the machine is not in use. Retracng the
power drawbar to the clamped posion with no tool holder in the collet will eventually fague the collet, and
may shorten its service life. For more informaon, refer to the documentaon that ships with the Power Drawbar
(PN 35927).
Assigning Tool Numbers
Use any tool number from 1-256 to assign a posion in the tool tray. You are not restricted to tool numbers 1-8.
Loading and Unloading a Tool into the Tool Tray
There are two ways to load and unload the tool tray:
1. Automac
2. Manual
TO AUTOMATICALLY LOAD A TOOL INTO THE 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 eld (see
Figure 34). Press ENTER on the keyboard.
3. Click the Store Current Tool buon.
The ATC assigns the tool to the nearest open
slot, fetches the tool from the spindle, and
stores the tool in the tray. The tool number is
displayed on the tray image in the center of
the screen (see Figure 34).
4. Click the Retract buon (see Figure 34).The
tray returns to machining posion.
Figure 34

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TD10487_PCNC440_ATC_Install_1220A
TO MANUALLY LOAD A TOOL INTO THE TRAY
1. From the PathPilot interface, on the ATC tab,
click the Go To Tray Load Posion buon (see
Figure 35).
The spindle head moves up and the ATC moves
into the door open posion.
2. Insert a tool into an open fork on the tray.
3. From the ATC tab, type the tool number into
the Insert DRO eld (see Figure 35). Press
ENTER on the keyboard.
4. Click the Insert buon (see Figure 35).
The tool is assigned to the exposed tray slot.
5. Click the Tray FWD buon or the Tray REV
buon (see Figure 35).
The tray advances to the next slot locaon.
6. Click the Retract buon (see Figure 35).
The tray returns to machining posion.
TO AUTOMATICALLY UNLOAD A TOOL FROM THE TRAY
NOTE: Typing a new tool number in the Tool DRO
does not remove the tool from its tray assignment.
1. From the PathPilot interface, on the ATC tab,
type the tool number in the Remove DRO eld
(see Figure 36). Press Enter on the keyboard.
2. Click the Remove buon (see Figure 36).
The ATC fetches the tool from the tray.
3. Remove the tool from the spindle.
4. From the ATC tab, click the ATC FWD buon or
the ATC REV buon (see Figure 36).
The tray advances to the next locaon and
fetches another tool.
5. Click the Retract buon.
The tray returns to machining posion.
Figure 35
Figure 36