Tormach BT30 User manual

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©Tormach® 2021
TECHNICAL DOCUMENT Version 0521A
INSTALLATION GUIDE
BT30 SPINDLE UPGRADE KIT FOR 1100M+

PURPOSE
PURPOSE
This document gives instructions on installing the BT30 Spindle Upgrade Kit for 1100M+.
LOOKING FOR A VIDEO?
Before you begin, select the image below to watch a walk-through video of this entire installation
procedure.
PRODUCT INFORMATION
Product: BT30 Spindle Upgrade Kit for 1100M+ (PN 50472)
Quantity Description
1 9-Position Terminal Block (PN32634)
1 1100MX Spindle Belt(PN50402)
1 BT30 Spindle Cartridge Assembly, 1100MX (PN39590)
1 BT30 Clamping Unit Installation Tool (PN 50385)
Note: Keep this item to use in the future if you need to replace the pull stud clamping unit.
This item isn't used in this installation procedure.
1 Cord Grip (PN 38758)
3 Cable Tie (PN32791)
3 Cable Tie Holder (PN33193)
1 Magnetic Encoder, Readhead (PN 38299)
1 Motor Pulley Spacer, 1100 (PN30347)
2 Screw, Button Head Cap (Flanged), M5 × 0.8 - 10, Stainless Steel (PN 38205)
1 Spanner Wrench (38-42 mm) (PN31038)
1 VFD, 1100MX(PN 35716)
Note: If any items are missing, we can help. Email [e-mail] to contact Tormach Technical
Support for guidance on how to proceed.
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TD10705: Installation Guide: BT30 Spindle Upgrade Kit for 1100M+ (0521A)

REQUIRED TOOLS
REQUIRED TOOLS
This procedure requires the following tools. Collect them before you begin.
l3 in. (7.6 cm) wooden block, 2
l6 in. Gear puller
lFlat-blade screwdriver
lMetric hex wrench set
lOpen-ended wrenches:
l13 mm
l19 mm
l25 mm
lPhillips screwdriver
lSafety eyewear
lSimple Green (or similar mild degreaser)
lTorque wrench
lWD-40® (or similar water displacement oil)
BEFORE YOU BEGIN
lM+Upgrade Required You must use servo motors with the BT30 spindle. If you haven't yet done so, install
the 1100M+ Servo Upgrade Kit (PN39274).
lPower Drawbar Required You must have a power drawbar to use with the BT30 spindle. Depending on
what's installed on your machine, do one of the following:
lTTSPower Drawbar Installed Use the TTS to BT30 Power Drawbar Conversion Kit (PN 50474) to
upgrade your existing power drawbar.
lNo Power Drawbar Installed Install the 1100MX/770MX Power Drawbar Kit (PN 50433).
lKeep All Hardware To install the BT30 spindle, you'll reuse many items currently used on the machine.
Keep all hardware unless you're specifically instructed to discard it. If you don't, there's a risk that you won't
have the hardware you need to complete the installation.
lPathPilot v2.4.2 or Later Required Only PathPilot v2.4.2 and later has settings required to use an MX
mill configuration. For information, go to "Update PathPilot" (page4).
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TD10705: Installation Guide: BT30 Spindle Upgrade Kit for 1100M+ (0521A)

UPDATE PATHPILOT
UPDATE PATHPILOT
Before you begin to install this kit, you must verify that the PathPilot controller is updated to the latest version of
PathPilot. This is because only PathPilot v2.4.2 and later has settings required to use a BT30 spindle mill
configuration.
To update PathPilot, do one of the following:
l"Download and Install an Update File from the Controller" (below)
l"Install an Update File from a USB Drive" (on the next page)
Download and Install an Update File from the Controller
1. Confirm that the PathPilot controller is powered on and out of Reset mode.
2. Downloading and installing an update file requires an Internet connection. From the Status tab, confirm that
the Internet button LEDlight is on. Then, select Update.
Figure 1: Update button on the Status tab.
3. From the Software Update dialog box, select Check Online.
Figure 2: Software Update dialog box.
4. Select Install.
Figure 3: Install button on the Software Update dialog box.
The update file is downloaded, and a notification dialog box displays.
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TD10705: Installation Guide: BT30 Spindle Upgrade Kit for 1100M+ (0521A)

INSTALL AN UPDATE FILE FROM A USB DRIVE
5. From the dialog box, select OK.
The update file is installed on the PathPilot controller.
6. Follow the on-screen instructions to restart the PathPilot controller.
Install an Update File from a USB Drive
1. From the PathPilot support center, download the most recent PathPilot update file.
2. Transfer the PathPilot update file to a USB drive.
3. Put the USBdrive into the PathPilot controller.
4. Confirm that the PathPilot controller is powered on and out of Reset mode.
5. From the Status tab, select Update.
Figure 4: Update button on the Status tab.
6. From the Software Update dialog box, select Browse.
Figure 5: Software Update dialog box.
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TD10705: Installation Guide: BT30 Spindle Upgrade Kit for 1100M+ (0521A)

INSTALL AN UPDATE FILE FROM A USB DRIVE
7. From the Browsedialog box, select USB.
Figure 6: Browse dialog box.
8. Select the desired update file, and then select Update.
The update file is installed on the PathPilot controller.
9. Follow the on-screen instructions to restart the PathPilot controller.
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TD10705: Installation Guide: BT30 Spindle Upgrade Kit for 1100M+ (0521A)

INSTALLATION
INSTALLATION
Complete the following steps in the order listed:
Remove the R8 Spindle 7
Install the BT30 Encoder 17
Install the BT30 Spindle and Align the Encoder 22
Install the VFD 29
Verify the Installation 32
Remove the R8 Spindle
Tip! For more information while removing original components of the machine, it may help to
refer to the "Spindle Head Exploded View" (page35).
Prepare the Machine
1. Remove any tooling, fixtures, workpieces, or parts from the machine.
2. Jog the spindle nose until it's approximately 6 in. (15.2 cm) above the machine table.
3. Power off the machine and the PathPilot controller.
a. Push in the machine's red Emergency Stop button, which removes power to motion control.
b. From the PathPilot interface, select Exit.
c. Turn the Main Disconnect switch to OFF on the side of the electrical cabinet.
4. Disconnect any pneumatic air lines on the machine, and verify that the lines are empty.
5. Open the spindle cover and lock it in the upposition.
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TD10705: Installation Guide: BT30 Spindle Upgrade Kit for 1100M+ (0521A)

REMOVE THE POWER DRAWBAR
6. Disconnect the spindle motor quick-connect fitting.
Figure 1: Spindle motor quick-connect fitting disconnected.
7. The procedure varies based on your tool changing method. Depending on what's installed on your machine,
do one of the following:
l"Remove the Power Drawbar" (below)
l"Disassemble the Original Drawbar" (page10)
Remove the Power Drawbar
1. Confirm that the top air line is labeled Top, and the bottom air line is labeled Bottom. If the air lines aren't
labeled, label them.
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TD10705: Installation Guide: BT30 Spindle Upgrade Kit for 1100M+ (0521A)

REMOVE THE POWER DRAWBAR
Figure 2: Power drawbar air lines labeled.
2. Disconnect the 1/4 in. air lines from the top and bottom push-to-connect fittings on the power drawbar
cylinder.
Figure 3: Power drawbar air lines disconnected.
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TD10705: Installation Guide: BT30 Spindle Upgrade Kit for 1100M+ (0521A)

DISASSEMBLE THE ORIGINAL DRAWBAR
3. Use a 5 mm hex wrench to remove the shoulder screw from the base plate. Then, pull out the quick-release
pin.
Figure 4: Components to remove on the power drawbar.
4. Remove the power drawbar cylinder.
5. Go to "Remove the R8 Spindle" (page12).
Disassemble the Original Drawbar
CAUTION! Loose Objects Hazard: The original drawbar contains spring-loaded hardware, which could
quickly become loose, causing serious injury. Before disassembling the original drawbar, you must put on
safety eyewear that meets ANSI Z87+.
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TD10705: Installation Guide: BT30 Spindle Upgrade Kit for 1100M+ (0521A)

DISASSEMBLE THE ORIGINAL DRAWBAR
1. Put on safety eyewear.
2. While using one hand to hold the spindle lock arm, use the other to remove the spindle lock arm pivot screw
with a 5 mm hex wrench.
Figure 5: Spindle lock arm pivot screw removed from the original drawbar assembly.
Note: The spindle lock arm assembly contains spring-loaded hardware, which could quickly
become loose.
3. Carefully remove the spindle lock arm.
Figure 6: Spindle lock arm removed from the original drawbar assembly.
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TD10705: Installation Guide: BT30 Spindle Upgrade Kit for 1100M+ (0521A)

REMOVE THE R8 SPINDLE
4. Remove the spindle lock base with a 5 mm hex wrench.
Figure 7: Spindle lock base from the original drawbar assembly.
5. From the spindle door, remove the spindle lock arm with a 4 mm hex wrench.
Figure 8: Spindle lock arm on the spindle door.
6. Go to "Remove the R8 Spindle" (below).
Remove the R8 Spindle
7. Remove the existing drawbar assembly (including its spring washers) and the R8 collet with a 13 mm and 19
mm open-ended wrench.
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TD10705: Installation Guide: BT30 Spindle Upgrade Kit for 1100M+ (0521A)

REMOVE THE R8 SPINDLE
Figure 9: Removing the existing drawbar.
8. Release the tension from the spindle belt, and then remove it from the machine.
Figure 10: Removing the spindle belt.
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TD10705: Installation Guide: BT30 Spindle Upgrade Kit for 1100M+ (0521A)

REMOVE THE R8 SPINDLE
9. Loosen the three set screws on the pulley retention nut with a 3 mm hex wrench.
Figure 11: Loosening the retention nut's set screws.
10. Remove the pulley retention nut from the machine with the spanner wrench (provided). The pulley retention
nut secures the power drawbar flange, pulley, and pulley spacer, which are keyed to the spindle shaft.
Figure 12: Removing the retention nut.
11. Remove the power drawbar flange.
Note: You'll remove the spindle pulley later in this procedure.
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TD10705: Installation Guide: BT30 Spindle Upgrade Kit for 1100M+ (0521A)

REMOVE THE R8 SPINDLE
12. Power on the machine and the PathPilot controller.
a. Turn the Main Disconnect switch to ONon the side of the electrical cabinet.
b. Twist out the machine's red Emergency Stop button, which enables movement to the machine axes and
the spindle.
c. Press the Reset button.
d. Bring the machine out of reset and reference it.
13. Remove five of the socket head cap screws that secure the spindle flange to the head casting with a 6 mm
hex wrench. Set them aside.
Figure 13: Six socket head cap screws retain the spindle flange.
14. Loosen the remaining socket head cap screw.
CAUTION! The spindle secures to the head casting with six socket head cap screws on the bottom face
of the spindle nose. Once you remove them, the spindle will begin to fall out of the casting. You must
rest the spindle on a block of wood before removing the final socket head cap screw. If you don't,
there's a risk of injury or machine damage.
15. Center the machine table: from the PathPilot interface, in the MDILine DROfield, type G20 G53 G1 X9
Y-5.5 Z0 F20. Then select the Enter key.
The machine table moves to the center position.
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TD10705: Installation Guide: BT30 Spindle Upgrade Kit for 1100M+ (0521A)

REMOVE THE R8 SPINDLE
16. Put a 3 in. (7.6 cm) wooden block on the machine table below the spindle nose.
Figure 14: Spindle nose on the wooden block.
17. Slowly lower the spindle until the spindle nose is on the wooden block.
18. Remove the remaining socket head cap screw with a 6 mm hex wrench. Set it aside.
19. Slowly jog the Z-axis up (+Z) to raise the head casting until you have enough clearance to remove the spindle
pulley.
Note: You may need to move the spindle pulley back-and-forth as the Z-axis moves up in order to
remove it.
20. Continue to jog the Z-axis up (+Z) to raise the head casting until you can remove the spindle.
21. Discard the following items:
lDrawbar
lPower drawbar flange
lR8 collet
lRetention nut
lSpindle
lSpindle pulley
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TD10705: Installation Guide: BT30 Spindle Upgrade Kit for 1100M+ (0521A)

INSTALL THE BT30 ENCODER
Install the BT30 Encoder
1. Remove the spindle motor's pivot plate clamping handle.
2. Remove the M10 socket head cap screw from the pivot bushing.
Figure 15: Components to removing the spindle motor and its pivot plate assembly from the spindle head.
3. Remove the spindle motor and its pivot plate assembly from the spindle head.
Set the assembly aside.
4. Slowly jog the Z-axis down (-Z) until the spindle motor housing is in a convenient location to work in.
5. Power off the machine and the PathPilot controller.
a. Push in the machine's red Emergency Stop button, which removes power to motion control.
b. From the PathPilot interface, select Exit.
c. Turn the Main Disconnect switch to OFF on the side of the electrical cabinet.
6. Clean the inside of the spindle motor housing with Simple Green (or similar mild degreaser).
7. Find the encoder read head and its two button head cap screws provided in this kit.
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TD10705: Installation Guide: BT30 Spindle Upgrade Kit for 1100M+ (0521A)

INSTALL THE BT30 ENCODER
8. Install the encoder read head on the head casting with the button head cap screws using a 3 mm hex
wrench. Leave the encoder just loose enough to make final adjustments later in this procedure.
Figure 16: Encoder read head installed on the head casting.
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TD10705: Installation Guide: BT30 Spindle Upgrade Kit for 1100M+ (0521A)

INSTALL THE BT30 ENCODER
9. Route the wire from the encoder along the floor of the casting, up behind the spindle door switch, and up
through the energy chain.
Figure 17: Encoder wiring management.
Tip! We recommend using a piece of heavy-gauge wire as a pull to route the encoder wire
through the energy chain.
10. Identify surfaces on which to secure the encoder wire to the machine with the provided cable ties and cable
tie holders. Then, clean the surfaces where you'll put the cable tie holders.
11. Put all three cable tie holders in the locations that you just cleaned.
12. While holding one of the cable tie mounts, secure the encoder wire with one cable tie. Repeat for all cable
tie holders. Once finished, verify that the encoder wire won't become entangled or damaged.
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TD10705: Installation Guide: BT30 Spindle Upgrade Kit for 1100M+ (0521A)

INSTALL THE BT30 ENCODER
13. Identify the knockout holes on the top of the electrical cabinet. Remove one, and put one provided cord grip
in its place.
Figure 18: Cord grip installed in place of one knockout hole.
14. Find the encoder wire that you routed through the energy chain. Then, route the wire through the cord grip
and into the electrical cabinet.
15. Open the electrical cabinet door.
16. Find the 9-position terminal block provided in this kit.
17. Identify the pin connection locations on the terminal block. Pin 1 is closest to the small triangle on the
outside edge of the connector, as shown in the following image. Pins 2 through 8 follow in sequential order.
Figure 19: Triangle on the terminal block, which indicates the location of pin 1.
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TD10705: Installation Guide: BT30 Spindle Upgrade Kit for 1100M+ (0521A)