Tormach PCNC 1100 User manual

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UM10349_PCNC1100_Manual_0916A
Document Part Number: 35426
©2015 Tormach Inc.
IMPORTANT: Read and understand all operator manual safety precautions and instructions
before attempting PCNC 1100 installation, operation, or maintenance.
Tormach®PCNC 1100
Operator Manual
™

Chapter 1 2UM10349_PCNC1100_Manual_0916A
Preface
SAVE THESE INSTRUCTIONS!
This manual contains important safety warnings and operang instrucons for the Tormach PCNC
1100 mill. Refer to these instrucons before aempng installaon, operaon or maintenance.
Keep these instrucons together with your PCNC 1100 mill so they are readily accessible. The most
recent version of this manual is available at: www.tormach.com/tormach_product_manuals
Read Before Operating
Read and follow all warnings, cauons, and operang instrucons before operang this mill. Failure
to do so may result in voided warranty, property damage, serious injury or death.
Symbol Description Example
WARNING! Indicates a hazard which, if not
avoided, could result in death or serious injury.
WARNING! Ejection Hazard: Tools and
workpieces must be clamped properly. Failure to do
so may result in serious injury or death.
CAUTION! Indicates a hazard which, if not
avoided, could result in injury or mill damage.
CAUTION! Sharp Objects: Be sure to wear
gloves when uncrating mill. Failure to do so may
result in serious injury.
IMPORTANT! IMPORTANT! Addresses important practices not
related to personal injury.
IMPORTANT! Damage to mill may occur if
motor weight is supported by motor wires.
NOTE: NOTE:Provides additional information, clarication,
reminders, or helpful hints.
NOTE: For further information on automatic oiler
troubleshooting, refer to operator manual.
Safety Overview
Any machine tool is potenally dangerous. The automaon inherent in a CNC machine presents
added risk not present in a manual mill. Tormach CNC mills can deliver sucient force to break
brile tools, crush bones, and tear esh.
This manual provides guidance on safety precauons and techniques, but because the specics of
any one workshop (or other local condions) can vary greatly, Tormach accepts no responsibility for
machine performance or any damage or injury caused by its use. It is your responsibility to ensure
you understand the implicaons of what you are doing and comply with any legislaon and codes
of pracce applicable to your city, state or naon.

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UM10349_PCNC1100_Manual_0916A
Preface
Machine Safety
Safe operaon of the machine depends on its proper use and the precauons taken by the operator.
Read and understand this manual prior to mill use. Only trained personnel — with a clear and
thorough understanding of its operaon and safety requirements — should operate this mill.
General Safety:
• Wear OSHA-approved safety glasses, safety shoes, and ear protecon.
• Remove loose-ng clothing, neckes, gloves, and jewelry.
• Tie up long hair or secure under a hat.
• Never operate a machine aer consuming alcohol or taking medicaon.
• Keep work area well lit and deploy addional lighng, if needed.
Operaonal Safety:
• Understand CNC mills are automacally controlled and may start at any me.
• Never operate with unbalanced tooling or spindle xtures.
• Remove all tools (wrenches, chuck keys, etc.) from spindle and machine table before starng
operaons; loose items can become dangerous projecles.
• Use adequate work clamping; loose workpieces can become dangerous projecles.
• Protect your hands. Stop machine spindle and ensure mill moon has stopped before:
- Reaching into any part of the machine moon envelope
- Changing tools, parts or adjusng the workpiece
- Changing belt/pulley posion
- Clearing away chips, oil or coolant; always use a chip scraper or brush
- Making an adjustment to part, xture, coolant nozzle or when taking measurements
- Removing protecve shields or safeguards; never reach around a guard
• Keep work area clear of cluer as mill moon can occur when keys are accidently pressed or
objects fall on keyboard, resulng in unexpected moon.
• Posion clamping aachments clear of tool path. Be aware of workpiece cutos that could be
cut free during operaons and become dangerous projecles.
• Always use proper feeds/speeds, as well as depth/width of cut to prevent tool breakage.
• Check for damaged tools/workpieces and cease operaons if detected; replace before
restarng operaons as these can become dangerous projecles. Never use longer or larger
tools than necessary.

Chapter 1 4UM10349_PCNC1100_Manual_0916A
Preface
• Chips and dust from certain materials (e.g., magnesium) can be ammable. Fine dust from
normally non-ammable materials may be ammable or even explosive.
• Chips, dust, and vapors from certain materials can be toxic. Always check the Materials Safety
Data Sheet (MSDS) for each material.
IMPORTANT: It is the responsibility of the employer/operator to provide and ensure point of operaon
safeguarding per the following:
• OSHA 1910.212 – General Requirements for All Machines
• OSHA 1910.212 – Milling Machines, point of operaon safeguarding
• ANSI B11.22-2002 Safety Requirements for Turning Centers and Automac Numerically
Controlled Turning Machines
• ANSI B11.TR3-2000 Risk Assessment and Risk Reducon – A Guideline to Esmate, Evaluate,
and Reduce Risks Associated with Machine Tools
• Safety Requirements for Construcon, Care, and Use of Drilling, Milling and Boring Machines
(ANSI B11.8-1983). Available from American Naonal Standards Instute, 1430 Broadway,
New York, New York 10018
• Concepts and Techniques of Machine Safeguarding (OSHA Publicaon Number 3067).
Available from The Publicaon Oce – OSHA, U.S. Department of Labor, 200 Constuon
Avenue, NW, Washington, DC 20210
Electrical Safety
WARNING! Electrical Shock Hazard: Be sure to power o machine before making any electrical
modicaons. Failure to do so may result in serious injury or death.
Input Power: The PCNC 1100 has two electrical power inputs, primary and secondary. The 230 VAC
primary input supplies axis and spindle power, while the 115 VAC secondary input supplies power
to the PathPilot®controller and accessory outlets. The wiring and electrical components associated
with either circuit are capable of delivering lethal electrical shocks. Care should be exercised when
working inside the electrical cabinet.
Grounding: Both primary and secondary power inputs must be grounded. Do not assume during
installaon that a wall outlet is properly grounded. Check connuity between the machine frame
and true earth ground (metal water pipe or similar) to ensure a good ground connecon.
Ground Fault Interrupter: A Ground Fault Interrupter or GFI (also known as a Residual Current
Circuit Breaker or RCCB) outlet must be used to supply power to the 115 VAC power input for the
secondary input.

Chapter 1
5
UM10349_PCNC1100_Manual_0916A
Preface
Electrical Cabinet: Never operate the machine tool with the electrical cabinet open. Never allow
coolant pump to operate with the electrical cabinet open. Do not allow the coolant system to ow
coolant directly at the electrical cabinet or the operator panel. Neither the electrical cabinet nor the
operator panel controls are hermecally sealed against liquids.
Electrical Service: Certain service and troubleshoong operaons require access to the electrical
cabinet while power is on. Only qualied electrical technicians should perform such operaons.
Retained Electrical Power: Electronic devices within the electrical cabinet may retain dangerous
electrical voltage aer the power is o.
Support
Tormach provides no-cost technical support to our customers through mulple channels. The
quickest way to get the answers you need is normally in this order:
• Refer to operator manual rst
• Reference related documents at: hp://www.tormach.com/documents
• Email: inf[email protected]
• Phone: [phone] x2001, Monday through Friday 8 a.m. to 5 p.m. (central standard me)
• Fax: [phone]
Scope and Intellectual Property
This document is intended to provide sucient informaon to allow you to install, setup, and use
your Tormach PCNC mill. It assumes that you have appropriate experience and/or access to training
for any computer-aided design/manufacturing soware to use with the mill.
Tormach Inc. is dedicated to connual improvement of its products, so suggesons for enhancements,
correcons, and claricaons are welcome.
The right to make copies of this manual is granted solely for the purpose of training courses related
to, evaluaon of, and/or use of the mill. It is not permied, under this right, for third pares to
charge for copies beyond the cost of prinng.
Every eort has been made to make this manual as complete and as accurate as possible but no
warranty or tness is claimed or implied. All informaon provided is on an as is basis. The authors,
publisher, and Tormach Inc. shall not have any liability for, or responsibility to, any person or enty
for any reason for any loss or damage arising from the informaon contained in this manual.
Tormach, PCNC 1100 Personal CNC, PCNC 770 Personal CNC, Tormach Tooling System (TTS), and
PathPilot are trademarks or registered trademarks of Tormach Inc. If other trademarks are used
in this manual, but not acknowledged, please nofy Tormach Inc. so this can be remedied in
subsequent edions. Tormach milling machines and accessories are covered by one or more of the
following U.S. Patents: 7,386,362, D606,568, D612,406, D621,859 and Patent(s) Pending.

Chapter 1 6UM10349_PCNC1100_Manual_0916A
Preface
Intended Use Statement
The PCNC 1100 is intended for use as a general purpose CNC milling machine. The intended use includes
cung convenonal (non-abrasive) materials such as unhardened mild or alloy steels, aluminum,
plascs, wood, and similar materials (or other material that can be cut with a rotang cuer).
Outside Scope of Intended Use
Applicaons for the equipment or modicaons of the equipment outside of the Intended Use
Statement are supported through consulng engineering and excluded from Tormach’s no-cost
technical support.
All of the technical informaon and insight required to support variaons from the intended use
cannot possibly be foreseen. If the extensive documentaon provided is insucient, Tormach can
provide addional informaon and engineering support on a consulng-engineering basis. If you
have your quesons well organized, we can normally provide all the informaon you need in short
order. Consulng engineering is done by electrical and mechanical engineers and billed at current
hourly rates.
All warranes for Tormach equipment are voided through modicaon to the equipment or use
outside of the intended use. Individuals or companies involved with modifying the equipment or
applying the products assume all consequent liability.
Performance Expectations and Cutting Ability
The following table summarizes the cung performance envelope of each PCNC mill.
PCNC 1100 PCNC 770
Spindle Speed Range1100-5140 RPM 175-10000 RPM
Spindle Power Rating 1.5 hp 1 hp
Feed Rate Range 0-110 ipm (X,Y)
0-90 ipm (Z)
0-135 ipm (X,Y)
0-110 ipm (Z)
1For standard R8 spindle
PCNC mills are capable of cung any material that can be cut with a rotang cuer at or near their
recommended feeds and speeds. As with any mill, care should be exercised so that programmed
cuts do not exceed the maximum available spindle horsepower. Small diameter cuers may perform
beer with use of a companion spindle or RPM mulplier such as the Tormach Speeder™ (for more
informaon, refer to chapter 8, Accessories).

Chapter 1
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UM10349_PCNC1100_Manual_0916A
Preface
Resolution, Accuracy, and Repeatability
The following table summarizes resoluon, accuracy, and repeatability of PCNC mills as delivered.
Resolution of Motion (minimum discrete positional move) 0.0001”
Ball Screw Positional Accuracy ≤ 0.0006” per foot
Combined Positional Accuracy1≤ 0.0013” per foot
1 Includes addional contribung factors such as compressibility of bearings, ball screw windup, fricon, etc.
Each PCNC Mill ships with a Cercate of Inspecon. This report details quality assurance
measurements performed at the factory by a Tormach quality assurance team member on each mill
prior to shipping.
A sample cercate of inspecon and more informaon on quality assurance measurements is
available at: hp://www.tormach.com/quality_overview.html
In pracce, accuracy and repeatability are heavily inuenced by the techniques used by the
machinist. A skilled machinist can oen deliver accuracy that exceeds the accuracy specied by
the manufacturer, while an inexperienced machinist may have diculty delivering the expected
accuracy. With this understanding, Tormach cannot predict operator accuracy. Nevertheless, the
accuracy specied by the manufacturer remains an important reference point.
Nomenclature
This manual uses the following typographical nomenclature.
Soware Control Refers to a Software Control, i.e., an on-screen button
Hardware Control Refers to a button or switch on mill’s Operator Panel
G-code (e.g., G01X34.8) Used to show G-code programs
Key name (i.e., Enter)Tells you to press the indicated key
Buon name (i.e., Stop)Tells you to press the indicated button

Chapter 1 8UM10349_PCNC1100_Manual_0916A
Preface
Table of Contents
1. Overview 20
1.1 Specicaons (PCNC 1100) 21
2. Site Planning and Prep 22
2.1 General Site Requirements 22
2.1.1 Space Requirements 22
2.2 Electrical Requirements 22
2.2.1 Grounding 22
2.2.2 Plug Paern 22
2.2.3 Ground Fault Interrupter (GFI) Use 23
2.2.4 Electrical Noise 23
2.2.5 Opons for Electrically Non-conforming Sites 23
2.2.5.1 Buck-Boost Transformer 23
2.2.5.2 Step-up/Step-down Transformer 23
2.2.5.3 Quick 220™ Voltage Converter Power Supply 23
3. Installaon 24
3.1 Receiving, Uncrang, and Inial Inspecon 24
3.1.1 Shipment Arrival 24
3.1.2 Moving the Crate 24
3.1.3 Inial Uncrang 25
3.1.4 Shipping Damage or Shortages 25
3.2 Installaon Sequence 25
3.3 Basic Installaon Procedure 25
3.3.1 Paral Stand Assembly 25
3.3.2 Remove Tool Tray (PCNC 1100 only) 26
3.3.3 Remove Accessory Tool Box 26
3.3.4 Assembling Y-Axis (PCNC 1100 only) 26

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Preface
3.3.5 Li and Move Mill 27
3.3.5.1 Remove Mill from Pallet 27
3.3.5.2 Liing Bar Kit 27
3.3.5.3 Liing from Below 27
3.3.5.4 Moving Kit (PCNC 770 Only) 28
3.3.5.5 Lowering Mill onto Stand 28
3.3.6 Install Tool Tray (PCNC 1100 only) 28
3.3.7 Install Drip Tray 28
3.3.8 Install PathPilot Controller 29
3.4 Installaon of Add-ons 31
3.4.1 Stand 31
3.4.2 Machine Arm 31
3.4.2.1 Mouse, Keyboard, and Jog Shule 31
3.4.3 USB Bulkhead Port 31
3.4.4 Manual or Automac Oiler 31
3.4.5 Coolant System 31
3.5 Essenal Controls Overview 32
3.5.1 E-stop, Start, Reset, and Power 32
3.6 Power O/Power On Procedure 33
3.6.1 Inial PathPilot Controller Conguraon 34
3.7 Validate Basic Installaon 34
3.7.1 Verify Spindle Funcon 34
3.7.2 Verify Limit Switch Funcon 35
3.7.3 Verify Axis Funcon 36
3.7.4 Coolant On/O 36
3.7.5 Installaon Troubleshoong 36
3.8 Controller Customizaon 37

Chapter 1 10 UM10349_PCNC1100_Manual_0916A
Preface
4. Operaon 38
4.1 Control Locaons 38
4.1.1 Operator Panel 38
4.1.2 PathPilot Interface 38
4.2 Inializing the Mill 39
4.2.1 Vital Reference 39
4.3 Jogging 39
4.3.1 Manual Control Group 39
4.4 Spindle Controls 40
4.4.1 Manual Spindle Control Via Operator Panel 40
4.4.2 Automated Spindle Control Via PathPilot Interface 41
4.4.3 Changing Spindle Speed Range 41
4.5 Tool Holders 42
4.6 Part Setup/Workholding 43
5. Intro to PathPilot 44
5.1 Making Your First Part 44
5.1.1 Referencing the Mill 44
5.1.2 Workpiece Preparaon 45
5.1.3 Tooling Preparaon 45
5.1.4 Mill Posion, Work Osets and Tool Osets 45
5.1.4.1 Seng Work Oset by Touching O Workpiece 46
5.1.4.2 Seng Tool Length Oset by Touching O Workpiece 48
5.1.5 Wring the G-code 49
5.1.5.1 Operaon 1 49
5.1.5.2 Operaon 2 51
6. PathPilot Interface 53
6.1 Overall Layout 53
6.2 Persistent Controls 54

Chapter 1
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Preface
6.2.1 Program Control Group 54
6.2.2 Posion Status Group 56
6.2.3 Manual Control Group 57
6.2.4 Keyboard Shortcuts 60
6.3 Main Tab 60
6.4 File Tab 64
6.5 Sengs Tab 65
6.6 Osets Tab 68
6.6.1 Tool Tab 68
6.6.1.1 Oine Measurement with Height Gauge 69
6.6.1.2 Automated Measurement with an Electronic Tool Seer 69
6.6.1.3 Measurement by Touching O Tool 70
6.6.2 Osets Table 70
6.6.3 Tool Oset and Fixture Informaon Backup 70
6.6.4 Work Tab 70
6.7 Conversaonal Tab 71
6.7.1 Face Tab 71
6.7.2 Prole Tab 72
6.7.3 Pocket Tab 73
6.7.3.1 Rectangular 73
6.7.3.2 Circular 75
6.7.4 Drill/Tap Tab 76
6.7.4.1 Drill 78
6.7.4.2 Tap 79
6.7.5 Thread Mill Tab 80
6.7.6 Engrave Tab 82
6.8 Probe Tab 84

Chapter 1 12 UM10349_PCNC1100_Manual_0916A
Preface
6.8.1 XYZ Probe Tab 84
6.8.2 Rect/Circ Tab 85
6.8.3 Probe/ETS Setup Tab 86
6.9 ADMIN Commands 86
7. Programming 87
7.1 Denions 87
7.2 G-code Programming Language 90
7.2.1 Overview 90
7.2.2 Block 90
7.2.3 Real Value 90
7.2.4 Number 90
7.3 Formang G-code Blocks 91
7.3.1 Oponal Program Stop Control – (M01 BREAK) 94
7.4 Addional G-code Formang Notes 94
7.4.1 Repeated Items 94
7.4.2 Order of Execuon 94
7.4.3 Error Handling 96
7.4.4 Modality and Modal Commands 96
7.4.5 Modal Groups 96
7.4.6 Default Modes 97
7.5 G-codes 97
7.5.1 Rapid Linear Moon – G00 99
7.5.2 Linear Moon at Feed Rate – G01 100
7.5.3 Arc at Feed Rate – G02 and G03 101
7.5.3.1 Radius Format Arc 101
7.5.3.2 Center Format Arc 102
7.5.4 Dwell – G04 105

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Preface
7.5.5 Set Osets – G10 105
7.5.5.1 Set Tool Table – G10 L1 105
7.5.5.2 Set Coordinate System – G10 L2 106
7.5.5.3 Set Tool Table – G10 L10 106
7.5.5.4 Set Tool Table – G10 L11 107
7.5.5.5 Set Coordinate System – G10 L20 107
7.5.6 Plane Selecon – G17, G18 and G19 108
7.5.7 Length Units – G20 and G21 108
7.5.8 Return to Pre-dened Posion – G28 and G28.1 108
7.5.9 Return to Pre-dened Posion – G30 and G30.1 109
7.5.10 Straight Probe – G38.x 109
7.5.10.1 Using the Straight Probe Command 110
7.5.11 Cuer Compensaon 111
7.5.12 Dynamic Cuer Compensaon – G41.1, G42.1 112
7.5.13 Apply Tool Length Oset – G43 112
7.5.14 Engrave Sequenal Serial Number – G47 113
7.5.15 G49 Cancel Tool Length Compensaon – G49 113
7.5.16 Absolute Coordinates – G53 114
7.5.17 Select Work Oset Coordinate System – G54 to G59.3 114
7.5.18 Set Exact Path Control Mode – G61 114
7.5.19 Set Blended Path Control Mode – G64 115
7.6 Canned Cycles 115
7.6.1 Preliminary Canned Cycle Moon 117
7.6.2 Canned Cycle – High Speed Peck Drill – G73 117
7.6.2.1 G80 Cycle 118
7.6.2.2 G81 Cycle 118
7.6.2.3 G82 Cycle 120

Chapter 1 14 UM10349_PCNC1100_Manual_0916A
Preface
7.6.2.4 G83 Cycle 121
7.6.2.5 G85 Cycle – Boring Cycle (Feed rate out) 121
7.6.2.6 G88 Cycle – Boring Cycle (Dwell, Manual Out) 122
7.6.2.7 G89 Cycle – Boring Cycle (Dwell, Feed rate out) 122
7.6.2.8 Distance Mode – G90 and G91 123
7.6.2.9 Arc Distance Mode – G90.1, G91.1 123
7.6.2.10 Temporary Work Osets – G92, G92.1, G92.2 and G92.3 123
7.6.2.11 Feed Rate Mode – G93, G94 and G95 124
7.6.2.12 Spindle Control Mode – G96, G97 125
7.7 Built-in M-codes 125
7.7.1 Program Stop and Program End – M00, M01, M02 and M30 126
7.7.2 Spindle Control – M03, M04 and M05 127
7.7.3 Tool Change – M06 127
7.7.4 Coolant Control – M07, M08 and M09 127
7.7.5 Override Control – M48 and M49 128
7.7.6 Feed Override Control – M50 128
7.7.7 Spindle Speed Override Control – M51 128
7.7.8 Set Current Tool Number – M61 128
7.7.9 Set Output State – M64/M65 128
7.7.10 Wait on Input – M66 130
7.7.11 Operator Dened Commands – M100 to M199 130
7.8 Other Input Codes 131
7.8.1 Feed Rate – F 131
7.8.2 Spindle Speed – S 131
7.8.3 Change Tool Number – T 131
7.9 Advanced Programming with Parameters and Expressions 131
7.9.1 Parameters 131

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7.9.2 Parameter Types 133
7.9.2.1 Numbered Parameters 133
7.9.2.2 Subroune Parameters 134
7.9.2.3 Named Parameters 135
7.9.3 Expressions 135
7.9.3.1 Binary Operators 136
7.9.3.2 Funcons 137
7.10 Programming with Subrounes 137
7.10.1 Subroune Labels and Subroune Keywords 137
7.10.1.1 Dening a Subroune 138
7.10.1.2 Calling a Subroune 139
7.10.1.3 Condional Subrounes 140
7.10.1.4 Repeang Subrounes 140
7.10.1.5 Looping Subrounes 141
8. Accessories 143
8.1 4th Axis Kits 143
8.2 Enclosures, Stands, and Machine Arms 145
8.3 Tapping Opons 146
8.4 Oil And Coolant System Opons 147
8.4.1 Automac Oiler 147
8.4.2 Spray Coolant 147
8.4.3 Chip Flap Kit 147
8.4.4 Coolant Hose and Accessories 148
8.4.5 Tramp Oil Pillow 148
8.5 Spindle Opons 148
8.5.1 High Speed Spindle Opons 148
8.5.1.1 Kress Companion Spindle Kit 149

Chapter 1 16 UM10349_PCNC1100_Manual_0916A
Preface
8.5.1.2 Tormach Speeder 149
8.5.1.3 High-speed Spindle 149
8.5.2 Other Spindle Opons 149
8.5.2.1 BT30 Spindle Cartridge 149
8.5.2.2 Spindle Load Meter 150
8.5.2.3 LED Spindle Light 150
8.6 Power Drawbar and ATC 150
8.6.1 Power Drawbar 150
8.6.2 Automac Tool Changer (ATC) 151
8.7 Auxiliary Electronic Opons 151
8.7.1 External Contactor Kit 151
8.7.2 Switchable Convenience Outlet Kit 152
8.7.3 USB M-code I/O Interface Kit 152
8.7.4 Integrated Remote E-stop Kit 152
8.8 Controller Opons 152
8.8.1 USB Bulkhead Port Assembly 152
8.9 Prototyping Accessories 153
8.9.1 Injecon Molder 153
8.9.2 CNC Scanner 153
8.9.3 Probe 154
8.9.3.1 Calibrang Probe Tip 155
8.9.3.2 Measuring Probe Tip Diameter 157
8.9.4 Tool Seer 157
8.9.4.1 Tool Seer Trigger Height 157
9. Maintenance 158
9.1 Regular Maintenance 158
9.1.1 Rust Prevenon 159
9.1.2 Way Covers 159

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Preface
9.1.3 Flood Coolant System 159
9.1.4 Lubricaon System 160
9.1.4.1 Manual Pump Specics 160
9.1.5 Drawbar and TTS Collet 161
9.2 Spindle Belt 161
9.3 Advanced Maintenance 162
9.3.1 Overview 162
9.3.2 Denions 162
9.3.2.1 How to Measure Lost Moon 163
9.3.3 Gib Adjustment 164
9.3.3.1 Overview 164
9.3.3.2 Adjustment Procedure 165
9.3.4 Angular Contact Bearing Preload Adjustment 166
9.3.4.1 Overview 166
9.3.4.2 Adjustment Procedure 168
9.3.4.3 Determining Proper Angular Contact Bearing Preload 168
9.3.5 Geometry Adjustment of Precision Mang Surfaces 169
9.4 Spindle Bearing Adjustment 170
9.5 Spindle Calibraon 170
9.6 Mill Transportaon 172
10. Troubleshoong 173
10.1 Troubleshoong Basics 173
10.2 Tips and Tools for Troubleshoong (equipment and procedures) 175
10.2.1 Safety 175
10.2.2 Tips on Controller Diagnoscs 175
10.2.3 Troubleshoong Tools 175
10.2.4 Using Digital Mulmeter for Electrical Tests 176

Chapter 1 18 UM10349_PCNC1100_Manual_0916A
Preface
10.2.4.1 Measuring DC Voltage 176
10.2.4.2 Measuring AC Voltage 176
10.2.4.3 Measuring Resistance 176
10.2.5 Contacng Technical Support 176
10.3 Frequently Found Problems 177
10.3.1 Loose Wires 177
10.3.2 Wire Hairs 178
10.3.3 Poor Cable Connecons 178
10.3.4 Sensors (Limit Switches) 178
10.3.5 Unexplained Stop or Limit Switch Error While Running 178
10.4 Electrical Maintenance 178
10.4.1 Electrical Service 178
10.5 System Troubleshoong 179
10.5.1 Power Distribuon Subsystem 181
10.5.1.1 Overview 181
10.5.1.2 Details of Power Distribuon Subsystem 185
10.5.2 Control Power Subsystem 186
10.5.2.1 Details of Control Power Subsystem 188
10.5.3 Controller Communicaon Subsystem 189
10.5.3.1 Overview 189
10.5.3.2 Details on Controller Communicaon Subsystem 189
10.5.4 Axes Drive Subsystem 191
10.5.4.1 Overview of Axis Drive Subsystem 191
10.5.4.2 Details of Axis Drive Subsystem 203
10.5.5 Spindle Drive Subsystem 207
10.5.5.1 Overview 207

Chapter 1
19
UM10349_PCNC1100_Manual_0916A
Preface
11. Diagrams and Parts List 218
11.1 Upper Mill Assembly (exploded view) 218
11.2 Lower Mill Assembly (exploded view) 221
11.3 Electrical Cabinet 223
11.4 Connecons 225
11.5 Stepper Connecons 226
11.6 Operator Panel 227
11.7 Ribbon Cable and Miscellaneous 228
11.8 Lubricaon System 230

Chapter 1 20 UM10349_PCNC1100_Manual_0916A
Overview
1. Overview
Tormach PCNC mills are intended for use as general purpose CNC mills. Pictured below is a typical
PCNC 1100 mill set up, including several opons.
Item # Component Item # Component
1 Electrical Cabinet 6PathPilot®Interface
2Serial Number Plate
Main Disconnect Switch
7Keyboard Table
8Machine Arm (2)
3 Red E-stop 9 Path Pilot Controller Compartment
4 Green Start Button 10 Storage Compartment
5 Operator Panel 11 Coolant Compartment
Figure 1.1
5
7
8
9
11
2
3
4
8
10
16