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PCNC User Manual

1. Ki Dynamic Machining gt New zj Parameters wi Run _ Reset Name i 5 Job list B M gE RwTop ER a M 4E RwBottom ER 4E RW Front 3 E M 4E RwBack Eu ii V Machine Tool Feedrate Toolpath Parameters Strategy WV Workpie Restricti w 2 C Scallop V Holes E ee Step byZ Distance Z D of tool Quantity 9 C Clear flats Deviation Outer 0 2 Tools Inner z 0 i oe L 7 Figure 4 16 The machined test piece Virtually any other commercially available CAD CAM systems can be used with the PCNC control software because of its compliance with industry standards CAD CAM software is configured to generate appropriate code for a particular machine tool by a post processor You should consult Tormach for advice on the best post processor option to purchase with your preferred software Using Tormach PCNC 1100 Series II 4 8 31138 Rev B1 4 4 4 4 4 1 4 4 1 1 4 4 1 2 From an idea to a part Programming with Wizards There will be situations when a simple piece of one off machining has to be performed and you do not have suitable CAD CAM software or perhaps the machine user is unfamiliar with the software that is available The Wizard facility built into the Control Software is an ideal solution Machining Wizard Concept Xcore i Final Cut Depth A Wizard is a special screen that is ice PS A a ax
2. Pari E T1 fem_0 25i Operation 1 i A E Part_1 T3 fem_im Operation 1 tf PocketMilling 6 GOO G17 G40 G49 G80 G30 TOOL COMMENT IS NOT FOUND M996 T3 M06 G00 G90 G54 X 0 0892 1 7348 56306 M03 G43 H3 21 M08 OPERATION NAME OPERATION 1 F31 5 MILLING POCKET GOO X 0 0892 1 7348 20 1 v Apply IESE F Autoapply PocketMilling 6 Time Oh 02m 40s RO 30 in S Figure 4 8 Path of tool and G code Smodet TPaceri a Using Tormach PCNC 1100 Series II 4 4 31138 Rev B1 4 From an idea to a part conventional milling to a depth of 0 5 with each pass being 0 1 deep The CAM software will generate a G code program for this In some freestanding CAM software if the size of the slot is changed so the drawing changes then you would have to create the pocket G code for the slot from scratch with each revision of the drawing Integrated CAD CAM software will work dynamically with the CAD and automatically recreate the new G code with each change in dimension A reasonably sophisticated CAM program will give you a choice of views of the finished part and the path of the tool as it is manufactured Figure 4 8 is a screen shot of a typical CAD CAM program and shows the toolpath for one version of the slot It is shown in a plan view together with a pane which displays the G code generated to perform the operation Figure 4 9 is th
3. cccceeeeeees 5 8 Tormach Machine Controller cccccceeeeeeees 2 8 Tormach Tooling System ONES ists hates E E tia ET E E E A a ten 5 3 Touching techniques ccccccsesecceseeceeseeeeeeeenes 6 6 Transportation of machine ccccceeeeeeeeeeees 9 54 Troubleshooting AXIS drive SUD SYSCEM cece cceeeeeseeeeeeeeeeees 9 31 computer control communications 9 29 control POWET ss essseesssesssesssessserssersserssersseeo 9 26 Electi cal riannee a 9 53 Frequently Found Problems 006 9 20 mechanical rerea e 9 53 OVET VIO W ia e e e alate 9 15 DAOSO IY ane a hana les 9 15 power distribution seesseesseesseersseesserssees 9 23 spindle drive sub systeM cccccseeeeneeeees 9 45 ra E E E E ture EE ie ET 9 19 TTS Tormach Tooling System ccceeceeees 5 3 TTS tooling inserting ANd removing ceeeeeseeeeeseeeeeeeeees 5 4 Typographics conventions in this manual U Unary operators denned arien E E E E 7 8 Un installation of driver TV AUUA xr at PEE A EEEE 10 16 Units inch degree ans millimetre cccceeeeeees 7 3 Unpacking new machine cccceececseseeeeeeeeees 2 4 Unusual modes when Control Software is running 5 13 W Windows Optimisation procedures cccceeeeeeeeeeeeees 10 16 Wizard checking code output by cccceeseeceeeeeeeees 4 10
4. Figure 9 20 Power distribution portion of schematic Details of the Power Distribution Sub system The PCNC is powered by a user provided nominal 230 1 60 230 V single phase 60HZ 20 Amp 3 wire electrical circuit in North America and a 220 1 50 20 Amp 3 wire electrical circuit in most other parts of the world Tormach allows the voltage range to be from 200VAC to 250 VAC The 2 current carrying conductors of this supply are connected to the Tormach disconnect switch located on the right side of the electrical panel When this disconnect switch is in the off position no power is applied to the main machine Find the relevant portion of the electrical schematic highlighted below You may find it helpful to have your electrical schematic available to use along with this discussion RIGHT SIDE 15 7 31 x 32 INSIDE DOOR OUTSIDE DOOR WO MOUNT PLATE wo ROTTOM Figure 9 21 Machine Cabinet Component Locations for Power Distribution In addition to the main electrical supply to the machine provisions are included so the user can supply a second electrical circuit to the cabinet This second circuit is used to provide power to Using Tormach PCNC 1100 Series II 9 26 31138 Rev B1 4 9 6 5 2 31138 Rev B1 4 Warranty Specifications Customization and Troubleshooting the computer and monitor and to the coolant pump The power source for this circuit is 110 1 50 115 1 60 or 220 1 50 single phase power wi
5. displayed on demand by the Control Software It has a series of Ss P DROs with which you define the a T i EH Gare cuts that need to be made Figure nee 4 17 shows the general appearance oe l Iam of a surfacing Wizard Tool Offset Y Ez lamp Figure 4 17 General view of a typical Wizard screen Selecting and Running a Wizard The Wizards gt Pick Wizard menu displays a list of Wizards which are installed on your control computer Wizards can be obtained from a variety of online sources and you can modify a standard one or write your own from scratch Figure 4 18 shows an example of what the list could contain Click on the Wizard that you want to use and click Run Notice that a list that is too large to fit in the dialog has a scrollbar but rather unusually it is on the left hand side of the list The Wizard screen will replace the screen currently visible Standard Wizard Features err Fane HER E Figure 4 19 shows a Wizard al Function Name for milling a circular pocket cut spline or gear Digitize Wizard Author Description Drill Circular Bolt Pattern Brian Barker Brian Barker Cut Circle Brian Barker Cut Splines and Gears Brian Barker Creates Digitzing Program Art Fenerty As many different authors write Wizards there are detailed differences between the screens but each one should have the following Creates Digitzing Program 4rt Fenerty Speed and Feed Table
6. Notes for all operations You can use these operations with a part program loaded or indeed with one partly run say to an optional stop The probing will however set the Control Software to Absolute Coordinates G90 No rotation G69 No axis scaling G50 and cancel canned cycles G80 Figure 8 13 Z Probing screen j Z Probing Figure 8 13 shows the Z probing screen It has two distinct functions depending on whether the probe is in the spindle or a normal tool is in the spindle and the tool setter is connected to the probe input The yellow buttons perform machine moves and set offsets Depending on the button these will be the Z offset in the current work offsets or the length of a tool Important If the probe or tool setter is not properly connected then the Control Software will keep moving even when the probe touches or the setter is touched This can cause the probe tip to be crushed or the cutting edges of the probing tool to be chipped on the carbide top of the setter the PCNC is very powerful Each time that you connect up the probe or tool setter you should check that the screen Figure 8 14 Probing Z Using Tormach PCNC 1100 Series II Machine upgrades and configuration LED marked Test probe before use lights when you gently displace the tip or cap The red lights in the device will illuminate too but the screen LED is a more complete test We strongly recommend use of the Jog Shuttle control
7. Now set the work offset with it touching the work to Z 0 0 by any of the gauging methods described above Now jog the Z axis so you can load each tool holder in turn Enter its number into the T DRO Jog and gauge by any of the touching methods already used but instead of entering the gauged position into the Z axis DRO you must always enter it into the Touch Correction DRO and click the tool Touch button marked Length not any of those in the Work Offsets column For completeness enter the diameter of the tool in the Tool Diameter DRO Do not forget that you have to press Enter to accept values typed into DROs Ea E R Z 0 0 lt 1 w peme wd Figure 6 20 Toolsetter 4U GAU GAU bot4 oog G43 HH GE applied vy In Program coord Goto Tool Change 0 0000 etC Onoff E Figure 6 19 Setting up a conventional tool holder as tool 4 TE 3 53005 Tool length E 3 1500 i Height inches E Sensor What you are doing is setting the lengths of all the tools relative to the Master Tool Figure 6 19 shows this having been done for tool 4 Tool table with the Tool Setter If you have the Tormach Tool Setter then this can easily be used to set entries in the tool table Details are given in Chapter 8 figure 6 20 Comments on Tool Offsets If you do not save the Tool Table then when you close down the Control Program you will be asked if you want to save it Unless you have
8. 9 6 4 1 Warranty Specifications Customization and Troubleshooting There is no polarity to resistance so either lead can be placed on either location we are having you measure however resistance measurements are always taken with power off Note When making resistance measurements on motors and other devices with low resistance always take a tare or zero reading on the meter before doing the resistance measurement on the motor or device A tare reading is a reading using only the instrument In the case of using a digital multi meter to measure resistance touch the probes together to get the tare reading Subtract the tare reading from the meter reading when measuring the resistance of the motor to get a true value Contacting Technical Support info tormach com 608 849 8381 There will be times when your troubleshooting efforts don t end up solving a problem There are a number of things that will make problem resolution easier should your be required to contact Tormach Technical Support 1 Always have the serial number of your machine 2 Tell Tormach if you have had the problem before Tormach uses a case management system for tracking problems If you contacted us in the past with a problem you should have a case management number which will be helpful to us 3 Tell us if you bought the machine from someone else and have the name of the party available so that we can consult our case management system for problems that m
9. The three types of item whose order may vary on a line as given at the beginning of this section are word parameter setting and comment Imagine that these three types of item are divided into three groups by type The first group the words may be reordered in any way without changing the meaning of the line If the second group the parameter settings is reordered there will be no change in the meaning of the line unless the same parameter is set more than once In this case only the last setting of the parameter will take effect For example after the line 3 15 3 6 has been interpreted the value of parameter 3 will be 6 If the order is reversed to 3 6 3 15 and the line is interpreted the value of parameter 3 will be 15 If the third group the comments contains more than one comment and is reordered only the last comment will be used If each group is kept in order or reordered without changing the meaning of the line then the three groups may be interleaved in any way without changing the meaning of the line For example the line g40 g01 3 15 so there 4 7 0 has five items and means 31138 Rev B1 4 7 9 Using Tormach PCNC 1100 Series II 7 5 8 7 6 Programming language reference exactly the same thing in any of the 120 possible orders such as 4 7 0 g01 3 15 g40 so there for the five items Commands and Machine Modes The Control Software has many commands that cause a machining system to ch
10. axis DRO to define the new Work Offsets Again check that the door is shut Click Cycle Start to run the program to cut the pocket Figure 3 10 shows this partially done When the pocket is completed the machine will stop and rewind the program so it can be used to cut another copy of the part The completed piece is Figure 3 11 The completed part shown in Figure 3 11 You can compare this with the CAD CAM visualization in figure 3 7 31138 Rev B1 4 3 5 Using Tormach PCNC 1100 Series Il Making your first part 3 3 5 Summary This chapter has allowed you to make your first part with the PCNC Although it is fairly simple it would be very difficult to make without a CNC machine When you are experienced you should be able to design and make something like it from scratch in about 45 minutes You might have wondered about some of the things that you were told to do Why did you cut the text then remove half its depth with the pocket Could the system be told how long each tool is so you do not need to touch tools each time you make a part Could the part be made in steel with the same program These are all good questions What you were told to do was to make this first part in the easiest way not necessarily the quickest or most accurate Subsequent chapters will tell you the answers to these questions and give you the understanding to make the right design and manufacturing decisions for yourself This experience and
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12. step 2 finally click on Apply step 3 6 Now click on the Startup tab 7 Click on Disable All then Apply Some people prefer to have the PCNC software called out in the Startup group so the control program is running as soon as the computer is turned on In this case leave that as the only Startup program 8 Click OK to complete 10 3 4 2 Disable Power Management 1 Right click on your desktop and then click Properties 2 Click on the Screen Saver tab 3 Set Screensaver to None 4 Press the Power button near the bottom 5 Set all options to NEVER shut down automatically 10 3 4 3 Disable sound card Background The Control Software emits a Beep sound when it executes a G code commen i e text in round brackets Some sound cards inhibit interrupts and can cause lost steps when doing this The trouble can happen even if no speakers are attached to the computer e Open the Control panel and double click on the icon or line for System e Select Hardware and click Device Manager e You will be shown a list of devices and their drivers Locate Sound Video and Game controllers Use the to expand the tree if necessary Right click on any driver gives 31138 Rev B1 4 10 17 Using Tormach PCNC 1100 Series II Appendices the option to Disable it Do this for all sound devices on the system there will usually only be one 10 3 4 4 Disable Automatic Updates 10 3 4 5 Background Automatic updates can initiate a CPU ste
13. G1 X1 Y4 5 make alignment move to point C G41 Gl Y3 5 turn compensation on and make first entry move to point B G3 X2 Y2 5 Il make second entry move to point A Figure 6 34 shows the two entry moves but not the alignment move First pick a point A on the contour where it is convenient to attach an entry arc Specify an arc outside the contour which begins at a point B and ends at A tangent to the contour and going in the same direction as it is planned to go around the contour The radius of the arc should be larger than half the diameter given in the tool table Then extend a line tangent to the arc from B to some point C located so that the line BC is more than one radius long After the construction is finished the code is written in the reverse order from the construction Cutter radius compensation is turned on after the alignment move and before the first entry move In the code above line N0010 is the alignment move line N0020 turns compensation on and makes the first entry move and line N0030 makes the second entry move In this example the arc AB and the line BC are fairly large but they need not be For a toolpath contour the radius of arc AB need only be slightly larger than the maximum possible deviation of the radius of the tool from the exact size Also for a toolpath contour the side chosen for compensation should be the one to use if the tool is oversized As mentioned earlier if the tool is undersized the interprete
14. G56 58 G59 G61 G64 G68 G69 G73 Q Gi Q QO Uo O Canned cycle peck drilling Canned cycle boring no dwell feed out Canned cycle boring spindle stop rapid out Canned cycle boring spindle stop manual out Canned cycle boring dwell feed out Absolute distance mode Incremental distance mode Offset coordinates and set parameters Cancel G92 etc Inverse time feed mode Feed per minute mode G95 Feed per rev mode Initial level return after canned cycles G99 R point level return after canned cycles Figure 7 3 Table of G codes Using Tormach PCNC 1100 Series II 7 12 31138 Rev B1 4 Programming language reference If cutter radius compensation is active the motion will differ from the above see Cutter Compensation If G53 is programmed on the same line the motion will also differ see Absolute Coordinates Note that the GOO rapid move should have two gt The GOO command is used to move the tool quickly from one point to another without cutting thus allowing for quick tool distinct movements to ensure that vertical moves are always separate from horizontal moves In a typical rapid move toward the part positioning the tool first rapids in the flat horizontal XY plane Then it feeds down in the Z axis When rapiding out of a part the GOO command always goes up in the Z axis first then laterally in the XY plane Depending on where the to
15. Mach3 License Installation ssc s2acscsaccansenoscasnocasponmnaacsannoansdinsaaansennasaasanssannsemmeonsaanned 2 9 Machine Controller Maintenance and Configuration cccccsecccceececeeeeeeeeseeneeeeeeeeeeseneees 2 9 Login and Software Installation cccceccccseccceesecceeeceseecsnseceesceesusesseeeesnsesauees 2 9 1iContents 2 8 Connecting and Running the PU NC 6 ccssssisecscsssssscnsecssicussaenssnsstesassssanssesssieetnasssscteessieasc 2 10 28 Mam Switch and Control Panel sis cscs anodes a a 2 10 2 8 2 Changing the Spindle Speed Range vessistsoverc sles ca steer stasis iseeendaaiawanieawawmsennete 2 12 2 8 3 Computer Control of the Spindle and Coolant ccccccccccccseseccseeeceeeceaeseceeeeeaeseeaeneens 2 13 2 8 4 MODI for Entering G and M code Commands ccccccccceecccseeeeceeseceeseeeaeseeaneeeaeseeseneens 2 13 28 VOD OIIO INCA CS cag fait rsd as Oped be a Dan ears doa e a eae tedeaduadels a 2 14 2 9 SULTRY EAE A AE E E AEE E E E T A EEE TEA 2 15 3 Making Your First Part cccccssscseseeeseeeeeeenseeeseeneeenseonseeeseeeasenees 3 1 3 1 Coordinates se aeoaea ae ea aee eE ESE oaao 3 1 ILT Rercrenc noie Mach Menruren konkan uror una oo a sti ialc 3 1 3 2 Loading a Demonstration Program ssecssecssecsscosscccseecseocseecssecseecssecoseccseesseecseecsseesseo 3 2 3 3 Running the Demonstration Part program ssssecssscccsseecssseccsseesssecosseecosseccssecsoseessseeo 3 3 So Part Mi
16. Never use longer or larger tools than necessary 19 Chips and dust from certain materials e g magnesium can be flammable Fine dust from normally non flammable materials can be flammable or even explosive 20 Chips and dust from certain materials can be toxic Vapours from certain overheated materials can be toxic Always check a Materials Safety Data Sheet MSDS of suspect materials Refuse machining work requests of unknown materials 21 If you are in any doubt you must seek guidance from a professionally qualified expert rather than risk injury to yourself or to others 1 2 Personal CNC Concept The PCNC 1100 Series II is a machine tool intended to make CNC machining more personal As with the evolution of personal computers the evolution of personal CNC alters the paradigm of what a machine tool is about We aim for a machine tool so affordable that anyone can have one We feel that the work of engineers inventors technicians hobbyists educators and others will be enhanced when they have access to CNC machinery In education each student can run his own machine instead of waiting in line when the machine tool costs less than 20 of a small machining center In R amp D turn around on prototype design takes minutes instead of days when a machine is at the ready and on site In general engineering designs sent to the production machine shop are improved when the design engineer has been more involved in the prototype creat
17. Offsets 6 8 Cutter Diameter Compensation 6 8 1 CAD CAM and Wizards We have shown how it is necessary to allow for the diameter of the tool when cutting around an object or cutting out a pocket You are strongly advised to do this by your CAD CAM software or the Wizard which generates the part program The advantage of it being done this way is that the software has knowledge of the future path of the tool so can avoid overshooting on sharp inside corners In general this cannot be done by the control software Some systems allow code written by hand of by CAM to be fine tuned when it is run by adjusting the diameter of the cutter We advise against trying to do this with the current version of the Control Software Generate code by using CAM or writing by hand to move the centre of the cutter along the path that will give you the cut you require with the planned diameter of cutter In other words avoid the use of G41 or G42 commands You are unlikely to need to read the remainder of this chapter which describes the actual operation of the Control Software 6 8 2 Concepts for Cutter Diameter Radius Compensation The standard mode is for cutter compensation to be off G40 Without cutter compensation the machine will follow a tool path that is defined by the G code program With cutter compensation turned on G41 G42 the actual path the machine follows will be offset left or right of the stated path by an amount specified in the tool off
18. Using Tormach PCNC 1100 Series II 4 10 31138 Rev B1 4 Machine controls 5 Machine Controls This chapter gives a description of all the PCNC controls on the operator s panel and the Control Program screens If you have been through the section Running the PCNC in Chapter 2 you already have a good grounding and may wish to skim through this chapter on first reading of the manual and come back to it when you want to understand exactly how some feature works 5 1 Machine Operation 5 1 1 Operator s Panel The operator s panel is illustrated in figure 5 1 It generally controls the PCNC directly and is independent of the software in the control computer When the Spindle and Coolant switches are in the Auto position then control of these functions is given to the computer y si i j 3o sf E Figure 5 1 Operator s panel Main Switch The main switch is mounted on the right hand side of the control cabinet A padlock can be inserted to lock it in the off position It controls the 230 volt power to the main machine and the separate power from the IEC inlet under the control cabinet to the computer and coolant system Note Disconnect the machine from the wall outlets before opening the control cabinet door as it is possible that live terminals can be touched even when the isolator is in the OFF position Computer On Off This rocker switch controls the power from the IEC inlet to the two outlet
19. mad Yel x 1 Y1 x1 Y1 xL Y 1 5 G40 GO X Leo ha aL MA p spindle GET Using Tormach PCNC 1100 Series II 6 16 31138 Rev B1 4 Offsets The result of the offset is that the planned 2 x 2 block is cut out A composite drawing figure 6 30 shows this along with the tool diameter Now let s look at a slightly different example to see what can go wrong The example below is nearly identical but a slightly different starting point is used which is 0 25 lower in Y At first glance it seems fine Example 2 G17 G20 G40 G49 G50 G64 G90 G94 M6 T1 G43 H1 Select tooll GO al M3 S1000 Start Spindle Algo L LiS Gl Z 50 G41 turn on cutter compensation Gi X1 Y 1 x 1 r l xed YL Xl Y1 XL VAL G40 GU X 1aS Yl aL MS M30 begin at X1 50 Y 1 25 end at X1 25 Y 1 50 Figure 6 30 Example 1 overlaid position above lead in point Z down to cutting level Actual Tool Path with Cutter Compensation G Code Path i J begin at X1 50 Y 1 50 WS n Y Ee PED begin at X1 50 Y 1 50 end at X1 25 Y 1 50 Figure 6 31 Toolpath in example 2 The coded path and resulting compensated tool look similar but the lead in here is coming in at a 45 degree angle Looking at the combined result figure 6 32 we what might seem correct 31138 Rev B1 4 iba at X1 50 Y 1 50 KX KY S at X1 25 Y 1 50 Figur
20. with finger dimple will jog by one Step as defined in the Step DRO for each click The move will be made at the current feed rate r HeH ES 2s Hi Low on Spindle Speed Control Family Max Speed 2000 RP hl The machine spindle can be controlled in two ways a S 5O by hand or b by switching to Auto on Operator s panel thus making the speed and direction set by the Control Software S S This control family is only important for case b The S DRO has its value set when an S word is used in ____ Spindle CV CWFS l a part program It is the desired spindle speed It can S also be set by typing into the DRO figure 5 13 Coolant Ctrl i It is an error to try to set it in either way to a speed Figure 5 13 Spindle speed greater than that displayed in Max Speed for the chosen control family pulley and the nearest legal value will be chosen The Hi Lo button toggles between the two belt pulley settings with the LEDs indicating the configuration spindle on left motor on right The maximum available speed is indicated Using Tormach PCNC 1100 Series II 5 8 31138 Rev B1 4 9 2 2 5 Machine controls The S and S buttons increase and decrease the value in the S DRO geometrically using a ratio of 1 15 for each click on the button This reflects the usual arrangement of gearbox in a manual machine tool The spindle can be started in a clockwise direction by the Spindle CW button An M code M4 in the MDI box is
21. 0 0000 0 0000 0 0000 Figure 6 2 Open tool table All Tool Entries are in your default setup measurement units inegardiess of G20 G1 modes Apply OK Figure 6 3 Tool table e Select the three tools to use we ll use the touch off tool as 1 and the cutting tools of drill end mill and face mill as 2 3 and 4 e Use the Config menu to open the tool table figure 6 2 It will look something like figure 6 3 e Using the TTS height gauge the standard spacer and the granite block measure the tools adding each one s name and length to the table The touch tool 1 length is measured when the dial indicator pointer reads 0 Figure 6 4a Figure 6 4d Figure 6 4b Figure 6 4c e Here are the measurements we took Tool Number Height Tool 1 Touch Tool 7 084 Tool 2 Drill 16 7 151 Tool 3 End Mill s rougher 4 396 Face Mill1 5 face 4 115 The completed table will look like figure 6 5 Note The Diameter Wear and Height Wear values in the table should have data in them as they are ignored by the current version of the control software Using Tormach PCNC 1100 Series II 6 2 31138 Rev B1 4 Offsets ToolT able l l x i Description DiameteriD Height tH Diam Wear Heightyear a in Ref Tool 0 0000 0 0000 0 0000 0 0000 Touch Tool O 0000 O64 0 0000 0 0000 3 16 twist drill O 0000 7 151 0 0000 0 0000 3 8 rougher 0 0000 4 369 0 0000 0 0000 4 1 5 Face mill 0 0000
22. 0 0025 in length with a 10 degree F change in temperature Adjusting Geometry It s not unheard of for a machine to need adjustment All of the iron castings of your machine undergo thermal stress reliving Major elements such as the column and base also undergo a vibratory stress relief process between rough machining and final machining Never the less it is possible that any iron casting can change shape a small amount whether due to changes in the crystalline structure over time or changes induced through tool crashes and abuse Before making any adjustment think carefully about the need for the adjustment and implications associated with it As an example consider the G6 test on your machine QC specification sheet This is simply mounting a dial indicator on the spindle about 4 from the spindle center then measuring the variation in distance to the table This is sometimes referred to as swinging the head or tramming It s an easy test to take but people often overrate the resulting measurements If there is 0 003 difference that s 0 003 in 8 or 0 00035 per inch This will put your milling out of square such that with a 3 8 end mill the flat bottom will be off by 0 00014 and the sidewall on a 1 thick piece will be slanted by 0 00035 The errors introduced by tool flex and other issues will be far larger so for most applications the error is acceptable and does not need correction Using Tormach P
23. 0 is not allowed If the repeat feature is used it is normally used in incremental distance mode so that the same sequence of motions is repeated in several equally spaced places along a straight line In absolute distance mode L gt 1 means do the same cycle in the same place several times Omitting the L word is equivalent to specifying L 1 The L number is not sticky When L gt 1 in incremental mode with the X Y plane selected the X and Y positions are determined by adding the given X and Y numbers either to the current X and Y positions on the first go around or to the X and Y positions at the end of the previous go around on the repetitions The R and Z positions do not change during the repeats The height of the retract move at the end of each repeat called clear Z in the descriptions below is determined by the setting of the retract mode either to the original Z position if that is above the R position and the retract mode is G98 or otherwise to the R position It is an error if e xX Y and Z words are all missing during a canned cycle e AP number is required and a negative P number is used e AnL number is used that does not evaluate to a positive integer e Rotational axis motion is used during a canned cycle e Inverse time feed rate is active during a canned cycle e Cutter radius compensation is active during a canned cycle When the XY plane is active the Z number is sticky and it is an error if e The Z
24. 1 FAULT SPINDLE ON J1 4 NOTE ORDER OPTIONAL LOAD METER OF WIRES T1 to LM1 J1 2 FROM T5 TO B1 to LM2 GRN WHT B2 TO B4 T6 TO LM3 aie B3 TO LM4 VFD WIRING DETAIL STEPPER MOTORS 31036 400 MOTOR White Wire White Wire WIRE 30541 aa L26 SEALE 206 A Black Wire WHITE 2040r203 N YELLOW X Drive p GREEN X Drive RED Y Drive Green Wire a hi VHITE Y Drive 404 Ground roun YELLOW Y Drive GREEN Y Drive Wire 30258 AC Inlet 30177 AC Outlet RED Z Drive Number Back View Back View WHITE YELLOW A Drive Multi Color 14GA STEPPER MOTORS to STEPPER DRIVER 30737 Wire Colors Tools and Related Items preload on ballscrew mount bearings Two wrenches are needed 3Uoa spindle speed calibration Includes case 31138 PCNC 1100 Manual Replace your old manual with the latest version Spiral bound Manual PDF can also be downloaded from www tormach com Touch Up Paint Dark Gray 2 5 oz matching the lower section of the stand Original paint is oil 30572 based touchup is latex Optical Tachometer 100 000 RPM laser optical tachometer 5 digit digital display Useful for Touch Up Paint Light Gray 2 5 oz matching the PCNC 1100 and the upper section of the stand Original paint is oil based touchup is latex 30571 DIN connector 5 pin This is a plug that will fit in the accessory jack on the front of the machine 30624 cabinet 30482 CPC connector reverse gender T
25. 1750 Rewind Ctrl W ___ Spindle CW F5 es 3 CHANGE TOOL Ji 2 2 al 2 at Pause spc Empty A z off 3 000 er _ Coolant Ctrl C D 0 000 MDI Regenerate Toolpath Jog Follow Job l L f E RESET D RaidJunk NCParts test2c tap E Histo Cleat MILLING POCKET PCNC M3 R2 6 SRev6 7 Program Run G Co des M Co des Simple Run CtLAlt 4 Comp Run Alt 1 MDI Alt2 Tootpath ans Offsets Alt 5 Settings Alt6 Diagnostics Alt Figure 4 10 Keyhole loaded and ready to run The CAM program will write the G code part program to disk Assuming you are using a different computer to design your part from that controlling the machine you need to transfer the file to the hard drive of the control computer Then you can load and run it in the same way you did for the FirstPart program Figure 4 10 shows the keyhole loaded into the Control Software Note Do not attempt to run part programs off a USB key drive or floppy disc CAD CAM Systems Vectric Cut 2D is a 2 2D system which will accept DXF drawings from virtually any source has powerful features and is very easy to learn If you already have a favorite CAD program then this will be a good choice for you to do CAM work Block of XMotorMount Figure 4 12 Model for mount Figure 4 11 Motor Mount DXF Figure 4 11 shows a DXF drawing of a mounting plate for a motor This was produced from the solid model in figure 4 12 but could have been
26. 2 Appendix 2 Exploded Parts VieWS sccsccecssccssccsscesscesscecscecscecsscesscesscesscesscesscecsseeseeo 10 1 10 3 Appendix 3 Use of a Standard PC to control PCNC essssessssecssseecsscesossesossesssseessoe 10 12 10 3 SCNOICEOF compute a e a a aa a 10 12 10 3 2 Optimizing the Windows Installation ccccccccescccsesecceeeccascceeneceseseeseusecseseesensessanss 10 13 10 33 _ Iinvstallane the Control SOM ware icc sicoslktec idan Sencdick a deci doal a a donload 10 13 PO S50 AUSTIN oat a a veto dost desl tontsbash daeideel a betalanl Jani dank boo udent Sendak brodenhds 10 13 IOS Vital RE DOCU enr leet elated bec ilael Soak dosh tot e loat dee lenl Soatdant tec udanl soatdosh bent deaks 10 14 IOo Westin then staan cestsshtistdatident saetdasl doles peat donk ben ulenh dead dat br Gdent ieatdashbro utente 10 14 10 3 3 4 DriverTest After a Software Crash cccccccscccsseccceeeecenecenseseceuscensuseseuseensnsesees 10 15 10 3 3 5 Manual Driver Installation and Un installation cee ceccccseeeceeeeecneseeeeeeeeaes 10 15 10 34 Optimization OL WIndows X P wenden sieidestooldcetdoss dowytonedeelt sasienaleees deshtouseandusseieentoabensddenndeess 10 16 10 3 4 1 Remove Unnecessary Services and Startup Programs ccccsecccsseeeeeeseeeeeeeenes 10 17 10 3 4 2 Disable Power Management cccccccsescccseccceeseceencecaeececansecseseceenseeseseeseneeeaes 10 17 ROSAS Disable sound tardo errea
27. 20 31138 Rev B1 4 7 7 12 2 7 7 12 3 Programming language reference e The current point is less than 0 01 inch 0 254 millimeter from the programmed point e G31 is used in inverse time feed rate mode e Any rotational axis is commanded to move e No X Y or Z axis word is used In response to this command the machine moves the controlled point which should be at the end of the probe tip in a straight line at the current feed rate toward the programmed point if the probe trips then the probe decelerates After successful probing parameters 2000 to 2005 will be set to the coordinates of the location of the controlled point at the time the probe tripped not where it stopped or if it does not trip to the coordinates at the end of the move and a triplet giving X Y and Z at the trip will be written to the triplet file if it has been opened by the M40 macro OpenDigFile function q v Code in macros or screen buttons can determine if a point is a trip or just the end of the move by inspecting if the DIGITIZE input is active after the G31 command or comparing the axis DROs with the requested move Using the Straight Probe Command Using the straight probe command if the probe shank is kept nominally parallel to the Z axis 1 e any rotational axes are at zero and the tool length offset for the probe is used so that the controlled point is at the end of the tip of the probe e Without additional knowledge about the probe t
28. 4 9 9 Using Tormach PCNC 1100 Series ll Warranty Specifications Customization and Troubleshooting The nut nearer the bearing housing is the adjustment nut and the one nearer the stepper motor is the lock nut When working on the Z axis you should remove any tooling from the spindle and support the head by resting the spindle nose on a block of lumber Loosen the lock nut and back it off about two turns Hold the ballscrew to prevent it from rotating with a pair of pliers on the coupling and tighten the adjustment nut until there is Slightly more backlash than you ultimately want to achieve tightening the lock nut will slightly increase the bearing preload Figure 9 6 Feeling preload in bearings There are two possible methods to judge the preload a You can use a dial test indicator to measure backlash between the ballscrew end and the structure to which the bearings are mounted table for X axis or machine frame for Y and Z axes b You can estimate the torque required to turn the ballscrew in the bearings If you are aiming for the smallest possible backlash then we suggest that you do both as it is not possible to be certain that you do not have excessive preload by just measuring backlash Figure 9 7 Tightening the lock nut To estimate bearing drag torque you need to eliminate the stepper detent torque and the ballnut friction This is done by allowing the stepper mounting box to r
29. A E A A 7 3 7 2 Interpreter Interaction with Controls esssesseecssecsseecseecseocscecssecseecsseccseccseosscecssecsseosseo 7 4 Fek BeCGsand Speed Override COMMONS simia a E E 7 4 Tee SBIOCKID Clee CONT O lasiuveseate aust atacsiccssnetnaeetocsbacesnwinee NTAN 7 4 Too Opona Propran Stop CONO lkara hautyaenddaveceusanivarnednecetdiatweeeies 7 4 7 3 OOM MG casos iis Gales e a ced du deced cntsev dua Covsawaiaauatwia GavdewidewssteadGosaededeesses 7 4 7 4 Part prosrams Landat esseede eenen a teers ceieusieestecesccuaevalecsteceavevecesescstecs 7 4 BEL SOV RVC Whicker es eles ished terion Geen tia hati AEA aan eanauetamon be naianbaetet 7 4 Pia Parane ea isla E he latte aedaas Uses yee asians nc seseaeaaa lace av eiouidandud ua ead Sate 7 5 TAS COOKUIMALES VSUCING este tiitet dared E r E R 7 5 7 5 Formattme Code Lines Block iccsstetccciscccscccateccsecevesscviasesseutuccessedeteisaceaevevevteducesuiateasevess 7 5 Tok Ee a1 elo caren eee ee ee ee Ee NOT I oe oR RE 7 6 ee DUDO ne LADE 6 raataa e e a EE EE EA aba E 7 7 i aT 10 EEPE EAE EA E ES EAE A ES EA E E A ES E A E ET 7 7 Tee e N O a A ee E AE E AA A EA 7 7 PI P er VAC e e E E AE E EE A OE N IEA 7 7 7 5 3 3 Expressions and Binary Operations ccccceccccsececceeeeceeseeceneecsesceeenseesseeeenseeaenes 7 8 T5534 mary Operation Value eierne a Cans ied bon ete aE eea ERa ISe EEN 7 8 Tad Parmeter SeH eaeoe a a a es eu E eden 7 8 oD Commentsand MESSIOS seeker dieu c
30. A E ree 8 14 8 3 Auto reverse tapping sssssccsscecseccscecssecssccssecsseesseocseecssecssecssecssecssecsseecssecssecsseesseesseesoe 8 14 9 Warranty Specifications Customization and Troubleshooting 9 1 9 1 Intended Use Statement ecseccccccccccecccoccecccocceccecccoccecccoccecceosceccecccoccecceoscecceescoccecsceccecseo 9 1 9 2 PEND QE ee E 9 1 This manual ALWAYS the first place to check nnnonnnnseennssennsseensssersseerssseeo 9 1 e Related documents found at http www tormach com documents html 9 1 e Our websile ai Wo TIom kare n Ee aE EE EE 9 1 e Em il to mio tormach GOM ossinirne eee a EP 9 1 e Telephone Tormach at 608 849 838 1 oo ccccccseecceeeecceeeeeneneeeseeesenseesseeseneeeees 9 1 e Fax I ormach at 2O0D 35 26 98 ost acti ctsiatninconnaesotaianoiycsaientutavantasashesdtiownivenseesigeaie 9 1 9 3 Outside of the Scope of Intended Use sssssssccsssscccsssscccsssscccsssscccssssccccscssccsssscoees 9 1 9 4 PPC MIC OS eancrecetccsspcceucevasatensrsccsateuecssvecsscctansnocatecccsceeassnecteecssesucdusscuseeussusnetscecetsesecass 9 2 DAL INTC COMA CAMs ee E E E sintered 9 2 242 Pleci ah soc a cele ass siespae icselap stern aedefisnelnaneemdwan detent 9 2 a e E NN sear EN eo ign mea ee steeped entrance ngage A yan N EE E E E E NE 9 3 Dea PIOS eE A E E E AE EAE AEE EA EEE EE EE E 9 3 9 5 Moni enAnCE oeiia oa s 9 3 9 5 1 Foreword Understanding Machine Design ecn
31. Cable Connections There are a number of cables on a PCNC Some are flat cables connecting the Tormach Control Board to the Axis Drives and other devices and some cables connect with the computer An improperly seated cable can allow some functions to work and others to not work We have found that the ribbon cables plug connections can become loose during the shipping process Software Restart It is rare but not impossible that the application software can get confused imagine that If an unexplained problem is occurring it may be worthwhile to restart the application in the case of the PCNC it is the Mach3 software It is usually not required to restart the computer but being a relatively easy thing to do it should be considered Sensors on the PCNC the End of Travel Sensors Sensors are one of the largest causes of problems with any machine On the PCNC the X and Y Axes have limit switch which actuates at the end of travel in each direction of both axes The Z axis on earlier machines has 2 limit switches one for up and one for down Newer machines have one for the up direction These sensors will be discussed at length in the Axis Troubleshooting section of the manual Flaky Computer Computers can exhibit some intermittent problems A number of Tormach customers have purchased used computers for a song but ended up singing the blues Remember the computer you bought on E Bay or the like were probably being sold for a reason Lo
32. Contents LLU Reer nee ines FCI S Ee mereseh satan wear eahemarande cna eaten caste E TEE ESEA 7 20 Pel aante Probes Cs Mem nem a S irr terrae eewere rs Serre ie 7 20 Datel ok Srah PROBS COMTAN siesta arco abo Mot hs tenactalte ta ae ctestncchatere etaleeaertedre ceiutntaees 7 20 7 7 12 2 Using the Straight Probe Command cc eecccccccccseecceesecceneceaeneecseseceeseeeensesaanes 7 21 Rs i ee EE CO eeu rrmen er rereener a eter Tetere rar errrar re 7 21 7 7 13 Cutter Radius Compensation G40 G41 and G42 0 ccc ceeccceeecceeeecaeeeeeaeeesneneens 7 22 7 714 Tool Length Offsets G43 G44 and G49 nsssesssesssessserssersserssersserssersseesssesssersserssersseess 7 23 Dekel Scale Pacos r 50 AIG Gr Wess oh cans sre aicet E ose tcc easoaeaeautalee 7 23 7 7 16 Temporary Coordinate System Offset G52 ecccccccseecceesecceeeeeseeeeeseeeseneeeeeseeseneees 7 23 7 7 17 Move in Absolute Coordinates G53 20 cecccccccccsescecseeeceeneecaeseeseneeeseseeeeneeeaeneesaneeeneneegs 7 24 7 7 18 Select Work Offset Coordinate System G54 to G59 amp G59 Pr eccccseeeeeteeeeneneees 7 24 1 119 Set Path Control Mode G61 and GOl arrena ede a a a bead davtaatars 7 25 7 7 20 Coordinate system rotation G68 and G69 sseesseesssenssessserssersserssersssrsssessserssersseess 7 25 7 7 21 Canned Cycle High Speed Peck Drill G73 iieri ai a a RS 7 25 ale Cancel Modal Moton Cre pais ecstatic atin a a titative tntettaa Wa
33. EAE AE E EAE 2 7 Power TOO BOING orenen senses vsseshsiancsossscesssbeasussuasedesssoesesssessisense 2 7 Power for Machine ACCESSOMIES tiisiavenscdesvecexciscersedeivecsusescureesesuasaucbevancedsaueceudhetentediiuessucas 2 7 Tormach Machine Controller and Software Installation cccccccsssssscccsssssscceeees 2 8 OMT OIG OTM LSE oee E E E E udagiueousona nonusers E 2 8 Pere Up Your CONTE OMEE sosissanssasnossatananescsestocnssasansa ccanmaeasaadandanceutobeatadsodscaenmedsccantoassnenied 2 8 Positioning The COM ONEL iccss2 2icssans seandenasacaniancanndorsaamaiaancanpbosnannnanansonaiansadanoannnonnad 2 8 Keyboard anid MOUSE peerenenmerernere ter eerereret te rrerrete rrr rrr er rerertr err rrr csr rer ererctt rere rere 2 8 DUS VAY osc tecaneneaaenonaaaana E N 2 8 Speaker and Microphone Connections ccccsececescecseseceeneeceescceeueeeseseeeenseeseeeees 2 9 Power Connections cccsecccceeecceesecceeeeeaeeeeeeeeeseneeeseeeeaeeeeesaeeeseneeeaaeesaeneesanseeaanes 2 9 Operaline the Controlle cosa cricsoasssancooaahensnnsnsannnonstaetananseanseaadataaaiaconmannsdeinodantenmeansaumnoonnbentee 2 9 About the Operating System s esseesseesseesseesseersseessersseessersssrossessseessersserssersseess 2 9 Pra CMS he COMET OUICL snosascssncasconsaeascansocns sontennssanecinaonaidnc santana Eirne 2 9 Stopping th controller sci csac scans gensaeascansocas santana sanoetaootaiansaaatoonbetsanmsaanmonaiaeananasennas 2 9
34. GCode FirstPart nc pm ae Run the Control Software and make sure iene aegis the screen LEDs by Reset button are not Joc flashing and that the axes are referenced Cycle Stari AHR Click the OpenG button You will be al norpan given a Windows open file dialog Rewind Cow oe Fa 7 Navigate to the G code folder and open _Povse ore A er i the file figure 3 3 S GE ANN NETA Figure 3 3 File opening You will see the code of the program in the window at the left of the screen and the path that the tool will take in the toolpath display Use the mouse to drag with the left hand button in the toolpath display to rotate the display It behaves as if it is drawn inside a clear ball and the mouse turns the ball lls Scale Scale pal Size x xpa gt ilal e Size Y So that you understand what is going to happen we should look at the way this file was produced using a Computer Aided Design Computer Aided Manufacturing CAD CAM program The PCNC will produce parts designed Pos x Pos Delta Delta 2 in a N S Ro Ar AO RX Z AA i al Ee in any available industry standard tools Kie AJ re Tormach offers a number of powerful E a yet reasonably priced software tools some of which are used as examples in this manual 2 y E amp Model Paper 1 j lt p gt NN Diria Figure 3 4 The drawing for FirstPart Using Tormach PCNC 1100 Series II 3 2
35. Go lt 3 3115 Y1 8122 1I 0 9890 30 0000 0250 G01 x3 5 940 Bass n a aa 1 8122 1 1 2515 30 0000 an mO270 GO 0280 P A Spt iral pocket Through Mill Router 0 375 inch diamete eae 290 2 3799 0306 20 0197 310 G01 20 0000 F1 4969 z EEEE EEEEELEETEEEEEEEEEEEE yA Sas g Ss fa Revd The Control Software can remember all the MDI lines as it g 0 1 y2 1 executes them and store them in a file by using the Teach facility Click Start Teach enter the Figure 5 20 MDI and Teach control family required commands and then Using Tormach PCNC 1100 Series II 5 12 31138 Rev B1 4 5 2 2 11 5 2 2 12 5 2 2 13 Machine controls click Stop Teach The LED blinks to remind you that you are in Teach Mode The commands are written in the file with the conventional name C PCNC3 GCode MDITeach tap Clicking Load Edit will load this file so it can be run or edited in the usual way you need to go to the Simple Run or Comp Run screen to see it If you wish to keep a given set of taught commands then you should Edit the file and use Save As in the editor to give it your own name and put it in a convenient folder Loop Control Family The Control Software can execute a part program many times automatically Cycles i q updating a limit to the depth to which the Z axis can move figure 5 21 Step amim Loop Active Z inhibit _ 0 750 _ Onott E Figure 5 21 Loop control The part
36. II Warranty Specifications Customization and Troubleshooting Axes Drive Sub System Checklist Table 4 5 Axis movement is extremely noisy Possible Cause Prob a Bad Capacitor for DC Bus Board Loose wire connection Action to identify Cause of Problem On 4 digit serial number machines turn off control power and unplug the lower connector contains 6 wires all labeled with 300 series numbers from all of the electronic axis modules With the cabinet door open turn on control power While observing the green LED on the DC Bus Board press the Stop button If the results are not conclusive turn off Control Power and unplug the power connectors from the axis drives Turn on control power and measure DC voltage on wires 300 common and 301 Turn off Control Power and plug the power connectors back on the axis drives Turn off power and tighten ek screw connections Bad stepper driver Medium See Table 4 2 module Wrong version of Mach Medium 3 for given machine configuration Failing control Low computer or control computer not suited for M3 Using Tormach PCNC 1100 Series II Contact Tormach Support Run DriveTest exe found in the c pcnc3 folder 9 38 Discussion This step is not required for 3 digit serial number machines Observe the green LED on the DC Bus Board illuminate If the LED extinguishes in 2 seconds or less the capacitor is bad and must be
37. In which you eg eee define your toolchange 3 0000 Q 0000 position can be configured 9999 do not move axis by the Toggle T C Units button Figure 5 25 Tool change position Note The move will take place correctly whatever units the machine is in at the time and because machine coordinates are used to a fixed place irrespective of the offsets in use The tool change position is also used when you want to use the central lubrication system This family also allows you to set the machine coordinates used if your part program executes a G28 We advise you to use the M998 toolchange location whenever possible as this checks that the machine is referenced 1 e the machine coordinates are valid G28 will use whatever values are in use irrespective of them being valid because the machine is referenced Inhibits and Overrides Control Family Axis Inhibit In testing a part program it is sometimes 5 Alp useful to be able to inhibit the movement of an axis e g typically Z This is done with the Axis Inhibit buttons figure 5 26 Overrides Auto LimitOverRide OverRide Limits Figure 5 26 Inhibits and overrides family When an axis hits a limit switch it will trigger a software EStop condition so all movement will cease If Auto LimitOverRide is enabled then you can reset the system and carefully jog off the limit If you want more security in this situation you can disable AutoLimitOverRide and click the
38. It is an error if all axis words are omitted 31138 Rev B1 4 7 13 Using Tormach PCNC 1100 Series II Programming language reference If cutter radius compensation is active the motion will differ from the above see Cutter Compensation If G53 is programmed on the same line the motion will also differ see Absolute Coordinates p gt Q2 2 PISA Ss fo Linear Interpolation or straightline feed G01 command using multi axis moves on the flat XY plane no Z values feed moves All diagonal feed are specified moves are a result of a G01 command where two or more axes are used at once Sample Program G01EX2 Workpiece Size X4 Y3 Z1 Tool Tool 3 3 8 Slot Drill Tool Start Position X0 YO Z1 N2 G90 G80 G40 G54 G20 G17 G50 G94 G64 safety block N5 G90 G20 Block 5 absolute in inches N10 MO6 T3 G43 H3 Tool change to Tool 3 NLS MOS S1250 Spindle on CW at 1250 rpm N20 GOO X1 0 Y1 0 Rapid over to X1 Y1 N25 ZO 1 Rapid down to Z0 1 N30 GO1l 4Z 0 125 F5 Feed down to Z 0 125 at 5 ipm N35 X3 Y2 F1O Feed diagonally to X3 Y2 at 10 ipm N40 GOO 41 0 Rapid up to Z1 N45 X0 0 YO 0O Rapid over to X0 YO N50 MO5 Spindle off N55 M30 Program end In the sample program several different examples of the G01 command are shown 1 The first GO1 command in N30 instructs the machine to plunge feed the tool below the surface of the part by 0 125 in at a feedrate of 5 in min 2 N3
39. J4 cable compute l To o oS 1 30454 Disconnect switch J o o o o oS yY O 31041 Potentiometer Ef r 1A 2 OA 3 3A 4 4A 5 7 7A 7B 10 12 13 14 15 16 17 18 1 Metric size is 5x20 mm 3 amp Use Bussmann GMD 750mA Littlefuse 239003 P 2 Metric size is 10x38 mm 15A Use Bussmann KTK 15 Littlefuse KLK 15 or Ferraz ATM 15 3 Metric size is 10x38 mm 6A Use Bussmann KTK 6 Littlefuse KLK 6 or Ferraz ATM 6 4 Metric size is 5x20mm 75A Use Bussmann GMD 3A Littlefuse 239 75P 5 Control Transformer is 230 115 100VA 6 Axis Power Transformer is 230 48 500VA 7 Inch size is 1 25x 25 1 amp Use JVP AGC 1 8 Inch size is 1 25x 25 6 3 amp Use JVP AGC 6 3 9 Preprogrammed with current PCNC software 10 Fuse for dc bus board 1 4 x 1 1 4 6 amp Bussman AGC3 6A Littlefuse 312 6A Ferraz GGC 6A 11 This component is included as part of the J4 cable callout 40 PN30684 12 This is a sealed limit switch that can be used on all machines for the X axis Machines with serial number 1688 and later came stock with this switch SWITCH SETTINGS FOR X Y AXIS AND 8 INCH SWITCH SETTINGS X 302 ROTARY TABLE TOREA CAP 300 CAP 301 X 303 PIN 4 ae J6 aeir Ym Z 306 PIN 1 He Z 307 J4 31045 4 A TORMACH MACHINE A CONTROL BOARD di BRAKE RLY 328 PIN 1 J1 48VAC L25 ee 22 SWITCH SETTINGS FOR J2 48VAC L15 E 6 ROTARY TABLE T ee E ios STEPPER DRIVER 30661 DC BUS Lables and wire numbers LED2
40. OK to program using no tool length offset if none is currently being used It is strongly advised to put the G43 command on the same line block as the T and the M06 which actually implements the change If this is done then the control software anticipates the new offset during the time the operator has control for changing the tool The operator can change the work Z offset safely if this condition is met Scale Factors G50 and G51 To define a scale factor which will be applied to an X Y Z A I amp J word before it is used program G51 X Y Z A where the X Y Z etc words are the scale factors for the given axes These values are of course never themselves scaled It is not permitted to use unequal scale factors to produce elliptical arcs with G2 or G3 To reset the scale factors of all axes to 1 0 program G50 Temporary Coordinate System Offset G52 To offset the current point by a given positive or negative distance without motion program G52 X Y Z A where the axis words contain the offsets you want to provide All axis 31138 Rev B1 4 7 23 Using Tormach PCNC 1100 Series Il Programming language reference words are optional except that at least one must be used If an axis word is not used for a given axis the coordinate on that axis of the current point is not changed It is an error if all axis words are omitted G52 and G92 use common internal mechanisms in the CS and may not be used together
41. These numbers are nice round values in practice if you jogged exactly to the top left corner of the stock they will have a decimal fraction part e g 9 076 Now look at Z The jog was about 9 5 down but we put the tool exactly on the surface of the stock The program coordinate is Z 0 5 from the GOO Z0O 5 The Z offset value is actually 9 5 Adding the program coordinate to the offset gives the machine coordinate of 9 0 This is of course the distance that the head currently is below the home switch position It may seem strange at first when you have negative numbers All you have to remember is that a sum 4 3 2 1 is identical to 4 3 2 1 The offsets we have been setting are called Work Offsets as they are different for each piece of work loaded onto the machine The Z offset includes the length of the tool If you change the tool then you would have to jog so the new one is just touching the work and click Zero again 31138 Rev B1 4 6 13 Using Tormach PCNC 1100 Series Il Offsets In the next section we will see how another sort of offsets Tool Offsets can allow for the different projection of different tools from the spindle nose You are probably wondering how you can jog so that the spindle axis i e the centre of the tool is exactly over the corner of a work piece to set X 0 0 and Y 0 0 and how to safely lower the tool to the top of the work to get Z 0 0 There are many possible techniques some of which are e
42. Windows will install the driver The driver can be uninstalled rather more simply e Open the Control panel and double click on the icon or line for System e Select Hardware and click Device Manager e You will be shown a list of devices and their drivers Mach x Pulsing Engine has the driver Mach3 Driver under it Use the to expand the tree if necessary Right click on Mach3 Driver gives the option to uninstall it This will remove the file Mach3 sys from the Windows folder The copy in the PCNC3 folder will still be there 10 3 4 Optimization of Windows XP The PC running your mill does not simply send G amp M codes down to the mill rather it is intimately involved with control of the axis motors and spindle It reviews and updates electrical signals to every axis motor 25 000 times each second If your PC is busy thinking about other things there can be problems in motion control We advise you not to cut a part with the control computer connected to a network Note If you have a computer supplied by Tormach as part of your mill package then you do not need to perform the steps in this section The steps listed below will optimize Windows XP There 2 System Configuration Utility General SYSTEMIN WIN TNI BOOT INI Services Startup are a large number of Boast atl Eliasa j O riz nwiz exe finstall HELMASOFT Wi GRE MicrosoFe Windows Currentyer esoteric Windows C mcp RUNDLLS2 EXE CWL HELMISO
43. X Y 90 IPM Z 65 IPM NEMA 34 stepper motors on X Y and Z Single Shot Lube Pump 15 point lubrication Each axis has an oil distribution channel milled full length on left and right vertical and horizontal surfaces all 4 sliding surfaces plus an oil line plumbed directly to the ball nut assembly Precision ground ball screws in the X Y and Z motion ISO DIN P4 grade Complete way covers Slide ways are a bonded low friction surface PTFE filled acetyl hand scraped slide ways with milled oil distribution slots 1 Year warranty There are no on site factory service personnel Warranty service will involve replacement of components with direction from Tormach support staff 9 4 2 Electrical Spindle safety is enhanced with a tool change safety interlock and key switch lockout Main spindle contactor VFD power is automatically disengaged when operator is changing a tool Spindle M codes or manual spindle start will reengage VFD power automatically after tool change is completed Operator console has manual override for all spindle controls PC Windows Control with integrated safety amp manual overrides PC not included Windows XP or Windows Vista is required Computer control is integrated with an Using Tormach PCNC 1100 Series II 9 2 31138 Rev B1 4 9 4 3 9 4 4 9 5 9 5 1 9 5 1 1 Warranty Specifications Customization and Troubleshooting operator control panel for spindle lockout manual spindle controls
44. Z1 N2 G90 G80 G40 G54 G20 G17 G50 G94 G64 safety block N5 G90 G20 N10 MO6 T2 G43 H2 N15 M03 S1200 N20 G00 XI Y1 N25 ZO 1 N30 GOd ZO F5 N35 GOZ X2 42 dd JU F20 Are teed Cw tadis LlyJO at 20pm N40 GOUT X3 5 N45 GO2 X3 YO 5 R2 Arc feed CW radius 2 N50 X1 Y1 R2 Arc feed CW radius 2 NSS GOO 20 c NGO X2 Yaleo N65 GOL A023 N70 GO2 X2 Y1 5 10 25 J 0 25 Full circle arc feed move CW N75 G00 Z1 N80 X0 YO N85 MO5 N90 M30 7 1 4 Dwell G04 T II For a dwell program G04 P This will keep the axes unmoving for the period of time in seconds specified by the P number The tool will pause for a short time only It is an error if the P number is negative rarely more than several seconds For a definite program pause gad aes a refer to the MOO and M01 commands Tool Tool 1 1 8 Slot Mill Being nonmodal the G04 must be Tool Start Position X0 YO Z1 reentered each time Dwell is to be executed N2 G90 G80 G40 G54 G20 G17 G50 G94 G64 safety block N5 G90 G20 Absolute programming in inch mode N10 MO6 T1 G43 H1 Tool change to Tool 1 NLS M0351300 Spindle on CW at 1300 rpm N20 GU AS YE Oe Rapid TO Xora N25 G01 Z 0 125 F5 0 Feed down to Z 0 125 at 5 ipm N30 G04 P2 Dwell for 2 seconds N35 GOO X2 2051 Rapid up to 0 1 and over tOo Xz N40 G01 Z 0 125 F5 0 Feed down to Z 0 125 N45 G04 Pl Dwell for 1 second N50 GOO Z1 0 Rapid out to Z1 Non 20s Us Rap
45. a E E E AE E O OEE 10 17 10 3 4 4 Disable Automatic Updates 20 0 ceccccseccccseeeceeseeeeececseeeeseneeeeeseeeenseesesessensesses 10 18 10 3 4 5 Set Computer to Standard PC not ACPI PC 20 ceccccescccseeeeeeneeeneseeeeneeenes 10 18 10 4 Revision Nistor y visccsovecacscauccsasscscccsecevecedeceusescecescedessavecsesuaasseesereseauseseecedeusssensseveseieseevess 10 19 11 MAO o 21 31138 Rev B1 4 vii Using Tormach PCNC 1100 Series ll Preface 1 Preface 1 1 Safety Any machine tool is potentially dangerous Computer controlled machines are potentially more dangerous than manual ones because for example a computer is quite prepared to plunge a 3 diameter facing cutter at 50 inches per minute into a block of high carbon steel or to mill the clamps off your table The PCNC 1100 Series II can deliver sufficient force to break brittle tools to crush bones and to tear flesh This manual tries to give you guidance on safety precautions and techniques but because we do not know the details of your workshop or other local conditions we can accept no responsibility for the performance of the machine or any damage or injury caused by its use It is your responsibility to ensure that you understand the implications of what you are doing and to comply with any legislation and codes of practice applicable to your country or state 1 1 1 Electrical Safety Dual Power Input The PCNC 1100 has two electrical power inputs The primary s
46. a key based pendant Tormach PN 30214 Pendent 10 key USB keypad and a jog shuttle controller pendant that gives very fine control of jogging speeds and distances Tormach PN 30616 Jog Shuttle Controller 5 LCD monitor signal cables are normally too short Most inexpensive VGA signal extension cables create serious signal degradation This is particularly true with Super VGA screen resolutions Tormach PN 30280 LOFT SVGA Super VGA M F Monitor Cable w ferrites is designed to extend Super VGA signals without degradation 6 This is simply the AC power cord of the computer The Computer switch on the operator console controls a convenience outlet on the bottom of the machine control cabinet If you set the BIOS CMOS configuration in your computer to start the computer when it sees AC power then the console switch will allow you to start the computer from the console You should not shut off the computer from this switch due to issues with the Microsoft Windows operating system but you can turn the computer on from the keyboard screen controls There are several important points to bear in mind when using devices interfaced with USB Universal Serial Bus Do not attempt to run a G code program that is stored on a USB drive often called pen drives memory stocks flash drives Copy your G code files into a folder on the hard drive usually C of the control computer Remove the USB drive after making the copy Do not use external USB hubs or
47. at least one of Y and Z must be used J and K are the offsets from the current location or coordinates depending on IJ mode Y and Z directions respectively of the center of the circle J and K are optional except that at least one of the two must be used It is an error if e Y and Z are both omitted e J and K are both omitted Here is an example of a center format command to mill an arc in Incremental IJ mode GL GUA he Vile 2023 Oe AI That means to make a clockwise as viewed from the positive Z axis circular or helical arc whose axis 1s parallel to the Z axis ending where X 1 0 Y 1 6 and Z 0 9 with its center offset in the X direction by 0 3 units from the current X location and offset in the Y direction by 0 4 units from the current Y location If the current location has X 0 7 Y 0 7 at the outset the center will be at X 1 0 Y 1 1 If the starting value of Z is 0 9 this is a circular arc otherwise it is a helical arc The radius of this arc would be 0 5 The above arc in Absolute IJ mode would be GA GOZ KRO Yle AO A de SZ Using Tormach PCNC 1100 Series II 7 16 31138 Rev B1 4 Programming language reference In the center format the radius of the arc is not specified but it may be found easily as the distance from the center of the circle to either the current point or the end point of the arc Sample Program GO2EX3 Workpiece Size X4 Y3 Z1 Tool Tool 2 1 4 Slot Drill Tool Start Position X0 YO
48. by half a turn sie Offset F 1 and re lock it The cable will now be to the left figure 8 20 Neston tap e Select Point 3 Again use the round yellow button to find the center of the alignment bore If the probe was perfectly set points 2 and 3 would be coincident They probably will not be so you need to know how to adjust the screws e Rotate the probe back to the Cable Right position Figure 8 21 Controls for probe alignment e Click the Adjust Probe from 2 and 3 button The message line will display the movement required on the three screws to centralize the probe tip o On the active probe the screw opposite the connector and cable is Screw 1 and the others number clockwise looking from the top So Screw 2 is facing the control cabinet and Screw 3 is visible on the southeast side of the probe The numbers are included on the probing photographs Using Tormach PCNC 1100 Series II 8 12 31138 Rev B1 4 Machine upgrades and configuration above for additional clarity A positive number is tightening the screw and a negative number loosening it The value is millimeters which equates to turns on the Tormach probe You must loosen the screw s first then tighten the other s o On the passive probe the adjustment screws are the small Allen set screws The larger socket head cap screws are retaining screws which need to be loosened at least 1 2 turns before adjusting the set screws The set screw under the connector is Scre
49. climbs out along path IH We would prefer that the controller would either 1 stop and generate an error message or 2 cut a path from D to I avoiding the cavity created by EFGH That s not what happens This type of error is less common when doing cutter offsets and exact path planning in your CAM software as opposed to using the controller to calculate offsets 6 8 6 Other Restrictions e All moves should be longer than the amount to be offset This restriction makes it clear the increased limitations of using cutter compensation to offset for the full tool radius instead of using it to only compensate for wear tolerance or final finish depth of cut e Leadin moves should be longer than the amount you want to offset e The radius of an inside arc should be greater than that of the cutting tool e The Mach3 tool table includes both Diameter and Diameter Wear columns Always use the Diameter column even when only using G41 G42 for wear compensation The Diameter Wear data column in the Mach3 tool table is for future development and does not function as of this writing e There must not be more than 50 consecutive lines of code without a movement command e g XY positions only e Cutter compensation must not be applied or canceled on a G02 or G03 command A legal line would be G01 G42 P2 5 X20 legal G02 G42 P2 5 X20 YO R10 illegal 6 8 7 Perspective on Cutter Compensation In the past effective and affordable CAM software
50. code that uses axis words appears on the line the activity of the group 1 G code is suspended for that line The axis word using G codes from group 0 are G10 G28 G30 and G92 The Control Software displays the current mode at the top of each screen G codes G codes of the CS input language are shown in figure 7 3 and are described in more detail in this section The descriptions contain command prototypes set in courier type In the command prototypes the tilde stands for a real value As described earlier a real value may be 1 an explicit number 4 4 for example 2 an expression 2 2 4 for example 3 a parameter value 88 for example or 4 a unary function value acos 0 for example In most cases if axis words any or all of X Y Z A Br Cr U V W are given they specify a destination point Axis numbers relate to the currently active coordinate system unless explicitly described as being in the absolute coordinate system Where axis words are optional any omitted axes will have their current value Any items in the command prototypes not explicitly described as optional are required It is an error if a required item is omitted U V and W are synonyms for A B and C Use of A with U B with V etc is erroneous like using A twice on a line In the detailed descriptions of codes U V and W are not explicitly mentioned each time but are implied by A B or C In the prototypes the values followin
51. disconnect wires from the switch and tape the end of each wire to prevent shorts Apply power If the diagnostic light is on the wiring is OK and the switch is bad If the diagnostic light is off the wiring has a short circuit Please note often times a defective switch can be cleaned blow out with compressed air and sprayed with WD 40 to fix a problem Please note On some machines the stainless steel bed pan does not sit tight against the front edge of the mill bed this allows coolant and chips to converge on the X limit switch Using a bit of silicon sealer between the pan and bed will prevent this from occurring Details of the Axis Drive Sub system Motion for the X Y Z and optionally the A axis are provided by DC Stepper Motors Each motor is powered by an electronic driver module The driver module receives nominal 65 VDC power from the DC Bus Board and receives control signals from the Tormach Machine Control Board which processes and formats information sent by the control computer Find the relevant portion of the electrical schematic highlighted below You may find it helpful to have your electrical schematic available to use along with this discussion 31138 Rev B1 4 9 41 Using Tormach PCNC 1100 Series II Warranty Specifications Customization and Troubleshooting Axes Drive Sub System Checklist Table 4 8 Steps are lost on Axis Travel NOTE It is advised to also consult Table 4 2 as the information there wi
52. document addresses troubleshooting in each of several subsystems on the machine Within this major troubleshooting section are three distinct areas e An overview of the Sub system e A Problem Resolution Checklist e A Detailed Description of the Electrical Circuit A detailed description of each subsystem is provided for users who want in depth knowledge of the machine and who would prefer to take that knowledge and apply it to troubleshooting rather than to follow a checklist For those who prefer to follow a step by step procedure the Problem Resolution Checklist is provided Figure 9 16 is flowchart showing the recommended order in which to use the sections of this troubleshooting section of the manual Philosophy of Troubleshooting The PCNC1100 like many modern machines is an integration of mechanical components electrical components a computer and software Taken as a whole the PCNC is a sophisticated machine however the machine is comprised of several sub systems each of which is much easier to understand than is the machine in its entirety That in fact is the first key principle in troubleshooting sometimes referred to as the Divide and Conquer approach It is working on one problem at a time and focusing on only those things that can be related to the problem So what is the second key principle in step in troubleshooting Simply put it 1s an understanding of how the machine is supposed to work It is not possible
53. drives The most common U S usage is flash drive and we will use that from now on Please note G code programs should not however be run directly from the USB storage device Transfer the G code programs to the local hard disk remove the flash drive and run the program off the hard disk not off the flash drive The computer can have network capability but it should not be used while the machine tool is being used In particular Ethernet cards which will auto negotiate to work at 10BaseT or 100BaseT should be set for a fixed speed or you will hear a tick from the steppers every second or so during jogging as Windows takes control to negotiate network speed Do not run G code programs off a network drive or remote computer Do not allow background automatic updates to be active while running the mill Do not leave Foxfire Mozilla Internet Explorer or Netscape run in the background while operating the mill There are some features in the computer that will make operation of the PCNC more convenient Things to look for are A computer which will boot up when it sees AC power switched on rather than needing you to press a button This feature generally is controlled by a BIOS option and can be enabled by entering the BIOS configuration mode A keyboard that includes a small USB hub to plug in a USB flash drive for loading part programs Connect all other USB devices directly to the PC motherboard Using Tormach PCNC 1100 Ser
54. eS Sins sar ges how Windows connects to Windows Update for drivers Alay E F Mac Change ilins ISE 9 Driver Signing windows Update Change This ap ill Hardware Profiles See inf A eo Hardware profiles provide a way for yau to set up and store Custon Po eae different hardware configurations i 2 hangi StarkSmart i Windows Firewall coro a ee XE Hardware Protiles Eir OF Cancel Apply Figure 9 12 Finding printer port 9 5 9 Using a Non standard Printer Port There are several reasons why you may wish to use a different printer parallel port from the one on your PC s motherboard for example a PCI bus plug in card In this case you will almost certainly need to reconfigure the PCNC Control Software to use a different address from the standard motherboard address which in hexadecimal is 0x378 Use this procedure 1 Close the Control Software if you have it open 2 Click on the Start Menu and choose Control Panel 3 On the top left hand side click on Switch to Classic View Note If it says Switch to Category View that means you have already switched to Classic View 4 Double click the System icon Choose the Hardware tab and click on Device Manager 6 Find the Ports COM amp LPT icon and click on the plus sign figure 9 12 shows the result of these steps 7 Double click on ECP Printer Port LPT1 wording may differ depending on your system If you are looki
55. enclosed vertical machining centers incorporate high volume coolant systems that make the inside of the machine look like the inside of a dishwasher The PCNC electrical cabinet and operator console should not be exposed to such conditions Additionally there should never be an enclosure or accessory that limits access to the emergency stop Please keep these limitations in mind when you plan your configuration If your prior experience is limited to manual mills then keep in mind that as CNC dramatically extends your machining capabilities it will also change the way you cut metal When your metal cutting is done by turning handles on a manual mill your operations will generally be limited to cleaning up a surface drilling a hole pattern or cutting to a dimensional Figure 2 1 An example mounting on stand outline With manual milling many people are accustom to dry cutting clearing chips with a small brush as they go 31138 Rev B1 4 2 1 Using Tormach PCNC 1100 Series II Preparation With CNC you have a whole new world open to you In many cases you may turn the majority of the stock into chips cutting a shape out of a solid block of metal the way Michelangelo would cut a sculpture from a block of marble Unless you are limiting yourself to cutting cast iron wood printed circuit boards or certain other materials you will probably want a coolant system on your machine Mist coolant can be effective for keeping your cutting to
56. end of travel bumper wedged against the motor mount casting this occurs sometimes after a limit switch failure and is more common on the Z axis Stepper Drivers have See electrical schematic wrong DIP switch in the back of the settings manual Note new steppers from Tormach will require the user to set these DIP switches at installation Additional Notes on Lost Steps In the spirit and philosophy of this guide divide and conquer has no better application than in the case of trouble shooting loss of position or lost steps Please note that as a general rule a properly operational Tormach PCNC being used in overloaded cutting situations should experience a spindle stall or a broken cutting tool long before an axis sees so high a cutting force that it stalls or skips Keeping this in mind it is worth mentioning that the vast majority of problems that are mistakenly associated with lost steps are actually due to one or more of the following 1 Improper use call out of machine offsets such as G54 55 as well as G43 2 Tool pull out as a result of a cutter or holder not secured properly 3 The wrong diameter tool used in the CAM program i e many 1 2 end mills aren t actually 500 inches 4 Machine referencing to the part was performed improperly and or relying on the end of travel limit switches to set machine offsets 5 Fixturing does not secure work or does not facilitate repeatable mounting of work from one pi
57. execute the macro M6End and continue running the part program You can provide Visual Basic code in the macros to operate your own mechanical tool changer and to move the axes to a convenient location for tool changing if you wish You are strongly advised to put the T the M06 and the G43 H on one line block of code See G43 for more details 31138 Rev B1 4 7 33 Using Tormach PCNC 1100 Series II 7 8 4 7 8 5 7 8 6 7 8 7 7 8 8 7 9 7 9 1 Programming language reference Coolant Control M7 M8 and M9 To turn mist coolant on program M7 To turn flood coolant on program M8 To turn all coolant off program M9 It is always OK to use any of these commands regardless of what coolant is on or off Re run from First Line M47 On encountering an M47 the part program will continue running from its first line It is an error if M47 is executed in a subroutine The run can be stopped by the Pause or Stop buttons See also the use of M99 outside a subroutine to achieve the same effect Override Control M48 and M49 To enable the speed and feed override program M48 To disable both overrides program M49 It is OK to enable or disable the switches when they are already enabled or disabled Call Subroutine M98 To call a subroutine program M98 P L or M98 P Q The program must contain a letter O line with the number of the P word of the Call for instance O1 O125 O777 This O line is a sort o
58. fon Be probe must be plugged Min gone pos in to the socket on the i PCNC control panel a toate before move and hence be connected to the computer and the Z height must be low For detailed manual control of probing go to Comp Probing Aha enough so the probe e E CA PCNC3 GCode T ormachkmasAnnotated tap tip will actually touch sherry Christmas rica mr the work G Codes M Codeg _ STOI Pan CIARN Comp Run ANA MOI Ah l Footpath ana osons an5 Sering an Diagnostics Ah KY Probe CH ARE Z Probe ANS j Important If the Figure 8 10 Simple XY Probing probe is not properly 31138 Rev B1 4 8 5 Using Tormach PCNC 1100 Series ll Machine upgrades and configuration connected then the Control Software will keep moving even when the probe touches the work This can cause it to be bent Each time that you connect up the probe you should check that the screen LED marked Test probe before use lights when you gently displace the tip The red lights in the probe will illuminate too but the screen LED is a more complete test We strongly recommend use of the Jog Shuttle controller for jogging the probe position because it combines precision with speed If you hit anything while jogging the machine does not stop and although the probe tip has a lot of over travel there is a risk of bending it or breaking the ruby tip You are also advised to set the current tool number to 99 when you insert the probe into th
59. for areas of CAD CAM CNC which are new to you Tormach sales can help point you in appropriate directions 2 2 Receiving Unpacking and Checking Shipment 2 2 1 Moving the Crate The PCNC is supplied on a standard pallet and can be offloaded from a truck with a tailgate lift and moved on smooth surfaces using a hydraulic pallet jack This makes delivery very economical figure 2 3 Remove the crate top and sides with care as the axis drive stepper motors are in vulnerable places figure 2 4 The crated system weighs less than 1300 Ibs 600 kg nevertheless it requires mechanical handling to move it over rough ground and to lift it onto the stand Tormach advises you to employ the services of a specialist rigger if the machine has to be moved in situations where the pallet lifter cannot be used or where there is no crane to lift the machine onto its stand It is possible to improvise using a small trailer a portable engine crane and similar tools if there is no alternative but this risks injury to you and damage to the machine 2 2 2 Uncrating and Inspection After uncrating you should check the contents against the parts listed on the packing slip and inspect the machine for any damage incurred during transit so any claims can be made within the carrier s deadline 2 3 Assembling Y axis Drive The PCNC is supplied with the Y axis drive motor mechanically disconnected You are advised to mount it before attempting t
60. logical If operations are strung together for example in the expression 2 0 3 1 5 5 5 11 0 operations in the first group are to be performed before operations in the second group and operations in the second group before operations in the third group If an expression contains more than one operation from the same group such as the first and in the example the operation on the left is performed first Thus the example is equivalent to 2 0 3 1 5 5 5 11 0 which simplifies to 1 0 0 5 whichis 0 5 The logical operations and modulus are to be performed on any real numbers not just on integers The number zero is equivalent to logical false and any non zero number is equivalent to logical true Unary Operation Value A unary operation value is either ATAN followed by one expression divided by another expression for example ATAN 2 1 3 or any other unary operation name followed by an expression for example SIN 90 The unary operations are ABS absolute value ACOS arc cosine ASIN arc sine ATAN arc tangent COS cosine EXP e raised to the given power FIX round down FUP round up LN natural logarithm ROUND round to the nearest whole number SIN sine SQRT square root and TAN tangent Arguments to unary operations which take angle measures COS SIN and TAN are in degrees Values returned by unary operations which return angle measures ACOS ASIN and ATAN are also in degrees T
61. manual coolant control and PC power control e Digitizing amp tool touch off port optically isolated e Coolant or accessory AC outlet The AC outlet for coolant is automatically controlled via M codes while the operator console offers a convenient manual override e PC or accessory AC outlets manually controlled on the operator console e Power requirements Machine tool 200 to 250 VAC single phase Auxiliary 115 VAC coolant system and computer USA System e Complete RS 274 G amp M codes implementation with virtually unlimited program size Conventional G amp M code operations are complemented with manual mode operations operation wizards Operation Wizards allow pocketing surfacing cutouts drill patterns and other standard operations to be completed without the need for addition software or manual code writing e Supported codes include GOO Default Positioning Rapid Traverse G01 Linear Interpolation G02 Circular Helical Interpolation CW G03 Circular Helical Interpolation CCW G04 Dwell G17 Default Circular Move XY Plane G18 Circular Move ZX Plane G19 Circular Move YZ Plane G20 Default 06 Inch Input G21 Millimeter Input G40 Default Cancel Cutter Compensation G41 Cutter Compensation Left G42 Cutter Compensation Right G50 G51 Scaling G52 Special offset G53 Work Offset Cancel G54 G59 Work Offset G74 Incremental Input I J K G75 Default Absolute Input I J K G80 Default Canned Cycle C
62. material meaning that it always obeys Hooks Law 31138 Rev B1 4 9 3 Using Tormach PCNC 1100 Series Il 9 5 1 2 9 5 1 3 9 5 1 4 Warranty Specifications Customization and Troubleshooting and will distort linearly in proportion to applied force In simple terms it acts like a spring Small force small distortion large force makes for a large distortion Precision dial indicators are also wonderful things The ability of a 20 indicator to show motion of a distance 0 0002 is amazing This sort of distance is outside the scope of normal human experience In the context of a dial indicator the iron and steel of your mill no longer seems rigid The motion of the frame under force becomes quite apparent You should know that this flexibility is natural You would see more flex on an 800 lb machine and less on an 8000 lb machine One of the keys to creating accurate parts with your mill is developing an awareness of machine flex The flexure of the machine and the cutting tool are the principle reasons that a light finishing cut yields a more accurate part There are of course many other implications that flex has in planning your machining processes such as the direction of cutting climb versus conventional milling tool geometry and much more Backlash Friction and Lost Motion All machines will show backlash Conventional backlash is the result of open spaces between moving parts For example most ball bearings have clearance bet
63. material if we also know the diameter of the part in the rotary axis The Control Software will take this value from the Rotational Diameter DRO on the settings page ee E 4 Ae N 7 4 Pa i g A 5 Note This feature only applies to coordinated moves A single G01 move of the A axis will use the feed rate defined by the F word as a number of degrees per minute L Figure 8 1 Engraving on a cylinder 31138 Rev B1 4 8 1 Using Tormach PCNC 1100 Series ll 8 1 3 8 1 3 1 Machine upgrades and configuration Fourth Axis Applications General use of a fourth axis requires CAD CAM software that will create a part program using the A axis but useful work can be done with three axis software Engraving on a Periphery of a Cylinder If you can engrave in X Y with a Wizard or CAD CAM software then it is easy to adapt an X Y part program to use the fourth axis figure 8 1 The rotary table is mounted with its axis parallel to the X axis The work to be engraved is mounted on a mandrel supported by the tailstock It is of course important that it runs true or the depth of the engraving will be uneven The engraving is prepared as if it to be engraved in the X direction 1 e the height of the letters is movement of Y The code may not use G02 or G03 arc commands There are then three stages in engraving on the cylinder a the part program is converted to be motion in A and X instead of X and Y b t
64. mode E EEE AEA E AE EA EES A AEN 7 30 Incremental IJ mode ec cecceeeeeeeeeeeeees 7 16 Inhibits and overrides control family 5 14 Installation CERO S AMON cs sie caacuesusetuieaon me asec 10 15 Of control SOftWALE cece cee cec cece eeeeeeeseees 10 13 of driver manya Mpa ee DU PE ERS CEN 10 15 Intelligent labels GSCI OC eana aaa even baa aa 5 6 Intended use policy if use is Out Of SCOpe ssensseesseesseessees 9 1 SEACCMICIIG OL uien a aii 9 1 NSOLALOR uriini ita See Main switch J Jerky motion with short lines Constant velofity mode to avoid seseessees 7 3 Jog Shuttle controller cece ccecccsesecceeseeeeeeeenes 5 8 Jogging Mirec domo isa vanes ti enevcdotauatdednstobedenaRaieone 2 15 DOS SIM OCA CS r T E OE TE 2 14 Jogging PENAANL cececeececsescccseseceeeeeeeseeeeeeees 5 16 L Laser finder methods civicisivisheteeveestirrtesteeaieaees 6 12 Learning and Training cccceccccseeeeeeeeeeeeeenes 2 3 Par SOLO stand oeira 2 5 Lighting for Machine cccsescceseeeeeeseeeeeeeenes 2 2 Line formato code siuii iaaii 7 5 Line DRO descr Det a retaslonatede nies eenen e ee 5 10 Line number formato aeaaaee 7 6 Linear axes LES a ERTE EEE EE TIE TEENE PE 7 1 Linear feedrate move COG ned ea a E EN 7 13 Location Of machine eci 2 1 Location to give Safety cccccccsecccssseeeeseeeeeeeenes 2 2 Locking Using Tormach PCNC 1100 Series II
65. offsets can be selected by G59 P e g G59 P23 would select fixture 23 The absolute coordinate system can be selected by G59 PO You can offset the current coordinate system using G92 or G92 3 This offset will then be applied on top of work offset coordinate systems This offset may be cancelled with G92 1 or G92 2 You can make straight moves in the absolute machine coordinate system by using G53 with either GO or G1 7 5 Formatting Code Lines Block A permissible line of input code consists of the following in order with the restriction that there is a maximum currently 256 to the number of characters allowed on a line e Optional block delete character which is a slash e Optional line number e Any number of words parameter settings and comments e End of line marker carriage return or line feed or both Any input not explicitly allowed is illegal and will cause the Interpreter to signal an error or to ignore the line Currently programs are limited to 999 999 lines of code Spaces and tabs are allowed anywhere on a line of code and do not change the meaning of the line except inside comments This makes some strange looking input legal For example the line gOx 0 12 34y 7 is equivalent to gO x 0 1234 y7 Blank lines are allowed in the input They will be ignored 31138 Rev B1 4 7 5 Using Tormach PCNC 1100 Series II Programming language reference Input is case insensitive except in comments thus any lett
66. or their hotkeys Step mode moves the axis by one increment as defined by the Step DRO for each key press The current feed rate as defined by the F word is used for these moves The size of increment can be set by typing it into the Step DRO or values can be set in this DRO by cycling through a set of predefined values using the Jog Step button Incremental mode is selected by the toggle button or if in Continuous Mode temporarily selected by holding down Ctrl before performing the jog Tormach Jog Shuttle Controller 5 2 2 4 This jogging device is available as an optional accessory part number 30616 figure 5 12 Many users will find that it increases their productivity especially on short run jobs requiring a lot of setting up of workpiece and tooling The four buttons starting at the left are allocated to select jogging of axes X Y Z and A respectively A LED beside an axis DRO indicates that this axis is the one that will be jogged The fifth button cycle through the available jog step sizes Alternatively you can type a step size into the Step DRO Continuous jogging is performed by Figure 5 12 Tormach Jog Shuttle Controller turning the spring loaded ring counterclockwise for the minus direction and clockwise for the plus direction There are seven speeds in geometric ratio from very slow to full speed so you can position any axis with great speed and precision www tormach com The inner wheel
67. path control mode The modal groups for M codes are group 4 M0 M1 M2 M30 stopping group 6 M6 tool change group 7 M3 M4 M5 spindle turning group 8 M7 M8 M9 coolant special case M7 and M8 may be active at the same time group 9 M48 M49 enable disable feed and speed override controls In addition to the above modal groups there is a group for non modal G codes group 0 G4 G10 G28 G30 G53 G92 G92 1 G92 2 G92 3 Figure 7 2 Modal groups in inches vs measure in millimeters A machining system may be in many modes at the same time with one mode from each modal group being in effect figure 7 2 For several modal groups when a machining system is ready to accept commands one member of the group must be in effect There are default settings for these modal groups When the machining system is turned on or otherwise re initialized the default values are automatically in effect Using Tormach PCNC 1100 Series II 7 10 31138 Rev B1 4 V0 1 7 1 Programming language reference Group 1 the first group on the table is a group of G codes for motion One of these is always in effect That one is called the current motion mode It is an error to put a G code from group and a G code from group O on the same line if both of them use axis words If an axis word using G code from group is implicitly in effect on a line by having been activated on an earlier line and a group 0 G
68. pdf For detailed reading on the subject feel free to read up on Preventing Collet Slip in the Engineering Documents section of the web site The system uses a precision 34 R8 collet in the spindle Insert this as described above for R8 tooling Tool holders can be changed by loosening the drawbar by just one turn and using the copper faced hammer on the squared end to disengage the collet taper You do not need to remove the collet Note You can change the tools in TTS drill chucks or the ER collet adaptor while these are fitted to the PCNC spindle although doing this will not exploit the pre settable nature of the tools You should use both spanners on the ER chuck rather than relying on the holder not turning in the 34 collet If you change a cutter or drill without opening the door to lock the spindle you should use the Spindle Lockout key to a a i d avoid any risk of the spindle starting If the Figure 5 8 Changing spindle spe door is open the spindle is automatically E ed range Using Tormach PCNC 1100 Series II 5 4 31138 Rev B1 4 5 2 5 2 1 Machine controls inhibited Note the draw bar is a wear part After many repeated tool changes the draw bar will become worn both at its threads and on the shoulder near the top This wear can adversely affect your ability to tighten tools properly Inspect your draw bar regularly and replace as required Spindle Speed Ranges The PCNC has two speed ranges
69. program must end with an M30 rewind code The number of passes you require is entered into the Cycles DRO The initial lowest Z position is put into Z inhibit note this will often be negative and the distance Z is to move down each cycle is put into Z Step usually positive The On Off button enables the feature The Multipass button will prompt for the values by a series of dialogs rather than requiring the DROs to be filled in Modes and Mode Alarm Control Family These families display the current modes of the Control Software and an alarm LED for unusual modes The alarm is on the Diagnostics screen Click on the flashing LED to see a list of unusual modes figure 5 22 Mil k s15 GeO G17 G40 620 Gel Gud God Gay Gud bid Figure 5 22 Current modes display These modes might arise from running a part program produced by a CAD CAM system not customized for all the features of the PCNC List of Abnormalities OffLine Currently Active An unusual mode does not imply a fault in your system simply a hint of what to Click on LED for details look for if unusual things are happening Doune Eii an TER i denne current state as Mormal figure 5 23 Gives a quick check on Unexpected IJ InchiMetric etc If for any reason the standard modes do Figure 5 23 Unusual modes display not suit your normal working then by on Diagnostics double click on the unusual modes LED you can define the current state as usu
70. removed following the reverse of the procedure described for installing the Y axis drive You can also remove the Z axis motor to reduce the overall height of the machine Take care to secure the motors after they are removed so strain is not placed on the wiring All bare metal surfaces should be oiled before moving the machine as a means of protection against condensation and corrosion Disassembly for Transport Warranty is void if the machine is disassembled Tormach recognizes that there are situations where users need to disassemble their mill and has made provisions in the design of the mill to facilitate this Never the less Tormach cannot be held responsible for alignment precision and operating functions after the machine has been disassembled Test your machine before disassembling it The major sub assemblies of spindle head column and base are bolted and dowelled together so the machine can be separated into smaller components to meet very challenging transport problems Note however that this entails disconnecting wiring and the lubrication lines We recommend taking a very large number of photographs from all angles including detail photographs of any wires or oil lines that will be take apart Dowel pins must be removed before the bolts on disassembly Dowel pins must be installed before the bolts on assembly Tormach strongly recommends that all precision sliding and rotating joints remain intact during disassembly This mean
71. required if you want to select counterclockwise running The main LED above the Spindle CW button indicates that the spindle is running although actual movement may be inhibited by the key and or door interlocks The two LEDs that flank it indicate a Dwell while the spindle gets up to speed or fully stops The Coolant button and its associated LED control the coolant power outlet under the control cabinet Feed Control Family Units Min 0 0 Feed Units per Minute Feed Units per Revolution The F DRO gives the feed rate in current units Units Rev 0 0 inches millimeters per minute It is set by the F word in a part program or by typing into the F F R O 6 00 DRO The control software will aim to use this speed as the actual rate of the coordinated el Ol movement of the tool through the material If this rate 1s not possible because of the maximum M410 a J OF i i FIO qr 100 F11 permitted speed of any axis then the actual feed rate will be the highest achievable figure 5 14 Figure 5 14 Feed control family As modern cutters are often specified by the permitted cut per tip it may be convenient to specify the feed per revolution i e feed per tip X number of tips on tool In this case the F DRO gives the feed rate in current units inches millimeters per rev of the spindle It is set by the F word in a part program or by typing into the DRO Notice that the numeric values in the control w
72. spindle pulleys are selected on the mis machine and are set on the screen using the Hi Lo button L a Use masking tape to indicate a 5 length near the middle This length must be clear of the clamps Setting Work Offsets Jog the axes so that the tool is just above the material at the top left hand corner of the 5 section figure 3 6 We suggest that you doa dummy run Regenerate Toolpath Jog Follow Display Mode cutting in the air so jog the Z axis up Figure 3 7 Toolpath during a cut 31138 Rev B1 4 3 3 Using Tormach PCNC 1100 Series Il 3 3 3 3 3 4 Making your first part about two inches Now click in the X Y and Z axis DROs in turn and type the value 0 into each of them Do not forget to press Enter to accept the values The reason for doing this is that you want the position of the tool 1 e at the top left of your material and an inch above it to be X 0 Y 0 and Z 0 The Control Software still refers to the home switches as zero internally but lets you have your own separate coordinate system for the work If you click the Machine Coords button then you will be shown how your zero relates to the home position The difference between the machine coordinates and your coordinates is called the Work Offset Figure 3 8 Touching a tool Note We are going to cut this part by giving you a recipe You will learn why and how it works later Please don t add anything extra to the rec
73. that you do not risk crashing the tool into anything If you are repeatedly gauging say multiple tools then you do not have to keep typing a measurement into the Control Program One disadvantage is that any backlash in the Z axis will cause an error as you are jogging on the other side of the backlash from that when a cut has been applied You also need to be able to jog slowly to get an accurate result The Jog Shuttle device is very convenient on account of its variable jogging speeds 31138 Rev B1 4 6 7 Using Tormach PCNC 1100 Series Il Offsets 6 3 1 3 Adjustable Parallel Method 6 3 2 6 3 3 You need an adjustable sliding parallel gauge Jog by eye so that the tool is about the nominal size of the parallel Insert it in the gap between tool and stock slide it to fill the gap and lock it off figure 6 14 Carefully remove the parallel and measure it with a micrometer or caliper figure 6 15 The advantage of this method is that you do not need any careful jogging The disadvantages are the need to measure Figure 6 15 Measuring the parallel gauge the parallel and then to accurately type the result which will generally be an awkward number into the DRO You can of course use a combination of these methods depending on what you have to hand on a job and which is most convenient Comments on Accuracy With practice you will be able to use these methods to measure to better than 0 001 It is however inte
74. the probe tip radius is known only approximately but the other conditions hold the location of the hole center will still be accurate but the hole diameter will not NO1O probe to find center and diameter of circular hole NO20 This program will not run as given here You have to NO30 insert numbers in place of lt description of number gt NO40 Delete lines NO20 NO30 and NO40 when you do that NO50 GO Z lt Z value of retracted position gt F lt feed rate gt NO60 1001 lt nominal X value of hole center gt NO7O 1002 lt nominal Y value of hole center gt NO80 1003 lt some Z value inside the hole gt 31138 Rev B1 4 7 21 Using Tormach PCNC 1100 Series II Programming language reference NO90 1004 lt probe tip radius gt N100 1005 lt nominal hole diameter gt 2 0 1004 N110 GO X 1001 Y 1002 move above nominal hole center N120 GO Z 1003 move into hole to be cautious substitute G1 for GO here N130 G31 X 1001 1005 probe X side of hole N140 1011 2000 save results N150 GO X 1001 Y 1002 back to center of hole N160 G31 X 1001 1005 probe X side of hole N170 1021 1011 2000 2 0 find pretty good X value of hole center N180 GO X 1021 Y 1002 back to center of hole N190 G31 Y 1002 1005 probe Y side of hole N200 1012 2001 save results N20 G0 X 1021 Y 1002 back to center of hole N220 G31 Y 1002 1005 probe Y side of hole N230 1022 1012 2
75. the simple screen It can set the origin to any corner of an object in any orientation Setting Rotation from Points This function is used to set up the machine to mill components where the X Y axis of the part is not i yf square to the X Y axis of the machine This might Figure 8 19 Probing Point 2 Cable right be because the part does not have any square faces accessible when it is mounted for a second operation The function uses the G68 code to rotate the working coordinate system relative to the machine coordinate system You should be sure you understand the working of G68 by running test pieces before you use it on a job Pa la ETEM Point 1 defines the center of rotation in the existing work coordinates It is often convenient to keep this as 0 0 or for it to be the same as one of the other points Points 2 and 3 define a line whose angle is the direction of the new coordinate system If no flat face is accessible it will often be useful to have Points 2 and 3 as the centers of holes already drilled or bored in the part 31138 Rev B1 4 8 11 Using Tormach PCNC 1100 Series Il 8 2 2 4 Machine upgrades and configuration Click the button Axes to set the G68 command The angle of rotation used is displayed in the DRO and if it is non zero the LED on this screen and next to all axis DROs will indicate that G68 is active The X and Y DROs will be red to remind you the rotation is active Rotation is removed by clicki
76. their driver database reloading Windows is the cure in this case 3 When the system says taking over 3 2 1 and then reboots one of two things has occurred Either you did not reboot when asked told you or the driver is corrupted or unable to be used in your system In this case follow the next section and remove the driver manually then re install If the same thing happens please notify Tormach by e mail and you will be given guidance A few systems have motherboards which have hardware for an APIC timer but whose BIOS code does not use it This will confuse the Control Software install A DOS batch file specialdriver bat to run in a DOS window is available this will make the driver use the older 18529 interrupt controller To display the DOS window enter CMD as the program after Start Button gt Run You will need to repeat this process whenever you download an upgraded version of the Control Software as installing the new version will replace the special driver DriverTest After a Software Crash Should you for any reason have a situation when the Control Software crashes this might be an intermittent hardware problem or software bug then you must run DriverTest as soon as possible after the Control Software has failed If you delay for two minutes then the Control Software driver will cause Windows to fail with the usual Blue Screen of Death Running DriverTest resets the driver to a stable condition even if the rest
77. this click from a relay contact on the board the board is functioning properly 9 48 115 VAC measured from wire 100 to wire 106 when OK Turn off power and search for loose wires Re apply power when finished and check operation Insure you have 115 VAC measured from wire 100 to wire 106 see above Make a jumper wire and using proper care associated with live circuits momentarily jumper wires 106 and 107 If Contactor C2 pulls in you will hear an audible clunk while you have the jumper on but drops out as soon as you remove the jumper the holding contact on C2 is defective If C2 stays energized the control board is not passing the run signal to the circuit Make certain you are commanding the drive to run If so the Tormach Machine Control Board is defective 31138 Rev B1 4 Warranty Specifications Customization and Troubleshooting Spindle Drive Sub System Checklist Table 5 1 continued Spindle will not turn in Manual or Auto Possible Cause Prob Action to identify Cause of Discussion Problem Drive has tripped Err 0 occurs Low Check wiring to braking resistor 31138 Rev B1 4 The display will show if the drive has tripped Record the information from the display should the trip be happening frequently or should the trip not clear as described in the Discussion column to the right The display will look similar to that shown to the right 9 49 Drive trips may be cleared by remo
78. to display load or vice versa press and hold the M button for 3 seconds Tormach highly recommends against changing any parameter values in the VFD There are no user settable parameters available Using Tormach PCNC 1100 Series II 9 54 31138 Rev B1 4 9 7 9 8 Warranty Specifications Customization and Troubleshooting Mechanical maintenance The mechanical design and assembly is conventional in all aspects Adjustments should be simple to make but rarely needed The exploded views are your primary resource for understanding assembly and adjustment We encourage you to contact Tormach if additional information is needed Specific items to be aware of include the following e The Z axis is held up by the Z axis ballscrew and motor Decoupling the motor will result in a dangerous and destructive fall with the entire spindle head crashing into the table e X Y and Z axis ballscrews are mounted on angular contact bearings The preload adjustment on these bearings affects the axis backlash and bearing wear Spanner wrenches are very helpful to adjusting the locknuts and setting the tension Tormach offers the correct spanner wrenches PN 30485 if you need to adjust or replace these bearings e X Y and Z axis ballscrew nuts are preloaded using precision ground spacers These are factory set and cannot be adjusted e X Y and Z axis slide ways each have a tapered gib plate locked in place at each end Tapered gibs can a
79. travel limit switches The next section is a Problem Resolution Checklist section which is presented in a table format For more in depth explanation of this subsystem please go to the Details section that is after the Checklist section Problem Resolution Checklists for the Axis Drive Sub system Using Tormach PCNC 1100 Series II 9 32 31138 Rev B1 4 Warranty Specifications Customization and Troubleshooting Contents of the Problem Resolution Checklists for the Axis Drive Sub system Table 4 1 None of the Axes will move when Commanded One axis will not move or moves in only one direction but other axes operate properly Table 4 6 Cannot Reference all Axes or End of Travel Limits don t Work aka Limit Switch Problems Table 4 7 Testing Limit Switch Problems Table 4 8 Steps are lost on Axis Travel Axes Drive Sub System Checklist Table 4 1 None of the Axes will move when Commanded Possible Cause Prob Action to identify Cause Discussion ability of Problem Software not Jog the axis and observe If the displayed position does not commanding the move the machine coordinate change while jogging there is a or computer problem display software computer problem Try restarting the software first If that does not solve the problem try restarting the computer Control signals not Medium Problem with 25 pin D reaching the electronic connector cable from driver modules computer to machine Problem with cable bottom of ma
80. ubocsca a aa 7 34 183 Rerin Om Furst EDE MIA aaa shales cade hogit e aa heca dient ued a lel 7 34 1 80 Override Control M48 and M49 aota ade a ee E E aE E awe eda 7 34 Tod Cal UOMO Ses ik hab ee hah aca aaa ead ce he 7 34 7 8 8 Return from Subroutine M99 ccc cceccccsesccceeeeeeeeeeeeeeeeaeneeesseesneeseeseeseneeeaeeeesneens 7 34 19 Application Defined M code s eeoosssecocsssccocsssecocsssesocsseecocsssesoossecscosssecocssseseossseseoso 7 34 TOA Self reversing Tapping Cycles sieri inueni eat dleavatReuseahs 7 34 7 9 2 Goto Toolchange Position M998 cccccccccsesccceececseeeeeeeeeeaeseeeaeeecseneeeaeseeseneeeaeseeneneees 7 35 IIS WserDeniied MiaCOdes res cas asa saes haeeatho slits uiintumes e abe tueeiiealelte 7 35 7 10 Other Tnput Codes soosoo soia eio eun lessee casted a ecea dake sanded Eiee aoi anoanoia sin 7 35 TAOL Eed Ree Eaa a iaa a a a 7 35 FAO Lt UIC SPET 29 egn a a a a A 7 36 TAGS DEEE TOORE Tie ane E E E E NA N REE E O A a neni 7 36 7 11 Order of Executi i dis Secesicaceccaccsssdesicestwaasccetdecsesaccaaeesescesiuaasecscasescssheeseeassssetdeceesatcanscsates 7 36 7 12 Error TRAINING eaire aE TAAA EENE SES AE 7 37 8 Machine Upgrades and Configuration cccccessseeseeeseeeeeeeeeeees 8 1 8 1 Fourth Axis Rotary Tal Gssscecccctszet sia aaa aa aa E EA EAN A S 8 1 Sr kuk Tnstalhine the BICCHONICS wccctud c bees i a a nGeen a e aaa aa a a neces 8 1 3 12 U lhzmne the Four AXIS esre ee ae e a a e
81. very carefully down to the stock with a piece of paper foil on it figure 6 11 You will be able to feel when the paper foil gets trapped You then know that the tool is 0 002 two thou above the stock The advantage of this method is that you will always be able to find a gauge and it can be used on a very small flat surface on the stock e g the boss of a casting The disadvantage particularly with hard stock and brittle tools e g carbide is that it is easy to jog down too far and damage the tool cutting edge Roller Gauge Method For this method you need a short length of rod of a known diameter 1 4 is quite suitable for most jobs The shank of a twist drill can be used in an emergency but take care to use one without scoring on it and measure the diameter rather than assuming it is the nominal size of Figure 6 13 Gauge just rolls under tool the drill Jog the tool so it is clear of the stock but no more than the gauge diameter above it You will be unable to roll the gauge under the tool figure 6 12 While attempting to roll the gauge into the gap very slowly jog upwards You will easily feel the point where the gauge rolls under figure 6 13 If you jog too far then it is easy to remove the gauge jog down a little and try again You know that the tool is the diameter of the gauge above the stock Figure 6 14 Parallel adjusted to gap The advantages of this method are
82. what length units are being used and which axis or axes are moving In units per rev feed rate mode an F word on the line is interpreted to mean the controlled point should move at a certain number of inches per spindle revolution millimeters per spindle revolution or degrees per spindle revolution depending upon what length units are being used and which axis or axes are moving When the inverse time feed rate mode is active an F word must appear on every line which has a G1 G2 or G3 motion and an F word on a line that does not have G1 G2 or G3 is ignored Being in inverse time feed rate mode does not affect GO rapid traverse motions It is an error 1f inverse time feed rate mode is active and a line with G1 G2 or G3 explicitly or implicitly does not have an F word Canned Cycle Return Level G98 and G99 When the spindle retracts during canned cycles there is a choice of how far it retracts 1 Retract perpendicular to the selected plane to the position indicated by the R word 2 Retract perpendicular to the selected plane to the position that axis was in just before the canned cycle started unless that position is lower than the position indicated by the R word in which case use the R word position To use option 1 program G99 To use option 2 program G98 Remember that the R word has different meanings in absolute distance mode and incremental distance mode Built in M codes M codes interpreted directly by the CS a
83. you to create two partitions on the hard drive Install Windows in both but keep one as the minimal installation for the control software for the PCNC The other partition can contain what you like When you switch on you can choose from which partition you want to boot The section below gives a checklist of actions to achieve the leanest Windows system The recommendations there are helpful but not always necessary Do not leap in and do everything unless you have problems with machine motion Apply them in the order given until jogging and rapid moves are smooth Optimization of Windows is more important on slower computers below 1 6 GHz 10 3 3 Installing the Control Software 10 3 3 1 Installing You do not need the PCNC connected to the computer by the parallel cable yet If you are just starting it would be better not to have it connected You must not have a printer connected to the parallel port The Control Software will not operate correctly with a printer attached to the parallel port and it may damage the printer Switch off the PC the PCNC and unplug the 25 pin connector from the back of the PC Now switch the PC back on Load the release CD into your CD drive If you have auto run configured on your computer then the installer will start running Otherwise use Windows Explorer or the My Computer icon to open the CD Select View gt Details from the menu Double click on the file Install BAT to run it You wil
84. your vise this will be remembered for subsequent uses of the screen The probe explores using the three moves shown on the screen panel figure 8 12 Move 1 establishes the rough position of the jaw Move 2 near the far end establishes the angle the vise is mounted at and displays it in the DRO Move 3 approaches the end of the jaw along a perpendicular The X Y origin of the current work offsets is then set to the calculated position of the corner and the probe moves to its starting point The angle DRO gives you a confidence check the setup accuracy of your vise If it is a long way from 0 0 degrees then Move 2 might not find the jaw or might even hit the moving jaw If you need to work with a significantly skewed vise or to very close tolerances then the Comprehensive X Y probing screen has features that will fie Config yew Wizerds Operator Help Mi G15 610 G17 G40 G20 G90 G34 G54 G49 G99 GH G97 a X 0 000 All buttons move in Z direction to touch the probe sensor then set the data y7 0 0000 Z 0 000 Override E100 l soa oworr curans 0 0050 Step ong ana Cont Siep sjToi O _Oftset Onion B Empty Test probe before move pe B E RESET CAPCNC3 GCode T ormachXmasAnnotated tap _Chean Merry Christmas FCNCM3 R27 SR623 GLodes M Codes Sine Fa CLARA Comp Rue An MDI Anz Footpath an3 l Ofteots ANS Senings Ans Diagnostics AKT XY Probe cuana Z Probe ana help
85. 0 2 30304 Screw M8x30 50 30354 Spring gt i O 3 30305 Spindle cartridge 51 30355 Screw M6x40 3A 30306 Spindle cartridge assembly 52 30356 Screw M6x60 _ _ _ 4 30307 Screw M5x12 53 30357 Screw M5x20 5 31198 Screw M3x12 54 30632__ Zaxisstepmotorw Brake 6 1 31199 Latch 80359 Screw M5x26 0 6A 31217 Latch Ki 56 80360 Washer 8 31201 Nu M5 58 30362 Clampingshaftcollar __ _ 9 31202 Screw M5x16 59 30363 NutM14X15 10 31203 Screw M6xi6 60 30364 Lockwasheri4mm 16 30320 Pin8x35 66 30370 ScrewM16 18 30322 Washeri2mm 68 30372_ Zpballscrew cover plate _ _ 19 30323 Head casting 69 30373 Zaxis ball screw bearing 30 30334 Screw M4x8 80 30384 Zaxsgib Z nut carrier Adjustable base pivot pin 6X45 86 30390 Unused i O 39 30343 Pin 30393 Key 8X26 40 30344 Spring 1x4 8x20 90 30394 Lower spindle spacer _ 46 30350 Sleeve 80507 Drawbarfor R8 taper 47 30351 Pulley washer 30506 Drawbar for BT30 taper __ 48 30352 Screw M8x20 30560 _ Alignment washer for drawbar_ O E Annular Bearing Engineering Council identification DT7008 DT double tandem pair ORDERED AS A PAIR aja Slon D gt Spindle Cartridge Assembly for R8 includes callout numbers 1 3 12 13 14 73 87 88 and 90 For BT30 Spindle Cartrid
86. 00 00 00 to check if the maximum excursion of the controlled point is reasonable e g not milling Figure 5 16 Toolpath and G code display the top of the table family 31138 Rev B1 4 5 11 Using Tormach PCNC 1100 Series Il Machine Controls The toolpath display can be rotated by left clicking and dragging the mouse in it It can be zoomed by shift left clicking and dragging and can be panned by dragging a right click The Regenerate button will regenerate the toolpath display from the G code with the currently enabled fixture and G92 offsets The Display Mode button will chose whether the default toolpath display is sized for the machine envelope as defined by the soft limits or the object defined by the extremis of the part program The Jog Follow button allows the toolpath display to be automatically scrolled as the controlled point is jogged 5 2 2 8 File Control Family These controls are involved with the file of your part program Most should be self evident in operation OpenG Recent Figure 5 17 File control family Change G Code ReLoad Close Change G code allows you to use the Notepad editor to edit the part program you have loaded When clicked it displays the current file figure 5 18 5 2 2 9 Work Offset and Tool Table Control Family Mil gt G15 G1 G17 G40 320 GEO GOL G54 G49 639 GE G97 react m ol Sra Sename She cbsta eee cain 0010 Post pr ch st 0 CD
87. 001 2 0 find very good Y value of hole center N240 1014 F1012 2001 2 410041 Cind hole diameter in Y direction N250 GO X 1021 Y 1022 back to center of hole N260 G31 X 1021 1005 probe X side of hole N270 1031 2000 save results N280 GO X 1021 Y 1022 back to center of hole N290 G31 X 1021 1005 probe X side of hole N300 1041 1031 2000 2 0 find very good X value of hole center N310 1024 41031 2000 2 1004 find hole diameter in X direction N320 1034 1014 1024 2 0 find average hole diameter N330 1035 1024 1014 find difference in hole diameters N340 GO X 1041 Y 1022 back to center of hole N350 M2 that s all folks In the above code an entry of the form lt description of a number gt is meant to be replaced by an actual number that matches the description of number After this section of code has executed the X value of the center will be in parameter 1041 the Y value of the center in parameter 1022 and the diameter in parameter 1034 In addition the diameter parallel to the X axis will be in parameter 1024 the diameter parallel to the Y axis in parameter 1014 and the difference an indicator of circularity in parameter 1035 The probe tip will be in the hole at the XY center of the hole The example does not include a tool change to put a probe in the spindle Add the tool change code at the beginning if needed 7 7 13 Cutter Radius Co
88. 1 X5 5160 Y5 1284 G3 X5 8594 Y5 7764 M amp G Code Program File Standard Text Editor Computer oT 7 hard disc R Microsoft Notepad PCNC 1100 Wizards Conversational Programming DXF HPGL JPG File Conversions ae CAM Program Methods to Create Program Files Figure 4 1 Schematic on how to generate part programs The PCNC is always controlled by commands in a part program Most of these are G codes although many other letters are used to define the details like the spindle speed feed rate etc which are required Thus a part program is sometimes referred to as a G code program Movement of the machine axes is controlled by three different G codes 31138 Rev B1 4 4 1 Using Tormach PCNC 1100 Series Il 4 2 4 3 From an Idea to a part e G00 moves at the maximum speed of the machine so is used when no cutting is required e GOI moves in a straight line between two points at the set feed rate e G02 and G03 move in a circular arc between two points in a plane and possibly in a straight line in other direction e g to make a spiral All the moves take place from the current position of the tool GOO and GO1 need the coordinates of the ending position e g G01 X3 2 Y2 1 Z 0 3 would move the three linear axes together so the tool will follow a straight line ending at X 3 2 Y 2 1 and Z 0 3 G02 and G03 clockwise and counterclockwise arcs respectively nee
89. 31138 Rev B1 4 3 3 3 3 1 3 3 2 Making your first part The original drawing is shown in figure 3 4 It consists of the characters PCNC and an irregular quadrilateral Having drawn the outline of the part we defined the material from which it will be cut the size of tool to cut the letters 14 the depth of the letters the size of tool to cut the recess 42 and the depth of the recess The program automatically creates the part program G and M codes to make the part and can display a visualization of the finished work figure 3 5 We will discuss the options which you have for designing your own parts in the next chapter lt BR j C3 e Ket BA Ze a in 2 ae You should now be able to relate the toolpath display to the part illustrated Figure 3 5 CAD CAM Visualization of finished part Running the Demonstration Part program Part Material We suggest that you use a free cutting material to make this first part MDF birch ply or as we used resin impregnated ply are all suitable You need a piece at least 12 thick and 7 by 4 Clamp this securely to the PCNC table For many jobs it is worth putting a layer of scrap material under the work This will protect the table when through holes are to be cut and may save damage in the event of a mistake in the part program or in operating the machine Put a 14 diameter tool into a tool holder in the spindle Ensure the lower
90. 4 115 0 0000 0 0000 oy 5 Empty 0 0000 O 0000 0 0000 0 0000 A hd All Tool Entries are in your default setup measurement units irregardless of G20 G1 modes Apply OF Figure 6 5 Data in tool table Note The values in this table are always in inches If you want to input tool lengths in millimetres then you can do this when you are in metric G21 mode by using the tool length part of the Offsets es Oe oe screen open Recemt Change G Code ReLoad Close If you change a tool for example by sharpening it if it x comes loose in its holder or fitting a new cutter then vat you must make sure you re measure it on the granite Zeroiil block and update the tool table Z 6 2 1 2 Zeroing to work height Here you are going to set the work offset of Z so tool Cycle stone wi te 1 is touching the top of the work when Z 0 0 As the ae tool table gives the lengths of all tools that means Z will be zero when each tool in on the spindle and e mmy i selected from the tool table by its number Pasea E Faiet To zoff _ 7 084 e Mount the touch tool 1 in the spindle Figure 6 6 Selecting tool 1 e Set the current tool by typing 1 followed by Enter into the DRO labelled T e Jog the Z axis down so the dial indicator touches the top of the work and reads 0 0 i e the 31138 Rev B1 4 6 3 Using Tormach PCNC 1100 Series Il Offsets position of the pointer when you measured the tool length rem
91. 5 PFOLECIION MONTOS ee ca asctidesidouecatand es 9 5 SpecdsCalOratiONn sisene a doskeets 9 1 WAN COVES fied ions crnadestacatenneherdeahaamicetnaanedeatacars 9 6 Manual Data Input to control Software 2 14 M code MMA CEOS cats cdcnccattocioust AEAEE 7 35 M codes built in Summar yia DIC aaan sted twekeneeincowaenweadts 7 32 TN UU a eet e ets ented cigs tatoo acoder tales seen 2 14 Mechanical specifications cccsescceseeeeeeeeeeees 9 2 Messages from part program defined ccccceeeeeeeees 7 9 Millimetre units EIA MEE 6 1 0 ROR Oe OCR RIO CERRO PORE tE 7 19 Mirroring parts secccs ashen tacmdtenesnebeaweareddeceaseeers va dboe 7 1 Modal groups CLEMO e Fide T hate A E 7 10 Modal motion cancelling EEE e e E A E 7 26 Mode OE JOS O HNO sarera eiee e dae husnatthnat oe 2 14 Modes Mache CHIN reenen 7 10 MSG string introduces an operator message 7 9 Using Tormach PCNC 1100 Series II Index 24 N Number Trma tO cal can hive dani a Nshbenueseeen 7 7 O Offsets I aio ahaa atch tree deel cntie aires dete aed Ges A OTA 7 23 GO ate dest isteGi ati sree dees Sa seta ea O 7 31 Offsets and coordinate systems eceeeeeeees 6 1 Operators binary S isa cracls actor autos catia sets tna setae dec emtonde amends 7 8 Operators unary CTI Crs sates E E E E E 7 8 Operalor SPAN Cl si5 02 matineniainanditie cea dite ss 5 1 Optimising Windows ccsece
92. 5 is a two axis X and Y diagonal feed move and the linear feedrate is increased to 10 ipm Note Because there is contact between the cutting tool and the workpiece it is imperative that the proper spindle speeds and feedrates be used It is the programmer s responsibility to ensure acceptable cutter speeds and feeds 7 7 3 Arc at Feed Rate G02 and G03 A circular or helical arc is specified using either G02 clockwise arc or G03 counterclockwise arc The axis of the circle or helix must be parallel to the X Y or Z axis of the machine coordinate system The axis or equivalently the plane perpendicular to the axis is selected with G17 Z axis XY plane G18 Y axis XZ plane or G19 X axis YZ plane If the arc is circular it lies in a plane parallel to the selected plane Using Tormach PCNC 1100 Series II 7 14 31138 Rev B1 4 7 7 3 1 Programming language reference If a line of code makes an arc and includes rotational axis motion the rotational axes turn at a constant rate so that the rotational motion starts and finishes when the X YZ motion starts and finishes Lines of this sort are hardly ever programmed If cutter radius compensation is active the motion will differ from the above see Cutter Compensation Two formats are allowed for specifying an arc We will call these the center format and the radius format In both formats the G02 or GO3 is optional if it is the current motion mode Radius Form
93. 6 in between Motion sssesseesssessseesseesserssees 7 27 preliminary MOTION cccceececeeeeeeeeeeeeeeees 7 27 repeats by L word ccecccseseceseeeeeeeeeeeeeens 7 27 retract defined by R word cccceseeeeneeeees 7 27 sticky numbers cece ceesceeeeeeceeeeeeeeeeeeeeeees eye Center format ar cece cceccccseecccseeeeeeseceeeeeeaeees 7 16 Centering microscope methods c 080ee 6 12 Circular pocket EI E T danas E 7 18 Code definition syntax explained 0006 7 11 Column and head assembly cseseeneeeees 10 1 Using Tormach PCNC 1100 Series II Comments de TM CO ernan a E sn neat 7 9 Computer LED Ol CON PO pane lessan uetadsweicsks 5 2 Computer mounting BECEGSOR ICs E E A E TARS 2 3 AE A E T E E A AE 2 3 Computer ON OFF control panel switch sseesseesssessees 2 11 5 1 Computer requireMent cccceeeccseeeeeeeeeeeeeees 2 8 Concept behinds PONG mracna ie uilavem outed 1 3 Connecting control computer to PCNC 2 10 Constant velocity mode GOF SOLUS caicetauce li aacdeliasuiattiaacslacahentses 7 25 purpose of explained ccceccccseeeeeseeeeeeeeees 7 3 Control panel controls explained 068 2 10 Control power troubleshooten 9 26 Control Software COMpPOHeNtS OF arae dawns lnemusert 10 14 SCLC SINS acacia EE E a AE E 5 5 Controlled point denned eeen E 7 2 Conversation pr
94. 73 and M874 are described in chapter 7 This section gives brief instructions of fitting the heads to the machine and installing a tap Both tapping heads are supplied with the Tormach Tooling System geometry whose y 34 shank can be mounted like any other Figure 8 23 Large tapping head ready for use tool 1 Figure 8 23 shows the large head fitted in the spindle The torque arm can be seen engaged in the recess in the head casting to prevent rotation on the fixed part of the mechanism Tapping will generally be performed between 500 and 900 RPM so the drive should be set to the low speed pulleys Figure 8 24 Tap collet and anti rotation block The tap is held by a rubberflex collet locked by the nut on the nose of the head spindle and prevented from rotating in the head by using its squared end The small head accepts a fixed square but the larger head which covers a bigger range of sizes has a set of alternative blocks which fit into a square hole above the collet nut The tap holding arrangement without the spindle is shown in figure 8 24 and the accessories for the large head are shown in figure 8 25 This picture also shows the square hole in the tapping spindle which houses the anti rotation block Figure 8 25 Accessories for large Using Tormach PCNC 1100 Series Il 8 14 tapping head 31138 Rev B1 4 Machine upgrades and configuration The top ring on the tapping head should be screwed down to g
95. 9 16 Troubleshooting overview We will build on these key principles by providing a description of each of the sub systems on the PCNC This will serve to help the user understand how the machine should work and provide an overview of the components that are involved in the sub system We will also list some guidelines for equipment and procedures used in troubleshooting Using Tormach PCNC 1100 Series II 9 18 31138 Rev B1 4 Warranty Specifications Customization and Troubleshooting As in most electromechanical machines it is frequently easier to see problems in the mechanical systems than the electrical and computer systems With this in mind most of the details in the troubleshooting section will address non mechanical areas The user may find that this background information will allow him to troubleshoot without any assistance from Tormach At the minimum it should allow the user to begin the process of troubleshooting and make any contact with Tormach Technical Support go more smoothly Review of the Key Principles for Troubleshooting e Know how the machine is supposed to work e Divide and Conquer focus on one area e Analyze what has changed e Work Smart do the easy and obvious tests first e Complete one test before starting another 9 6 3 Tips and Tools for Troubleshooting Equipment and Procedures 9 6 3 1 Safety Safety is always important During troubleshooting one tends to expose themselves to more h
96. Brian Barker Cut Keyway Brian Barker Milling 2D with radius linking Olivier ADLER No Description Brian Barker DigitizeTest Feeds and Speeds Offset Setup Rectangular Bolt Pattern Drill Rectangular Bolt Pattern Brian Barker Rectangular Pocket Cut a Rectangular Pocket Brian Barker Row Bolt Pattern Side Cleaning Full Depth Row Hole Pattern Brian Barker Side Clean Full Depth Kiran e Save Settings button This causes a the Control Software Figure 4 18 Wizard selection list to remember the values in each DRO so they will be available next time you choose the particular Wizard e Post Code button This causes the Wizard to generate a G code program to cut the shape with the sizes you have specified Most Wizards have a toolpath window and you will see the cuts to be made in it You can manipulate the toolpath display in the usual way with the mouse Rotate Zoom if Shift depressed and Pan if Right button drag e Exit button This returns you to the screen that was displayed before you ran the Wizard in preparation for running its code e An error line and button to Clear the text from it This will display any problems found trying to post code using the values that you defined 31138 Rev B1 4 4 9 Using Tormach PCNC 1100 Series Il 4 4 1 3 4 4 1 4 From an Idea to a part Note A common problem when filling in the DROs of a Wizard is to forget to press Enter to accept each value It is easy to t
97. CNC 1100 Series II 9 4 31138 Rev B1 4 9 5 1 5 9 5 2 9 5 3 Warranty Specifications Customization and Troubleshooting If you do decide to correct don t make assumptions as to where the error comes from The error could be a specific problem like the spindle head leaning down because the gib in the Z axis is too loose or it could be the combined effect from gib adjustments the column base interface or the Z saddle head interface If you make an adjustment in the wrong place you could make matters worse As an example if the Z axis gib is loose and the head tilts down someone could easily assume that they should shim the column base connection This would make the column slant back to correct for the head leaning down Now they have the machine running in a slight parallelogram in addition to a loose head Accuracy in deep hole drilling will certainly suffer We don t mean to overcomplicate the issue here Adjustments can be made and are sometimes necessary The point of this discussion is that you should proceed slowly and think carefully assessing the need for any adjustment and the best method for making that adjustment Drawing out the machine on a piece of paper while thinking about how to do it will often make the process clear Achieving Accuracy in Machining The key to achieving maximum accuracy is understanding and controlling the magnitude and direction of forces Maximum accuracy is achieved when the forces are minimi
98. COMMUN OWS ereinen EER 5 7 E Le e IEEE E E A E 5 7 IVE E EE E E E O 5 7 POU O Ga 5 7 Step selected by Ctrl key eeccceeeeee ees 5 8 with Tormach Jog Shuttle Controller 5 8 B Base assembly exploded view cccs00008 10 3 Bearings ballscrew adjustment of preload ccccceecccseseeeseeeeeeees 9 8 Binary operations GA FING acts at ct aera ce nies eiacnera ie eie cessed 7 8 31138 Rev B1 4 21 Block format Of code ceeecccsescccseseceeeeeeeseeeeeeeeaenes 7 5 Block Delete EES AE E EE E E A 7 4 Block delete SWC Ba sis rst ci caaiaachcntesdudaapabaehinwreans 5 10 Blue Screen of Death ACHIOM TOA VOI osm enceosianetdansaasacnetaestansetaaioweate 10 15 Boring and reaming canned cycle E oa RE O tact uta EE E EE E 7 30 Boring manual retract canned cycle E E E E E A E E E 7 30 Boring with dwell and retract canned cycle Ee o E E E E A E E E T 7 30 Boring with dwell canned cycle Eo 0 EEA ea EE eee S EAE A AT 7 30 C Cabinet stand ccccccceccccceseeccceseecccaeesceceeeeeeeaees 2 5 CAD 2d 2 2D and 3D explained ceeeeeeeees 4 2 CAD CAM software What to LOOK for 00 0 ceececseeeecseeeeeeeeeeseeeeeeneees 4 2 Calculator ME COS ans Speeds aiumcnmcdacnenannwronadetomnateadatnennenae 5 14 Cancel modal motion ROU XO AINC Gs ras2caanedsenemaaancmeadatmuantenantnensehous 7 26 Canned cycle return level isch ce sete O E N 7 32 Canned CYC IES esien REEE RAER 7 2
99. Check the connections on The connection at the Control Board between bulkhead both ends and ensure they has been known to loosen up during are firmly seated shipping between the computer cable for damage and the machine Parallel port assignment Low Consult the PCNC If you supply your own computer incorrect Manual section 9 5 9 you will most likely need to Se Using a Non standard configure the port printer port This problem is unlikely if you High purchased the computer from Tormach Parallel Port bad Low Try a new parallel port You may have to perform the step card above Tormach Machine Low Swap boards This is by far the least likely problem Control Board defective Details of the Computer Control Communication Mach3 software is installed under Windows XP or Windows Vista The software allows the user to jog or position the X Y Z and A axes and to control the spindle speed and coolant pump operation by use of the keyboard mouse and the jog shuttle control The software also accepts G code programs that automatically control the machine The Windows computer s parallel port communicates with the Tormach Machine Control Board through via a printer cable which has 25 pin D connectors on each end In order for the computer to control the machine the Mach3 software application must be running the machine LED must be on and communication must established between the computer and the Control Board Communication is establi
100. Click to ch Touch 0 2500 oo B Correction 0 250 Gauge Block thickness etc On Off C Alt T Figure 6 18 Touch done on Z with roller gauge 31138 Rev B1 4 6 9 Using Tormach PCNC 1100 Series Il 6 3 4 6 3 5 6 4 Using Tormach PCNC 1100 Series II Offsets Tool Table with General Tooling With conventional tool holders you will not be able to measure them with a height gauge unless of course you make your own dummy R8 spindle nose The following procedure uses the PCNC as a measuring rig Note If you follow these instructions very carefully you can mix tool entered into the tool table by measuring on the TTS granite block with those measured in the machine We suggest however that you do not mix the two methods If you want to use TTS and R8 tools on a job the just measure all of them on the machine as described below Mount a piece of flat stock on the table or in a vise on the PCNC Work throughout on the Offsets screen If you have some TTS tools preset in the tool table then one of these must be the master tool If you have R8 tooling choose one that you do not expect to wear much in use to be tool 1 This is termed the master tool Load the master tool select tool 1 or tool 0 if you have a non cutting master in the T DRO If it is a TTS tool and so already in the table then its length should be shown as in the Length DRO If it is not in the table them type 0 0 in the Length press Enter to accept it
101. D number to be zero a radius value of zero will be used G41 and G42 can be qualified by a P word This will override the value of the diameter of the tool Gf any given in the current tool table entry It is an error 1f e The D number is not an integer is negative or is larger than the number of carousel slots e The XY plane is not active e Cutter radius compensation is commanded to turn on when it is already on The behavior of the machining system when cutter radius compensation is ON is described in the chapter on Cutter Compensation Notice the importance of programming valid entry and exit moves Note The tool offsets must have been applied with a G43 H for compensation to work Tool Length Offsets G43 G44 and G49 To use a tool length offset program G43 H where the H number is the desired index in the tool table It is expected that all entries in this table will be positive The H number should be but does not have to be the same as the slot number of the tool currently in the spindle The H number may be zero an offset value of zero will be used Omitting H has the same effect as a zero value G44 is provided for compatibility and is used 1f entries in the table give negative offsets It is an error if the H number is not an integer is negative or is larger than the number of carousel slots To use no tool length offset program G49 It is OK to program using the same offset already in use It is also
102. FT WAR E Microsofti Windows Currentver functions which if C SOUNDMAN SOUNDMAN EXE HELIN SOF T WARE Microsofti windowsi Currentver bl d O mma Er INED WS MEV HELMI SOFTWAR Ei Microsofti Windows Currentyer enabled can an C ImScinst CoWINDOWSisystem HELMISOFT WARE Microsofti Windows Currentyer problems You will C TINTSETP COWINDOWS system HELMISOFTWARE Microsoft Windows Currentver know if you have C TINTSETR CuWINDOWS system HELMI SOFTWARE Microsoft Windows Currentver _ cheeks C jusched Program FilesJay HELMSOFTWAREMicrosofkl Windows Currentyer difficulties if machine O HP WwPTES C Program Files Hewl HELM SOFTWARE Microsoft windows Current er motion sounds rough C Nerocheck CAWINDOWS system HELMISOFTWARE Microsoft Windows Currentyer A LI Fopdis3a CUWINDOWS Syste HELMI SOFTWARE Microsoft windows Currentyer or if a long move C Nemctray RUNDLLS2 EXE C Wil HKLMISOFTWARE Microsoft Windows Currentier gt makes a periodic al ticking sound Enable all In difficult cases Co please consult _ Tormach for more Figure A3 2 Disable Startup programs detail changes that could be made Using Tormach PCNC 1100 Series II 10 16 31138 Rev B1 4 Appendices 10 3 4 1 Remove Unnecessary Services and Startup Programs Background There are a variety of programs that can run in the background stealing CPU power These programs may watch your keystrokes track communications
103. MI tO NONG ea 7 20 G28 k rer renee aE Sse a da hacivbonksen 7 20 G30 returm to OMG atch i aeaee 7 20 G31 and probe hardware options 00608 8 5 Sil Star ChE DROBO care R 7 20 G40 cutter radius compensation Off 7 22 G41 cutter radius compensation Left 1 22 G42 cutter radius compensation Right 7 22 G43 enable tool length offset eee 7 23 G44 enable tool length offset eee 7 23 G49 disable tool length offset ee eee 7 23 G50 clear axis scale factOIs ccceceeeeeeeneeeees 7 23 G51 set axis scale factors eecccseeeceeeeeeeeees 7 23 GIL OSES a Sota cit cla cael Sancta eal Geeta eo Ges 7 23 G53 move in absolute machine coordinates 7 24 G54 select fixture 1 oo eeccceecccseseeeeeeeeeenes 7 24 G55 select MIXUULE 2 indica ten eenia 7 24 G56 SClOCE TI XtURC Janean ciated das 7 24 97 SCLC CET CUS Ponien e se 7 24 95 eselet TUG Soene e ie 7 24 99 select any Ml KUNG odine Meolwcandiatecn ite 7 24 G61 set exact Stop mode ee eeeeeeeseeeeeeeeees 7 25 G64 set constant velocity mode ccceee 7 25 G68 define coordinate system rotation 006 7 25 G69 Clear coordinate system rotation 006 7 25 G73 high speed peck drilling canned cycle 7 25 DUE DACK DRO soc eatileccnenamncaoed esana o 7 26 G80 cancel modal MOTION ccseeeeeeeeeeeees 7 26 G81
104. MO tui cntinces tata taluka tenths ace tetsu ct 6 7 6AL Adjustable Parallel Method nisreen i a a a 6 8 O32 C OMMENS On COUT Gis a e a outs a a a a 6 8 63 3 Workine withoutthe tool table ieie i aa a 6 8 Oak Direc Ey TOFS DRO vee e a a a a a e 6 9 0a Usmo he Tonci is esiaine a a a ieauiolasna toatl tale 6 9 6 34 Tool Vable with General Toon Teresie a e e a e a a a dented 6 10 6 3 5 Tool table withthe Tool Seer ace svaccose cock ieres naaa ai etnai iae 6 10 6 4 Comments on Tool Offsets siseses aere secs 6 10 6 5 Settima X and Y OM SClS is ccccks cece cecccccsedeecch cc sececseccececseccesccccedescetcessacdsceceeccccstscecsucccetssects 6 11 Oo SCY aipa a aa An 6 11 W WEP OD e e a a A acess 6 11 O3 Merari Oils ai EOS Cee a 6 11 03A Waser Centerme Lechnigu essiens in a 6 12 6 6 How Work Offsets WORK istostied scssisccidaversdssiesavsi Eo se sstnedsasdaneiueasssacuadaveaneasoeadsasdeuecsisdoues 6 12 6 7 Multiple Work Origins a ccesatesccccsseeteeecceessvosceaseeccccesrcwcccslesestestocessesioeecdeescvecdeebssecdesbevecccs 6 14 OLE GIA WORK OTMSCE ierioremis gat adonl cintdasaeetdunhsieddeh debater sdatdeshbatidondcdnideskaattdalens 6 14 G72 Other Work OMS ClS sith tek th dart a a a drei lontienid hide aaa 6 14 6 8 Cutter Diameter Compensation ssssescsseccsseccsseccossecossecsssecosseesossesossesssseessseessssessssesso 6 15 6S1 CAD CAM and Wizards eriein is Ea EEA LE ASE ETE 6 15 6 8 2 Concepts for Cutter Diameter Radius Compensat
105. N CIN G eninin 5 3 PCNC computer mounting arrangements 2 3 PONG concepto AAE NAE 1 3 PCNCConfig Deinine Probe typeren a 9 14 Peck drilling canned cycle Ere E E E E Ad T ET 7 29 Peck drilling canned cycle high speed CTOs artes E E E E E 7 25 Pondant 408 SN Innan 5 16 31138 Rev B1 4 Appendices Performance expectations sincessansssessetcnensseecenuneatins 1 3 Plane selection CTF GIS GID CUNEO aasre 7 19 POLAR MOJE aoe aA 7 18 Power distribution FOUDICSN OCU NO oaiae ATRAS 9 23 Power supply requirements 0cccseeeee 2 3 2 7 PE TOA A A 1 1 Printer port setting non standard address ccceeeeeee es 9 12 P ODO a E weal See Straight probe CaltbratlOncn2 cineca thee eee 8 12 Probes and Tool setters lt tcsudea lucent chet iueen hate aleiaein 8 4 Probing comprehensive ASY ciseau ei 8 9 finding center Of Dore assieta 8 6 finding position Of a face ccceceeeeeseeeeeeeeees 8 6 TOP COMET OLA VISE eea a 8 6 setting coordinate rotation ccccceceeseeeeeees 8 11 SPIE A A aea e E 8 5 SUCE Auna a e a e Maa 8 7 PA EE O aut E ATE ET 8 7 Profile display name of profile in use ccceeeeees 5 6 Program error bandhing ssc salah cots chos eae seul reniei aait 7 37 Program end IVI OZ M Oseere nan ail 7 32 Program extremae a 5 11 Program stop INOW ssc duct eased carte ttre aura E A 7 32 Pullback DRO OT assessed ear E E ee a 7 26 Pulleys spindle speed
106. NC ashe tlsas st ccaee har ee RE 5 3 L op control Tamil yieee 5 13 M MOO program stop sssesssesssessseesserssersseesssesssee 7 32 MO1 optional program Stop cccccseseeseeeees 7 32 MOZ SRO OT AIM CNG spies Serco parades sence viata ares 7 32 MO3 spindle clockwise eccceeeeeeneseeeeeeees 7 33 M04 spindle counterclockwise ccseeeee 7 33 MOS stop spindle serisinin eana 7 33 MO7 mist coolant on cceceeeeeeceeeeeeeseeeeeeees 7 34 MO8 flood coolant ON csececseeeeeseeeeeeeeees 7 34 MO9 all coolant Off cc eccceecccseeeeeeeeeeneees 7 34 M30 programy end vesteod enea ada 7 32 M48 feed and speed override oM 00068 7 34 M49 feed and speed override Off 00068 7 34 M871 tapping canned cycles cccceecccseeeceeeeeeeees 7 34 M87x tapping canned cycles cceceecccseeeeeeeeeneees 7 34 M98 subroutine Call cc eecccceeeeeneseeeeneees 7 34 M99 subroutine return ceecceceeeeeeeeeeeeeee ees 7 34 Mach license installation cccccescceseeeeeeeeeeees 2 9 Machine coordinates COSA MOVE Mien N sess 7 24 Machine modes de Ned eiin E 7 10 Machine ON LEDaren eninin 2 12 Mac hOS sarro E e i 2 9 MactO M COIE eeii aE 7 35 Macros OVER VICW On WUN G ei soni co shaestas ninna ian 7 35 Main SWIM ense aA 2 10 5 1 Maintenance Bearing preload adjustment c ccceeeeeees 9 8 MOA OM oa E 9
107. Nothing else except a comment should appear on the same line as a subroutine label Note that line numbers are not permitted with an O word in the current release of the software Word A word is a letter other than N or O followed by a real value Words may begin with any of the letters figure 7 1 The table includes N and O for completeness even though as defined above line numbers are not words Several letters I J K L P and R may have different meanings in different contexts A real value is some collection of characters that can be processed to come up with a number A real value may be an explicit number such as 341 or 0 8807 a parameter value an expression or a unary operation value Definitions of these follow immediately Processing characters to come up with a number is called evaluating An explicit number evaluates to itself Number The following rules are used for explicit numbers In these rules a digit is a single character between 0 and 9 e A number consists of 1 an optional plus or minus sign followed by 2 zero to many digits followed possibly by 3 one decimal point followed by 4 zero to many digits provided that there is at least one digit somewhere in the number e There are two kinds of numbers integers and decimals An integer does not have a decimal point in it a decimal does e Numbers may have any number of digits subject to the limitation on line length Only about seve
108. O MAN we ASSY a l l 2 PN 30737 A DRIVE 325 l PN 30737 Y DRIVE X DRIVE L J ACCESSORY a b ePt P220 l j ee 324 403 Pp P 1 P2 320 Brake Wires Be So lee a ea N fo 404 F er Pg oo j D Cie 22 A Al as NOTE RESISTOR x r EE k COMES PRE WIRED feat 6 thru J6 12 1thru J6 6 9 fifty Eoso J6 19 thru J6 24 J6 13 thru J6 18 seo tie 6 POT1 31041 A MANUAL SPEED E LM1 J1 2 T2 to J1 1 T1 to J1 2 B5 to J1 3 T5 to B2 to B4 to J1 4 B6 to J1 6 J1 4 jumpered to J1 5 B1 B2 B3 B4 B5 B6 B7 A OPTIONAL LOAD METER T1 to LM1 J1 2 31101 B1 to LM2 W T6 TO LM3 B3 TO LM4 INSIDE BOX RIGHT SIDE 15 A 4 j INSIDE DOOR OUTSIDE DOOR STEPPER DRIVER A AXIS TORMACH MACHINE CONTROL BOARD SEE MOUNTING BOLT PATTERN IN DETAIL BELOW YOLSISSY ONINVd VO MOUNT PLATE 30210 BOTTOM Parts List for PCNC 1100 Series Il Drawing D40182 Electrical Overview June 2011 Number Description ID Number Description Number Description 0 1 22 22A 4 5 6 7 9 0 1 2 30462 Estop PB1 3 31104 Terminal Block 30742 X amp Z Limit Switch non sealed 30463 Push button PB2 4 31049 Braking Resistor 31860 X limit Switch sealed 1 30464 Key switch with keys SW7 5 30177 AC Power Outlet 30461 Y Limit Switch 1 6 7 8 30165 O Mount Plate o 9 30685 J3 cable console l Jo o ooo o 0 30684
109. OUTLET__ OUTLET A eee D40182 I O MOUNT PLATE DB25 MALE a June 2011 sai EN Cy L ee EO ee ee O E E AE i ee et ONE J SW6 If Fa ele he q 206 l COMPUTER a best 4 o 203 TPT I 2 202 E 202 taal ALL THICK LINES 14GA WIRE BLACK nae 1 p 4 __ PB2 ae a ee ee ee 206 p 207 l 200 ISTART 30684 ae ESTOP 205 m z NOTE FU3 AND FU7 PERE 4 O O 202 l l MOUNTED TO TRANSFORMER i et A se ee ee TOY ee ee ee Black Wire aus l KEY SWITCH s Ig 4 p lt aoe MES 103 104 oe ecu a l BELT GUARD nas RANS A Tormach Machine Control Board ls aT ai nil 30685 Tan 100 EETA FU7 3 15 2 15 AMP DISCONNECT a 230 120 PRIMARY SECONDARY o J1 TE CONTROL POWER TRANSFORMER yoy pongo E KA MIYE FRAME BONDED TO EARTH GROUND STIT 100 L23 230 48 PRIMARY SECONDARY DC BUS BOARD l Z C1 a DC BUS ower i See D a J2 1 J2 2 LED2 v h h COMPUTER A EERE RA LS1 7 LS2 7 LS4 AND J2 0 OMITTED P DERE 7 o o ON LATER MACHINES PET C XMF2 SW1 FWD REV 1 1 A VFD C1 CAP 15 000 uF 301 L J p LED1 31036 Brakes ra g MACHINE X LIMIT Y LIMIT Z UPPER Z LOWER o C2 Brake RLY Bente swe STOP a ne LED ASSY LI D P N 31040 T SW3 START 8 ane ALL THICK LINES 14GA WIRE BLACK cpg a SSS Se SS SS SS SS SS SS SS SS SS SSS E25 oe FUTURE ADDITION 302 Io os O PE PE GND SW4 AUT
110. OverRide Limits button before clicking Reset on each occasion Feeds and Speeds Calculator Different materials and tooling require different cutting speeds and feed so you will need to use published tables and your experience to define the optimum spindle speed and the feed rate for any given job A simple calculator on Imperial Speed Feed calculator the Settings screen will however do Don t forget to press lt Enter after setting a DRO the math for you when you know a Cutting speed Cutter diameter in m i alc RPM Feed cutting speed in feet per minute and required SFM _From toottabie i a chip per tooth loading figure 5 27 12x 23 0 375 x Pi P 4 RPM Enter your cutting data into the No of flutes Chipflute Feed atthis speed DROs not forgetting to press Enter RPM x 3 x 0 01 o 7 0 in min for each value and click the Calc Don t forget to press lt Enter gt after setting a DRO RPM Feed button The screen labels show the calculation that is being Figure 5 27 Speed Feed calculator Using Tormach PCNC 1100 Series II 5 14 31138 Rev B1 4 5 2 2 17 5 2 2 18 Machine controls done for you Tapping Configuration Family The control software allows use of the Tormach Tapping Heads PN 30612 and 30613 without a detailed understanding of the sequence of moves that are needed to control the head The holes are tapped by using one of the M code macros M871 M872 M873 or M874 The macros work as ser Mu
111. Spindle Drive subsystem Using Tormach PCNC 1100 Series II 9 46 31138 Rev B1 4 Warranty Specifications Customization and Troubleshooting stop Rocker Switch start Rocker Switch manual auto Rocker Switch www tormach com 4 on CAUTION Read and understand the computer off manual before operating ai macis _ ot Wear eye protection an machining practices at all ai coolant computer machine start manual Atart stop forward C A Ew 3 aay D 0 accessory eieae RPM x 100 spindle reverse stop Personal CNC 1100 Speed Pot spindle lockout Keyswitch Figure 9 31 Operator spindle control components With Control Power On the Spindle Lockout Keyswitch On and the Spindle Drive Door closed the drive is in a ready to run condition When the Manual Auto Switch is in the Manual position the drive is turned on and off with the Start and Stop Rocker Switches The Speed Pot will then control motor speed When the Manual Auto Switch is in the Auto position the machine control software provides start stop and speed information based on user input You will find listed immediately below a Problem Resolution Checklist section For more in depth explanation of this subsystem please go to the Details section that is after the Checklist section 31138 Rev B1 4 9 47 Using Tormach PCNC 1100 Series Il Warranty Specifications Customization and Troubleshooting Problem Resolution Checklist fo
112. Subroutine call IVS dase Steet daa ude tla ac delaaa nde E 7 34 repeating several tiMes cccceeeeeseeeeeeeeees 7 34 Subroutine label LOMA Ol eaae E AA 7 7 Subroutine return MID terete sare cracthass Pen aurea T E 7 34 Support irom Torma Minsan nennen nE e a 9 1 Sweis m aiaa a A 2 10 Syntax Code definition cccceeccseeeeeeeeeeees 7 11 Syst m specification Sisirin iaei 9 3 T ED WOEG 4100 selects eats sa temedestdontecauees 7 36 Tapping Dwell mode for blind holes e 8 16 sequence for threading a hole 060 8 14 Tapping heads description of the heads ccccceeeeeeeeeeee es 8 14 Teach contol Paty reini 5 12 Testing Control Software installation 06 10 14 DiverTest program cccccccseeeccseseceeeeeeees 10 14 Tool change Supplied M6 Macros cccceeeecseseeeseeeeeeeeees 7 33 Tool change position SOO Oaea ne ee ea ro ie 7 35 Tool Chan sin senan E 5 3 Tool length setting by tool Setter eecccseecceseeeeeeeeeenes 8 8 Tool length offset Areena DE ee E te 7 23 Er e T ol l e A E A EA 7 23 OD disa blenenn A 7 23 Tool select TWO aer E 7 36 Tool setters and probes ceccccseeeceseeeeeeeeees 8 4 Toolchange position control family 0 5 14 Toolpath display looks inaccurate ceccceeeeeeeeeeeees 5 11 Using Tormach PCNC 1100 Series II Index 26 Tormach Jog Shuttle controller
113. The low range 100 to 2000 RPM is suitable for most machining operations with ferrous and other tough materials The high range 250 to 5140 RPM is suitable for small diameter cutters and plastics and non ferrous materials The range change is performed by moving the V belt from the motor from the top pair of pulleys high speed range to the lower pair low speed range To change the belt position e Open the protective door Use the rear handle to unlock the motor mounting plate and pull the motor forwards The belt will slacken and can be moved from one pulley to another figure 5 8 It is slightly fiddly to get the belt through the slot between the bottom pulley and the head casting e Retighten the belt so there is between and 14 belt movement midway between the pulleys Lock the motor mounting and stow the handles in the vertical position Screen Control Panels Using the Screens Although at first sight you may feel daunted by the range of options and data displayed by Control Software this is actually organized into a few logical groups We refer to these as Families of Controls By way of explanation of the term control this covers both buttons and their associated keyboard shortcuts used to operate the software and the information displayed by DROs digital read outs labels or LEDs light emitting diodes The elements of each control family are defined for reference in this chapter The families are explained in
114. Tomach Machine C ontral Board Jog Shuttle Control Ribbon Cable Bulkhead Connector In Bottom of Cabinet Parallel Port Cable 5 Pin D Connector Com puter Figure 9 25 Computer control communications The Mach3 Software is the machine control software for the PCNC It allows for manual jogging of the X Y Z and A axes the spindle speed and the coolant pump through the computer interface It also allows the machine to run automatically with user supplied programs The Mach 3 Software runs on a Personal Computer and communicates with the Tormach Machine Control Board to provide machine control The computer LED on the machine operator panel must be illuminated before the computer can control the machine Using Tormach PCNC 1100 Series II 9 30 31138 Rev B1 4 Warranty Specifications Customization and Troubleshooting Problem Resolution Checklists for the Computer Control Communication Sub Section Computer Control Communications Sub system Checklist Table 3 1 Computer Communication cannot be established machine LED cannot be turned on Possible Cause Prob Action to identify Cause Discussion ability of Problem Control Power is off Turn on Control Power See Control Power Sub section connector and the Machine Control Board not plugged in Parallel Port cable is Medium Check the cable You may want to try a new cable if not connected properly connections Check the you have one Ribbon Cable J4 Medium
115. Using the Tormach PCNC 117100 Programmer s and Operator s Guide to the Personal CNC 1100 TORACH Series LI 2011 Tormach LLC All rights reserved Questions or comments Az Please email us at PCNC 1100 Series II Manual info tormach com ORMACH Part Number 31138 Rev B1 4 Using Tormach PCNC 1100 Series II ii 31138 Rev B1 4 1 1 SN ee ef SN ee ee B OW Ne 1 2 1 3 1 3 1 1 3 2 1 3 3 1 4 1 5 2 1 2 1 1 212 2 1 3 2 1 4 2 2 2 2 1 22 2 2 3 2 4 2 4 1 2 4 2 2 4 3 2 5 2 6 2 7 2 1 1 212 2 7 3 2 1 4 2 4 1 1 2ZAN2 2d Lek 2422 21253 22A Blad 2 1 3 1 Blaz 21 53 2 7 3 4 2 7 4 1 Contents CU AGC va giocscapeescaeeceeeeecssenneseecoesaneec saneec demec seen apenessauescenensaueedsaaneceeeeecs 1 1 By OY saeco ce saectae ats cae ea eos c sect sae decease ald oe see wuts e eles os cea scenes sede susoeun scaweceedcunoeseieecesesteee se eues 1 1 PVG CUR CaP SAT Cy ig chao anlos E E nanan oitstus conden E E E E 1 1 General Operating SAICIy scarce ssascsastoananersadacaiamoonsaneaanacaenmasaaaananasncaatenasdetnodaasenmeasesentocsahenses 1 1 Safety PUBLICATIONS cccceccccseeccceeeeceeeeeceeeeesneeeseeeeseneeeseeeeseeeeeseeeeseusessaseeeensesseneesasesaaaes 1 2 Say e Orc O e E rer rrr trey terre rrr Te 1 2 Personal CNC CONGO wsssccscscssesceseisnseccssscetweasaseasssscesesssceusecsseeessesucswencesaesteesassseasesessuess 1 3 Periormance Expectations siscesssscececseccs
116. We will give less detail on using these e g assume you know about shortcuts and when to use Enter in subsequent chapters 31138 Rev B1 4 2 15 Using Tormach PCNC 1100 Series Il 3 3 1 Making your first part Making Your First Part This chapter shows you how to make your first part with the PCNC It assumes that you have no prior experience with running a part program on a Computer Numerically Controlled machine tool Even if you have previous experience you will find that following this tutorial gives you an introduction to the controls of the machine Coordinates Coordinates are simply how you describe where the tool is positioned We assume that you have the computer and PCNC setup and switched on and are looking at the Simple screen Referencing the Machine You have seen that jogging the machine moves the tool and this changes the numbers in the X Y and Z axis DROs You may have wondered where these numbers come from and indeed doubted that they are very sensible The answer is that they are probably meaningless The computer has no way of knowing yet where the tool or table 1s positioned Referencing is the process which puts the machine in a known mechanical position and sets the corresponding axis DROs 3 564 3 Ret A The known position is where the limit switches operate with Z at the top of the a 2 6 D 4 0 o column and the spindle over the top left hand corner of the table This position is calle
117. When G52 is executed the origin of the currently active coordinate system moves by the values given The effect of G52 is cancelled by programming G52 X0 YO etc Here is an example Suppose the current point is at X 4 in the currently specified coordinate system then G52 X7 sets the X axis offset to 7 and so causes the X coordinate of the current point to be 3 The axis offsets are always used when motion is specified in absolute distance mode using any of the fixture coordinate systems Thus all fixture coordinate systems are affected by G52 7 7 17 Move in Absolute Coordinates G53 For linear motion to a point expressed in absolute coordinates program G1 G53 X Y Z A or similarly with GO instead of G1 where all the axis words are optional except that at least one must be used The GO or G1 is optional if it is in the current motion mode G53 is not modal and must be programmed on each line on which it is intended to be active This will produce coordinated linear motion to the programmed point If G1 is active the speed of motion is the current feed rate or slower if the machine will not go that fast If GO is active the speed of motion is the current traverse rate or slower if the machine will not go that fast It is an error if e G53 is used without GO or G1 being active e G53 is used while cutter radius compensation is on See relevant chapter for an overview of coordinate systems 7 7 18 Select Work Offset Co
118. Wizards for conversational programming cc eee 4 8 Word 18 A001 0g 0 Gee enn en eee ae ee ew ae ee ea 7 7 maal CC CLS escapee a a E 7 7 Work offsets by Touch DUTLONS cca ti craves Giles elentiedsceatilecunleatnicdene 6 9 by typing into DRO 1 eecccseeeceeeeeeneeeees 6 8 setting X and Y by probe ccccceeeeeeeeeees 6 11 USING More than One iienaa 6 13 X XMLTweak setting non standard address cc seeeee 9 12 spindle speed calibration cccseseeeeeeeeees 9 11 Y Y axis drive assembling on new machine ccceeeeeeeees 2 4 31138 Rev B1 4
119. act the Z axis at traverse rate to clear Z Example 1 Suppose the current position is 1 2 3 and the X Y plane has been selected and the following line of NC code is interpreted SoU Gow Gye XA Vo Alag R20 This calls for absolute distance mode G90 old Z retract mode G98 and calls for the G81 drilling cycle to be performed once The X number and X position are 4 The Y number and Y position are 5 The Z number and Z position are 1 5 The R number and clear Z are 2 8 The following moves take place e a traverse parallel to the X Y plane to 4 5 3 e a traverse parallel to the Z axis to 4 5 2 8 e a feed parallel to the Z axis to 4 5 1 5 e a traverse parallel to the Z axis to 4 5 3 Example 2 Suppose the current position is 1 2 3 and the X Y plane has been selected and the following line of NC code is interpreted GIL GoL GIG XA YS ARU Rico Es This calls for incremental distance mode G91 old Z retract mode and calls for the G81 drilling cycle to be repeated three times The X number is 4 the Y number is 5 the Z number is 0 6 and the R number is 1 8 The initial X position is 5 1 4 the initial Y position is 7 2 5 the clear Z position is 4 8 1 8 3 and the Z position is 4 2 4 8 0 6 Old Z is 3 0 The first move is a traverse along the Z axis to 1 2 4 8 since old Z lt clear Z The first repeat consists of 3 moves e a traverse parallel to the XY plane to 5 7 4 8 e a feed paral
120. al Rotation Diameter Rotational Diameter Control Family A 0 0 0 0 0 As described in the Feed Rate control family it is possible to define the approximate size of a rotated work piece so the rotational axis speed can be correctly included in the blended feed rate The relevant diameters are entered in the DRO on this family figure 5 24 Figure 5 24 Rotational diameters The Axis control Family has a warning LED to indicate the setting of a non zero value here Note A value is not required if rotary movement is not to be coordinated with linear axes In this case a suitable F word for degrees per minute or degrees per rev should be programmed 31138 Rev B1 4 5 13 Using Tormach PCNC 1100 Series II 5 2 2 14 5 2 2 15 5 2 2 16 Machine Controls Toolchange Position Control Family This family defines the place the machine should go to when a request to change a tool occurs or when the Goto Toolchange button is clicked A part program can go to it by using the M998 code figure 5 25 The position is defined in ae machine coordinates i e Define Toolchange position units mm inch 0 Toggle T C Units Currently set for inches relative to the home switches and in the default machine units Tool Change Location G28 Home Absolute coordinates fram Enter the special value piace INCHES coordinates 9999 if you do not want a given axis to move when a x 9999 0000 0 0000 oe Y 9999 0000 0 0000 e units
121. aling background task This can create havoc if it occurs while the machine is running a program Some updates force a system re boot after a timeout period This is disastrous when running a job with the screen unattended 1 Right Click My Computer and select Properties 2 Click Automatic Updates tab 3 Uncheck Keep my computer updated 4 Click OK Set Computer to Standard PC not ACPI PC Background This optimization procedure is not needed on most computers but it is required on some We recommend this procedure only be applied last and only if necessary Advanced Configuration and Power Interface is a power management specification that allows the operating system to control the how power is applied to the computer s devices For example an ACPI PC can be turned off completely by using Windows Shutdown function With a Standard PC not ACPI the Windows Shutdown function will close programs and prepare the operating system then open a window with the statement You can now turn off your computer A Standard PC can only be turned off at the power switch on the box itself not through the operating system Right Click My Computer and select Properties Click Hardware tab Click Device Manager button in the middle Double click Computer Right click on Standard ACPI PC and choose Update Driver Choose Install the software from a Specific Location Advanced Click Next Choose Do not search I will choose driv
122. all the information is correct click the Done button Close the PCNCConfig software program 8 Open the PCNC control software program again and confirm that the computer is calibrated with the machine by repeating step 4 and checking that the frequency is 34 6 Hz 9 Occasionally repeating the above steps may be required to hone in on the target speed Note Since each computer is different it is important to re run the PCNCConfig program whenever you connect a new computer to your PCNC Using Tormach PCNC 1100 Series II Configure PONC Profile 1 Machine Config is for PCNC770 ESPEN C3SPCNC1100M3 l1 xml 3 Now configure data in the panels below Jog Steps CAUTION Do not run this utility when machine Control Software is running or you will lose your changes when you close the Control Software r Printer Port Printer port address in Hex 378 does not need Ox in number Duick settings PCNC3 Default Hel 0 005 2E 002 Small steps linch oO Perii Spindle Calibration Small steps Spindle steps per unit are 11780 willbe 1178 0 0005 mm Run spindle in low 0 001 or type in the gear with S word as frood sequence 002 you want For YFD Fr reading safety avoid f a big change from last Help L r Probe Logic Sense back to first Probe makes circuit on touch Tormach standart Info m 4th Axis Homing Homing disabled Info 4 Save P
123. also offer an alternative algorithm which is slower may cause more wear on the tapping head but allows more accurate control of depth and so is suitable for tapping blind holes Notes 31138 Rev B1 4 Feed the Z axis down at a rate corresponding to the pitch of the thread and the spindle speed The distance of this move will be the depth to be tapped minus the distance that the head needs to be extended for the clutch to disengage plus the initial Z clearance Pause for 2 seconds The rotating tap will be pulled into the work by the existing thread until the clutch disengages This depth in independent of speeds or feeds The tap stops rotating and stays at the de clutch depth Feed the Z axis up at a rate corresponding to the pitch of the thread and the geared up speed of the reverse running tap The distance of this move should be sufficient to ensure the tap completely leaves the thread Optionally position the Z axis at the initial Z clearance height 8 15 Using Tormach PCNC 1100 Series II Machine upgrades and configuration It is usual to underfeed slightly in both directions 2 to 5 This might result in the clutch disengaging but it is better than hitting the stops on the retractable spindle The choice of a suitable tap designed for machine tapping is important Conventional taps for manual use are unlikely to give satisfactory results except on shallow depths with easy to machine materials The exact depth fed in metho
124. ancel G81 Spotting Drill Cycle G82 Speed Peck Drill Cycle G83 Full Retract Peck Drill Cycle G85 Boring Cycle G86 Boring Cycle Spindle Stop G87 89 User Definable G90 Default Absolute Input G91 Incremental Input G92 Set Program Part Zero MOO Program Stop MO1 Optional Program Stop M02 Program End M03 Spindle Clockwise M04 Spindle Counter clockwise M05 Spindle stop M06 Tool change MO7 M08 Coolant M09 All Coolant Off Options The PCNC comes preconfigured for low cost 4th axis addition Software support wiring cabinet holes and drive mount holes are all in place for an easy 4th axis addition A wide range of accessories such as tapping heads probes tool setting sensors Power Draw Bar and Automatic Tool Changer are available Maintenance Foreword Understanding Machine Design The PCNC has been designed for user maintenance but an important prerequisite to effective maintenance is an understanding of some general machine design concepts For many owners the PCNC is their first experience with a serious machine tool and they may be unfamiliar with the ideas presented here This section should be read and understood before attempting any adjustments to the machine Machine Stiffness Iron is a wonderful thing In the context of the human experience the iron and steel of your mill seems exceptionally stiff and essentially immovable Never the less any physicist or material scientist will tell you that iron is a Hookean
125. and feed override controlled by M48 M49 000 eccceccceseeeeeeees 7 34 Spindle belt Chan gQing ccccccecccceseeceeseceseeeeeeseeeeeseeees 5 5 Changing the belt position cccceeeeeeeeees 2 12 Control panel Forward Reverse switch 2 12 Control panel Start SWitch ccceccceeeeeee ees 2 12 Control panel Stop SWitch cccececeseeeeeeees 2 12 LOCKS cai donk sort acht aelduca bach dostsosntuh denies beaudeakeos 5 3 LOCKOUE SWILCH ooreen arenae na s 2 12 M03 clockwise snnnsonnseenseesssessseessersserssees 7 33 M04 counterclockWise ccccccseseceseeeeeeees 7 33 MOS SIOP sions atau cage dase o E EE O 7 33 Using Tormach PCNC 1100 Series II IVI CTU AICO ceca cn sencnn sian O 2 12 Spindle controls Ol COMMON pane lessi uretadswetcsahs 5 2 Spindle speed control family described cccceecceseeeeeeeeees 5 8 DW OLG TOS CU ccscsshonsesaetcncnancnceaanestcasneaseinananaas 7 36 Spindle speed calibration cccccceeeeeeeeeeeees 9 11 Sand CADIE ee Renae ieee a a renee ereeee rere 2 5 SAC DUON este cae a vanedeasescadacsnartdeaistataaacbtewadennedent 2 11 On control panel cecccceececseseceeeeeeeeseeeeneees 5 2 Status LEDs On Control panelon aoe 5 2 Step size customizing the standard list eee 9 13 SCOP DUON Sarasa belts e bree authactsae 5 10 Straight probe EXAMPIle protai aia a a 1 21 Goa elo nies eee yee eee eee See Straight probe
126. and machine coordinates for the given head position would have been a bigger if Referenced In practice the zero position of the referenced machine is chosen to be where the head stops after clicking Ref Z i e just below the Z limit home switch figure 6 10 This means that in normal use all Z machine coordinate values will be negative numbers and the work offset Figure 6 10 Actual machine zero values will be negative too The arithmetic of the equation Program Coordinates Work Offset Tool Length Machine Coordinates works fine with the negative values but it is not possible to draw a simple sketch like figure 6 9 The fact that machine zero can be anywhere and the work offset relates it to the work location explains why it is possible to use the machine un referenced In this case machine zero can be anywhere below the floor up in the roof space etc The work offset value when you have touched the tool on the top of the work will make this position be program coordinate Z 0 0 6 2 3 Programming Buttons or Direct Entry The example above shows the tool being selected directly through typing a number into the tool DRO 31138 Rev B1 4 6 5 Using Tormach PCNC 1100 Series Il 6 3 6 3 1 Offsets You can also command the tool change by entering directly into the MDI line Specifically when switching to tool number n enter Tn M6 G43 Hn on the MDI line M6 is the command to do a tool change and T indicates the to
127. ange from one mode to another The mode stays active until some other command changes it implicitly or explicitly Such commands are called modal For example if coolant is turned on it stays on until it is explicitly turned off The G codes for motion are also modal If a G1 straight move command is given on one line for example it will be executed again on the next line if one or more axis words is available on the line unless an explicit command is given on that next line using the axis words or canceling motion Non modal codes have effect only on the lines on which they occur For example G4 dwell is non modal Modal Groups Modal commands are arranged in sets called modal groups and only one member of a modal group may be in force at any given time In general a modal group contains commands for which it is logically impossible for two members to be in effect at the same time e g measure The modal groups for G codes are e group 1 G00 G01 G02 G03 G38 2 G80 G81 G82 G84 G85 G86 G87 G88 G89 motion group 2 G17 G18 G19 plane selection group 3 G90 G91 distance mode group 5 G93 G94 feed rate mode group 6 G20 G21 units group 7 G40 G41 G42 cutter radius compensation group 8 G43 G49 tool length offset group 10 G98 G99 return mode in canned cycles group 12 G54 G55 G56 G57 G58 G59 G59 xxx coordinate system selection group 13 G61 G61 1 G64
128. ape each wire coolant pump in Manual until your individually so it cannot are able to replace the Control short out then re apply Board power Using Tormach PCNC 1100 Series II 9 24 31138 Rev B1 4 Warranty Specifications Customization and Troubleshooting Power Distribution Checklist Table 1 2 Computer will not power up Possible Cause Prob Action to identify Cause Discussion ability of Problem Computer switch Check the switch Turn it on if required SW6 on Operator panel turned off Disconnect Switch in Medium Check the switch Turn it on if required off position Breaker turned off in Medium Check the breaker and GFI Turn it on and or reset if required user panel supplying PCNC or GFI if used Tripped Computer not plugged Medium Check the plug Plug it in if required into outlet Power Distribution Checklist Table 1 3 Coolant Pump will not run when Coolant Switch is in the ON Position Possible Cause Prob Action to identify Cause Discussion ability of Problem Coolant Pump not High Check the plug Plug it in if required plugged into outlet Breaker turned off in Medium Check the breaker and GFI Turn it on and or reset if required electrical wall cabinet supplying PCNC or GFI Gf used Tripped Disconnect Switch in Low Check the switch Turn it on if required off position 31138 Rev B1 4 9 25 Using Tormach PCNC 1100 Series II Warranty Specifications Customization and Troubleshooting
129. arting from 0 Note that this is not related to the N word line number You can type into this DRO to set the current line Run from Here Run from here performs a dummy run of the part program to establish what the modal state G20 G21 G90 G91 etc should be and then prompts for a move to put the controlled point in the correct position to for the start of the line in Line Number You should not attempt to Run from here in the middle of a subroutine Set next line Like Run from here but without the preparatory mode setting up processing Block Delete Using Tormach PCNC 1100 Series II 5 10 31138 Rev B1 4 Machine controls The Ignore Blocks button toggles the Block Delete switch If enabled then lines of G code which start with a slash e will not be executed Optional Stop The M01 Break button toggles the Optional Stop switch If enabled then the M01 command will be treated as MOO Goto Toolchange This button provides manual movement of the controlled point when the part program is stopped Tool Details Controls display the current tool its name the offsets for its length and diameter and whether the offsets are active ON Unless tool change requests are being ignored on encountering an M6 the Control Software will stop and flash the Change Req LED You continue after changing the tool by clicking Cycle Start Work Offset Details The name of the current work offset coordinate sy
130. aspects of safety setup location operation security and all other factors that involve safety The PCNC requires a minimum plan area of 67 wide by 43 deep This gives clearance for the full motion of the table and for minimal access for cabling etc The overall height required is 84 assuming that it is installed with the table at a working height of 36 Tormach offers a range of stands both ready made and designs for you to have constructed locally You should choose a well lit location and provide any additional task lighting to make it easy to setup work on the table Over time you will find that you accumulate a range of tools and tool holders so you should allocate space for storage of these near the machine A rack with numbered slots is convenient USB jogging i pendant LCD ho te a Screen q 4 i Keyboard 3 ae a 2 1 Ae Satie Personal A0 computer computer Figure 2 2 Computer and display to avoid errors when doing tool changes during a job Using Tormach PCNC 1100 Series II 2 2 31138 Rev B1 4 Prepa
131. at Arc Center In the radius format the coordinates of the end Shows G02 arc start point endpoint and point of the arc in the selected plane are specified center point along with the radius of the arc Program G02 X Y Z A R or use G03 instead of G02 R is the radius The axis words Y are all optional except that at least one of 3 the two words for the axes in the selected plane must be used The R number is the Center radius A positive radius indicates that the 2 arc turns through 180 degrees or less while a negative radius indicates a turn of 180 degrees to 359 999 degrees If the arc is helical the value of the end point of the arc on the coordinate axis parallel to the axis of the helix is also specified It is an error if 1 2 3 a e Both of the axis words for the Shows G03 arc start point endpoint and center axes of the selected plane are point omitted e NoR word is given e The end point of the arc is the same as the current point It is not good practice to program radius format arcs that are nearly full circles or are semicircles or nearly semicircles because a small change in the location of the end point will produce a much larger change in the location of the center of the circle and hence the middle of the arc The magnification effect is large enough that rounding error in a number can produce out of tolerance cuts Nearly full circles are outrageously bad semicircles and nearly so are only ver
132. ate 05708720073 nit 5 This family is explained in detail in Chapter 6 figure 5 19 ANAN Part XMATOrMA ath F Rack 0070 Process Spi iral pocket Register Mill Router 0 375 inch diamet 0 21 1811 0090 MOG T Mill Router 0 375 inch diameter 0 2 5 2 2 10 MDI and Teach Control Family G code lines blocks can be entered for immediate execution into the MDI Manual Data Input line This is selected by clicking in it or the MDI hotkey Enter When the MDI line is active its color SE S changes and a fly out box showing SEES orme zeai AARAA AREPAN the recently entered commands is Figure 5 18 Notepad to edit G code displayed figure 5 20 The cursor up and down arrow keys can be used to select from the fly out so that you can reuse a line that you have already entered The Enter key causes the current MDI line to be executed and the MDI remains active for input of another set of commands The Esc key clears the line and de selects it You need to remember that when it is selected all Load Edit stam Teach stop Teach keyboard is written in the MDI Start Teach eTe line rather than controlling the Offset On Off E T 1 machine In particular jogging keys will not be recognized you Offset 1 must Esc after entering MDI os a 5440 Y1 8122 T 0 2015 20 oo 55 0200 oo a 8065 1 8122 1I 0 4640 30 0000 0210 Gol x3 0690 ets ae a 690 1 8122 I 0 7265 30 0000 315 0240
133. ay have occurred on the machine for the previous owner 4 Analyze what might have changed since the machine worked properly 5 Read over the description of the subsystem involved to improve your understanding of that subsystem 6 Make sure you can repeat the problems Do it a few times and record the results Determine if you can repeat the problem exactly 7 Record information from the diagnostic screen of the control software 8 Try to define the problem as concisely as possible Most often it is a good idea to write down the problem definition Many times when doing this you find it leads you to answering the problem yourself 9 Consider sending Technical Support an email rather than calling if time permits It is often best to send an email rather than call because it tends to force you to define the problem better When you correspond by email you don t have to worry about keeping notes or having to interpret the hastily transcribed notes one takes during a phone conversation Even if you want to call having first sent an email can help the conversation go better Frequently Found Problems Repeat Offenders There are several frequently found problems with all electro mechanical machinery such as the Tormach PCNC It is not that the problems are frequent but among the problems that have occurred these are more frequent than others The first 6 items in this list fall into the category of machinery in general while the last item
134. ays at some location called the current position and the Control Software always knows where that is The numbers representing the current position are adjusted in the absence of any axis motion if any of several events take place e Length units are changed see Warning above e Tool length offset is changed e Coordinate system offsets are changed Selected Plane There is always a selected plane which must be the XY plane the YZ plane or the XZ plane of the machining system The Z axis is of course perpendicular to the X Y plane the X axis to the YZ plane and the Y axis to the XZ plane Tool Table Zero or one tool is assigned to each slot in the tool table Path Control Modes The machining system may be put into any one of two path control modes 1 exact stop mode 2 constant velocity mode In exact stop mode the machine stops briefly at the end of each programmed move In constant velocity mode sharp corners of the path may be rounded 31138 Rev B1 4 7 3 Using Tormach PCNC 1100 Series I 7 2 7 2 1 7 2 2 7 2 3 7 3 7 4 7 4 1 Programming language reference slightly so that the feed rate may be kept up These modes are to allow the user to control the compromise involved in turning corners because a real machine has a finite acceleration due to the inertia of its mechanism Exact stop does what it says The machine will come to rest at each change of direction and the tool will therefore p
135. azards than they incur during normal operation Electrical tests may have to be done to live circuits Guards may have to be removed and sometimes a safety switch will have to be fooled in order to make an observation Take things slow and be extra cautious Keep in mind that we are not going to repeat a big safety paragraph before or between every step of a troubleshooting procedure Doing so tends to underscore its importance But do yourself a favor and think about safety whenever you are taking any action e Never do anything with machine power on that can be done with machine power off e Wear eye protection and use appropriate protective clothing such as gloves e Don t wear loose clothing e Don t wear jewellery e Don t do any electric testing if the floor is wet Don t run the machine either e Don t put your hands anywhere you don t have to Keep your hands in your pockets if you can e Think about each move you are going to make and what you can do to be as safe as possible before making the move e Focus on the task alone If you feel preoccupied with something else and you think your mind could be wandering wait until such time as you can concentrate fully on the task 9 6 3 2 Tip on Computer Diagnostics The Control Software provides a diagnostic screen which can be useful for troubleshooting Become familiar with this screen The software also has an information line next to the Reset that can provide va
136. ble to send very accurately timed signals to control the axes of the machine tool Windows likes to be in charge and runs normal user programs when it has nothing better to do itself So the Control Software cannot be a normal user program it must be at the lowest level highest priority in the computer inside Windows that is it handles interrupts Furthermore to do this at the high speeds possibly required each axis is given attention 25 000 times per second the driver needs to tune its own code Windows does not approve of this viruses often play this trick so it has to be asked to give special permission This process requires the reboot So if you have not done the re boot then Windows will give the Blue Screen of Death and the driver will be corrupt The only way out of this will be to manually remove the driver Having given these dire warnings it is only fair to say that although requested when upgrades are installed the reboot is only strictly required when the driver 1s first installed Windows XP boots reasonably quickly that it is not much hardship to do it every time Testing the Installation It is now highly recommended to test the system The Control Software is not a simple program It takes great liberties with Windows in order to perform its job in fact it actually runs Windows rather than Windows running it this means it will not work on all systems due to many factors For example QuickTime s system monitor qtas
137. blem We will rank the probability of the various potential causes of problems We will also make note of those problems we have found to be FFP s Frequently Found Problems A fifth key principle is to complete one test before starting anther Don t fall victim to making things worse by troubleshooting More than once a troubleshooter has removed a wire to make a measurement and in his haste to solve the problem moved on to the next test without putting the wire back on This can impact the next test and certainly will impact the machine operation 31138 Rev B1 4 9 17 Using Tormach PCNC 1100 Series II Warranty Specifications Customization and Troubleshooting Philosophy y Tips and Tools for Troubleshooting t Frequently Found Problems l Find Appropriate Sub System i Read Subsystem Overview Do you find yourself needing an electrical schematic to troubleshoot or would you like to be able to use one when troubleshooting Yes Proceed to the Details Section in the Relevant No Sub section Apply your knowledge and try to solve the problem Is your problem s No solved y Proceed to Problem Yes Resolution Checklist in the Relevant Sub Section y Yes Congratulations Well done Is your problem solved No Call Tormach Technical Support Figure
138. bricated slideways and superior to plain ground surfaces or hardened amp chromed surfaces We don t have data on how long the material will last on the PCNC but we do know that there have been no reports of appreciable wear even on machines that are reported to have seen more than 5000 hours of operation If you use the oil lubrication system and keep the protective bellows in good shape the slideways are not normally maintenance items The central lubrication pump should be filled with quality way oil This could be Perkins Perlube WL 68 Tonna 68 Shell Vactra No 2 Mobil Way lube 68 Sunoco WayLube 68 Texaco Febis 68 Esso or equivalent oil A shot of lubrication should be given for each 4 hours of operation and after the machine has stood unused for more than 48 hours Always make certain that the lubrication oil is clean The oil is delivered to 15 points throughout the machine This includes the 12 sliding surfaces 4 each on the 3 axes and 3 31138 Rev B1 4 9 5 Using Tormach PCNC 1100 Series II 9 5 4 9 5 5 Warranty Specifications Customization and Troubleshooting ballscrew nuts These are some of the most critical and expensive mechanical parts of the machine Any dirt or foreign material suspended in the oil is going to be delivered directly to these parts and can dramatically shorten the effective life of the machine Be sure to clean off the cover and surrounding area before refilling the oil reservoir The
139. byeddaneeyctenugh oie deuce Gecush a E a Er ealtouetee desea 7 9 POO Mem Repeal Serer abacus e EE a ESE 7 9 LIL MEON ani E E 7 9 TaS Commands and Machine Modes crr n a a a a a 7 10 7 6 Modal GroUPS aeris aaa AE Ea ER A EA ACNEE SATENA 7 10 7 7 G COMEG aia scacelsasdenedoasdeaa ess daveiedssaxesedssaniielesdasudeceiawsdcdesawedadedenedsdvaenaiecsdevadedsseseseasdeneieasseees 7 11 7 7 1 Rapid Linear Motion G00 vacscsccicssseaciadcodaesacasaedesdancags etveastuetasts pnandawasneounte guannsoneneucauedesces 7 11 kha inearMotionat Feed Rate G0 Uc icteeise oak vanciatend teva vartealiou A 7 13 Toho Are at Fed Rate O amna C103 eia A ied Vevcatonareabieen A A 7 14 Toe Rad s Format ANC soiuis a vdcuaestecem E E densa S AE 7 15 Tolede CEMEC Oat PLC a a a a a a a a aa 7 16 Tek DWIE a E ae I Oe ve OO Oo RO 7 17 7 7 5 Coordinate System Data Tool and Work Offset Tables G10 eee ceeeeeeseeeeeeneees 7 17 7 7 6 Clockwise Counterclockwise Circular Pocket G12 and G13 cece cece eee eceeeeeeeees 7 18 7 71 1 Exit and Enter Polar Mode G15 and G16 cccccccecceccscescescseeseseeceecensenseess 7 18 7 7 8 Plane Selection G17 G18 and G19 ce ecceccececcnccececcececcscescesescsescesenseneeces 7 19 Tatoo enms AICI Massie sie cntnatadnadea ane taataaliadsa tA seadnavadtida iid saadsazestadeaidenadsatenlianeaiacs 7 19 Tell Return to Home G28 and G3 O snieni saes a aaa apea eae aaen 7 20 Using Tormach PCNC 1100 Series II iv 31138 Rev B1 4
140. cate stock 6 7 2 Other Work Offsets The control software allows you to setup a total of more than 250 different sets of work offsets most people will only use the first six as these are easily selected using the codes G54 to G59 The Offsets screen has a pair of buttons to select the work offsets that are in use and displayed figure 6 28 Edit Save table How lt Work Offset gt 0 0000 Touch 0 0000 When you Touch or enter values in the axis DROs then you will update the current set of work offsets yE m I You can save the work offset values using the Edit Save table Now button above the Work Offset DROs This button displays the complete table It can be edited manually and is saved by clicking the Save button The dialog is closed by clicking OK D C s O LSE mim 3 QO QO If you do not save the work offset table then when you close down the Control Program you will be asked if you Touch bla J r want to save it Unless you have made a serious error in Do not update by typing new value setting up work offsets you should save them or you will into ofset DRO if GSaiGa2 isinuse have to enter them again next time you run the Control a Program We advise you not to alter the G54 offsets although it is remembered from run to run of the Control Figure 6 28 Choosing Software Work Offsets Using Tormach PCNC 1100 Series ll 6 14 31138 Rev B1 4
141. cccccseceeeeeeeeeseeeeeeees 5 12 Diver test program cccccceeccceeseeeeeeeeeneeeaes 10 14 Drilling canned cycle Ee Reet OE an reat we ee ee SOR 7 28 Drilling with dwell canned cycle E e see tetas tates Ritson E eee 7 29 DG AEE E E A EA A E T AT 7 3 G04 defined onessonesesseeesssseersssssersssseee 7 17 E Electrical overview diagram scccceseeeeneeeees 10 5 Electrical specifications cecccseeeeeseeeeeeeeeees 9 2 ESOP DUON einne a 2 11 Ow COMMON pane asasan AS 5 2 Exact stop mode COLS SCUUIN Gfx Jock peo indechaats e e 7 25 purpose of explained ccceecccseseeeseeeeeeeeees 7 3 Excecution of words ordor Olien es tema uhaense easaeneeadeeeonsse 7 36 Exploded view base assem DIY sie casicsic Aatesseeeiesadosseccaceaieianssi 10 3 column and head assembllJ cccseeeeeees 10 1 Expressions denne ener en ener ene nena E erence nen 7 8 F Bo WOPG SICCUTALE 265 Ads ots sl acctbactaatenss ageinetaeekoas 7 35 Feed amp Speed Cal CUlator sisii ia 5 14 Feed and speed override controlled by M48 M49 1 00 eccccsececeeeeeeees 7 34 Feedrate GETTING d eni A erence eee 7 2 display DROs described seati nean a ncan E EN 5 9 PY WOR 1O So ionsasaitani a eae 7 35 inverse Ume GY Jeee eteo 7 31 units per minute G94 oo ec cceeeceeeeeeneees 7 31 UHS DEE LOY oane a e sens 5 9 units PSP TCV GO Seina 7 31 Feedrate control family ELSE e S AE A E AA A E E ET 5 9 Feedrate
142. ccceesccseseeeeeeeeeees 7 36 Safety CHOCIMSU aerieni e 1 2 Dual supply implications of eeeeeeee 1 1 from machine location and mounting 2 2 further TEAGIN G yo o55ic dL ih nlidam eid sadn dads 1 2 rE T EES PEIEE T EE EE E Soeaeneks 1 1 Groundin ocho Site sae Pena aca EE EN 1 1 Safety Warning ereina i ea 1 1 professional advice cceccesescceeeeeceeseeeeeeeenes 1 1 Scale factor on axis data G50 G51 0 7 23 Scale factor DRO CE SCE DCC oie tccaaesnnceasactocuen E eacemnsoepemieeenens 5 7 Scaling COOLPGINALES anseia teen Hewnleiuses 7 1 SCAN GO Parts xa eeaceeieren ariel eee ete 7 1 Screen switching DuttONS cccececseeeeeseeeeeeeeees 5 6 Screen switching controls GE SCI DCU EEEE EE E A N E 5 5 Selected plane ETI CU PARE E PEE A E EN E 7 3 Set fixture coordinate systems G1O 0 7 17 Sotnex Ime DunO erissa 5 10 SKUIS CONTON G eaen R 5 8 Simulate Program Run button ccceeeeeeeees 5 11 Sinole DUON erer ea a 5 10 Space required MINIMUM nssnnssessseesseesseesseesseeo 2 2 Special Mach3 sys driver AS PAW ACONC OL e S 10 15 TCC ON oeenn cients eiecncile tise ae acmete aca tanec 10 15 SPECIAIGIIVER Dale cx sashes esnwitcceateSsaieseeddasbebisecsee 10 15 Specification OD LO INS tsetse sete von ccs Geet eh E an eee 9 3 Specifications LEETE er I EEEN ne a oe ee eae ere 9 2 mechanical aerea EAE ER 9 2 Sy SUG A EA E TA ETE T TT 9 3 Speed
143. ce between moving parts but the technique cannot eliminate compressibility The key to achieving maximum accuracy is understanding and controlling the magnitude and direction of forces Maximum accuracy is achieved when the forces are minimized as occurs in a finishing cut Maximum repeatability is achieved when the forces are repeatable both in magnitude and direction Working without the tool table You do not need to use the tool table If you hold your tools by a method which does not give a consistent length e g exchanging tools in a collet then you will not be able to use a tool table Using Tormach PCNC 1100 Series II 6 8 31138 Rev B1 4 6 3 3 1 6 3 3 2 Offsets If you have work which is generally one off and you use a very wide range of tools e g many different drill diameters then it is probably not worth the trouble of setting up the tool table To work without a tool table you merely reset the Z axis work offset value each time you change the tool X Ref X Direct Entry to Axis DRO Zero L 0000 E All the measurement methods give the current Y z 1 4 O O 0 I Ret Y position of the tool relative to the stock Zero assuming the face you have measured to is to be Z O 5 4 0 l RefZ zero in the program coordinates all you needto 2e atts do is to type the value into the relevant axis A of l RefA DRO You can do this on any screen Zero 0 OO 0 0 OU aa radius Ref xywz For example after usin
144. ch PCNC 1100 Series II 7 34 31138 Rev B1 4 7 9 2 7 9 3 7 10 7 10 1 Programming language reference Before use of these codes the size of tapping head to be used and the pitch of the thread must be defined in the appropriated place on the Settings screen If the part program is running in Inch G20 mode then the pitch is taken as a number of threads per inch If it is metric G21 then the pitch will be in millimeters If the spindle speed is too high for the chosen pitch then an error message will be displayed and the cycle will not be performed The cycle operates as follows The currently set spindle speed and thread pitch are used to calculate the feed rate required to move the tap at the correct speed The corresponding feedrate for the high speed retraction of the tap is also calculated If this exceeds the available rapid rate then an error is displayed The tap is then fed downwards for the commanded depth P word At the end of the down feed the spindle is rapidly retracted by the appropriate distance for the size of the head in use This engages the reverse drive The spindle is then retracted at the higher reverse rate previously calculated for a distance sufficient to ensure the tap springs clear of the hole The Z axis is then positioned at the original height above the work ready to move to another hole or another tool and operation Note e The above explanation is slightly simplified from the actual code use
145. chine cabinet to Tormach Machine Control Board Problem with cable from Tormach Machine Control Board to Axis Drives A malfunction of the Troubleshoot using the DC Bus information in the Details section 31138 Rev B1 4 9 33 Using Tormach PCNC 1100 Series II Warranty Specifications Customization and Troubleshooting Control f Signal Command Control og Mal Control Sig hal Parallel Port Cable with 25 Pin D Connector Controller Computer Figure 9 27 Diagnosis by swapping two axes Axis drivers are mounted left to right in the sequence X Y Z A Using Tormach PCNC 1100 Series II 9 34 31138 Rev B1 4 Warranty Specifications Customization and Troubleshooting Axes Drive Sub System Checklist Table 4 2 One axis will not move or moves in only one direction but other axes operate properly Possible Cause Prob Action to identify Cause Discussion ability of Problem Parallel Port cable not fully plugged in or pin bent on connector High Loose Wires or Ribbon Cables A loose coupling on the motor A bad Electronic Driver Module 31138 Rev B1 4 Investigate connections Remove power and check the ribbon cable and the wires from the DC Bus Board Jog the axis and listen to determine if you can hear the motor run Swap the ribbon cable connector for the control signals and the motor AC supply connector between a known functioning drive X Axis in figure 9 27 and the malf
146. ciiiriiseisriissicsiiieriseriiiiiisr inisenisi ennan 9 3 LLL Machne lI GS aoroneen Autrrare ind adatom oar ersaadep atsoadeanneaad arclena doanuncndymieatdate 9 3 9 5 1 2 Backlash Friction and Lost Motion ccc cece ecceceececsccccecsceccecsceccscscseeceseseeeucecs 9 4 Dulas Factors COMO sosirea iaar EAE EEEE EANA 9 4 95 14 Adjus ng Geometry soresiinre eie ua aaia 9 4 9 5 1 5 Achieving Accuracy in Machining eeseesseesssessserssersserssersseesssrsssesssersserssereseees 9 5 932 Proccime Fom RUS esris nne EEEE E 9 5 9 5 3 Gibs Dovetail Slideways and Lubrication eesenssoesseesseesssersserssersseesssesssesssersserssersseess 9 5 WN CO a A 9 6 JIa AKS CDAS MENT santunan a a eet ce N a EE 9 6 936 Adjusting Ballserew Prelad ios cs tadewncuncandaanaia sit ensnan aa nE a E ENEE 9 8 9 5 6 1 Understanding Preloaded Angular Contact Bearings ccccccsesccceeeeeeeeeeeeeeeeaeees 9 9 9 30 2 Makne he Adsm ensigns EA NEE ENTANS 9 9 93 7 AGUS I Malino SUH ACES ankenn aE EEE E EE AEN Ean 9 11 PoS PE a a O a A 9 11 9 5 9 Using aNon standard Printer Port 2 0 iccieceisesiacsctswisssasecssnnsaealsecasnvaseusvarseeedsusnaesosenescnasewnet 9 13 9 5 10 Defining Your Own Sizes for Step mode Jogging essenssoesseesseesssersseessersssrsssessersseeo 9 14 9511 Denime Probe Type sierasrieirion EAE eertrerrre tree tr nrrerere etter ter 9 15 9 5 12 Enabling 4th axis HOMING cc cccecccssecccseeccceecceaeecccenscc
147. command is executed Pressing cycle start will resume the program M2 or start the program back at the beginning of the file M30 Spindle Control M3 M4 and M5 To start the spindle turning clockwise at the currently programmed speed program M3 To start the spindle turning counterclockwise at the currently programmed speed program M4 For a PWM or Step Dir spindle the speed is programmed by the S word For an on off spindle control it will be set by the gearing pulleys on the machine To stop the spindle from turning program M5 It is OK to use M3 or M4 if the spindle speed is set to zero if this is done or if the speed override switch is enabled and set to zero the spindle will not start turning If later the spindle speed is set above zero or the override switch is turned up the spindle will start turning It is permitted to use M3 or M4 when the spindle is already turning or to use M5 when the spindle is already stopped but see the discussion on safety interlocks in configuration for the implications of a sequence that would reverse an already running spindle M30 M49 Figure 7 4 Built in M codes Note 1 These codes are built in but application specific to the PCNC 1100 Tool change M6 Provided tool change requests are not to be ignored as defined in Configure gt Logic The CS will call a macro q v M6Start when the command is encountered It will then wait for Cycle Start to be pressed
148. control CES Ci DOG ia carn etateendee e 5 8 R R8 tooling inserting ANd removing ceeeeseeeeeeeeeeeeeeees 5 3 Radius format arc cccccccsescccseeeeeeseeeeeseeneneees 7 15 Rapid motion GP ictes oh 1g6 oesie genee re Omni ern ime te 7 11 Reaming and boring canned cycle CO ieee E etree ead dee eae edema ae 7 30 Re boot during installation how to manually uninstall driver if you fail to do it PE EEEE E AEE ET E T T 10 16 REI D LOR A E E scone 10 14 Receiving new machine ssseesseesseessersssesssers 2 4 Reference G2 8 ln 3 i tecascentcran ent ee 7 20 Referenced LED deseri bedi wloulueshentdse niece nemeaeeeiiestouaue 5 7 Referencing TEM PORLANICS OF hid ores heterichendl si atieleeneentoseuioddun 3 2 OJU CUON Onein eE e 3 1 Recon DUO userei R 5 11 Repeating part program indefinitely M47 7 34 Repeating part program indefinitely M99 7 34 Reset button desen bedaren a e i anhenaks 5 6 31138 Rev B1 4 25 Return level after canned cycle CIOSI COO artana eE E E TE 7 32 Rewind button cccccceccccsesccceeeeeeeeeeeeeseenneees 5 10 Roller CA Ce 4 ruen 6 7 Roll you OWN gauge ccccceccccsesecceeeeeaeeeeeeeeeeaes 6 6 Rotational axes CTU ING esde a hath tr Baceha E 7 1 Rotational diameter correction controls family 0 0 ee eee eceeececeeeeeeeseceeeeeeneees 5 13 Run from here button ccccccecceeseseeeseeeeeeeeees 5 10 S S word spindle speed cc
149. cseeeeeeeeeeeeeeeenes 10 13 Optimising Windows for PCNC 0 008 10 16 Optional program stop IVI Ot sss te dienes iaech tc a Cou saaeeeeads 7 32 Optional Stop CONO E nekieti eecths Uaeehan eermtaaieeseeen 7 4 Optional Stop SWllChic 3 4 s6 ci56 cach taser hevandddawe edhe 5 11 Order of G code items on line eee eeeeeeeees 7 9 Override for feed and speed disabling cccceeeeeee 7 4 Override feed and speed controlled by M48 M49 oneness 7 34 p Parameter setting value of sseesseesssesssessserssersserssees 7 8 usine valie O ic s2 ont uctiod lesb attececiotsvoideseeveaedbea dels 7 7 Parameters PRECAST tint Gatti cel salela iden hea lalate da eleoed 7 5 Part program repeating indefinitely M47 cceeeeeeeees 7 34 repeating indefinitely M99 cceeeeeeees 7 34 running controls family described eunea mervanknaatoake 5 10 Part program making with Wizards ccccecccsseeeeseseeeeneees 4 8 Pause DUON erzed iarge ei aa 5 10 PCNC Choosing location Of cccccseseeeeeeeeeeeeeeeeens 2 1 computer requirements ccceeccceseeeeeeeeeeeeees 2 8 connecting to control computer 06 2 10 control panel essene A RA 5 1 control panel controls explained 2 10 fourth axis Option eesessseessoesssesssesssesssersserss 8 1 Operator s panel secie RA 5 1 receiving and unpacking cccseeeeeeeeeeeeeeees 2 4 tool CHA
150. ct as wedges and jam the machine if the lock screws are not tight e When correctly adjusted for preload sustained high spindle speed will bring the spindle bearings to about 155 F 68 C This is a normal condition Higher preload in the spindle bearings will result in even higher temperatures and excessive wear e Service Bulletin SB0024 covers the rebuilding of PCNC1100 spindle cartridges e Major castings are fitted or scraped for precision fits and machine accuracy Exchanging parts between machines or replacing parts can affect the machine accuracy Dowel pins are used for alignment between parts The dowel holes are drilled after alignment between parts and are unique the original parts Replacement parts cannot use the original dowel holes The following tightening torques are appropriate to the metric fasteners used in the PCNC a a Electrical maintenance Electrical Service Certain service and troubleshooting operations require access to the electrical cabinet while the electrical power is on Only qualified electrical technicians should perform such operations Many electrical problems are self apparent Tracing electrical problems can be done with a combination of the machine control software the LED indicators within the machine cabinet and the machine actions 31138 Rev B1 4 9 55 Using Tormach PCNC 1100 Series Il 9 9 9 10 Warranty Specifications Customization and Troubleshooting The operating software ha
151. ction 1 e the conventional four quadrant conventions Coordinates of the current point at the time of executing the G16 are the polar origin 31138 Rev B1 4 7 11 Using Tormach PCNC 1100 Series I Programming language reference It is an error if all axis words are omitted Summary of G codes Rapid positioning Linear interpolation G02 Clockwise circular helical interpolation Counterclockwise circular helical interpolation G04 Dwell Coordinate system origin setting Clockwise circular pocket Counterclockwise circular pocket Polar Coordinate moves in GOO and GO1 XY Plane select XZ plane select YZ plane select Inch millimeter unit Return home Reference axes Return home Straight probe Cancel cutter radius compensation Start cutter radius compensation left right Apply tool length offset plus Cancel tool length offset Reset all scale factors to 1 0 Set axis data input scale factors Temporary coordinate system offsets Move in absolute machine coordinate system Use fixture offset 1 Use fixture offset 2 Use fixture offset 3 4 5 Use fixture offset 6 use general fixture number Exact stop Constant Velocity mode Coordinate system rotation Canned cycle peck drilling Cancel motion mode including canned cycles G81 Canned cycle drilling G82 Canned cycle drilling with dwell G12 G15 G16 G17 G18 G19 G20 G21 G28 G28 1 30 G31 40 G41 G42 G43 49 G50 G51 G52 G53 G54 G55
152. d 1 depends on the accuracy and stability of the spindle speed This makes tapping blind holes where the thread depth is nearly as deep as the drilled hole a process which requires experiment to get the optimum depth 2 is an alternative feed strategy which can increase the accuracy of tapping depth with the trade off of greater wear on the tapping head clutch In tapping blind holes it is common practice to rough tap by machine and then clean the ppnaniatit hole and the bottom the thread with a hand gA held tap or pneumatic power head If you are writing your own G code the rapid retraction is best done by a G01 move with a large feedrate say F99999 as this ensures that the control software Constant Velocity is used to make the fastest and smoothest reversal CV would not be used if GOO is employed In method 1 during the start of the rapid retraction the tap is still actually moving into the hole and not stationary This should be N l allowed for when calculating distances Figure 8 27 Measuring spindle speed For best results especially with long threads you should check that the actual spindle speed corresponds to that commanded by the S word by using a tachometer e g Tormach p n 30527 figure 8 27 It is not advised to use the Pause feature in Mach3 during a tapping routine For more information on tapping please review our tapping guide called TD_tapping_Guidelines 4 pdf available on our web
153. d Home and so these limit switches T on 1 8 16 5 5 are called the Home switches Their Zero ae operation is very obvious on the Z axis A software trick makes the X and Y Figure 3 1 The axis DROS un referenced arrangement slightly harder to understand but this is of no importance at present Figure 3 1 shows how the DROs might look when you start up the system They have arbitrary values in them and the three screen LEDs are red Check that the LEDs by the red Reset button are not flashing and that nothing is in the way of movement of the table and head of the PCNC Click the Ref All button The Z axis will first move up to the top of a 5 8 8 le the column stop at the switch and then move down a fraction The Z DRO will be set to zero and its LED turn to green This 3 oe re Q s Q 8 7 will be followed by the same action with X and Y Be wary the first time you do this and if an axis does not stop at its switch you 5 i 0 0 00 must hit the EStop button on the PCNC control panel and look at the Maintenance Troubleshooting section of Figure 3 2 Referenced and ready to use this manual figure 3 2 31138 Rev B1 4 3 1 Using Tormach PCNC 1100 Series Il 3 2 Making your first part Note It is important to reference the PCNC before using it Failure to do so can result in running into the limit switches or worse the tool attempting to cut into the vise or table The Control Program tries to protect you from thi
154. d additional information to define the center point to be used Most G codes are what is termed Modal This means they stay in effect until another one is used So if GOI has been used on one line of code then the following lines only need to give the position of the end of the move As an example the following code will move the tool to a start position X 1 Y 2 and then move it in a square of side 3 1 GUC AL 1240 GOA X4 1 Ioel X1 Y2 In practice however the simplicity of G codes is deceptive Calculating the position of the center of the tool by hand is tedious and error prone If you wanted to cut around the outside of a block of material to make the 3 1 square then you need to allow for the diameter of the tool and need to move the Z axis to take acceptable sized cuts in each of several passes You will easily be able to learn what a part program is intended to do but it is unusual to write one by hand as there is a wide range of software tools that can help you figure 4 1 Choosing the Appropriate Design Software A mill is capable of producing three different classes of work which are usually referred to as 3D 2 2D and 2D A 3D product has complex and often smooth curves in all three dimensions A typical example is a mold for die casting vacuum forming or injection molding A 22D product has detail at several depths from the surface of the material but each piece of detail has a flat bottom surface The Fi
155. d nate tatiaatiins 7 26 TADS Canmed Cycles GSU Geo chiles ete aia lati atcevades a 7 26 7 7 23 1 Preliminary and In Between Motion cccccsescccseecceesecceeseceeneceaeseeeseeeansesaenes UTZ ee Ai A CNC a ete teete ee ma le tse deans aadhectuea dated etiam iah A 7 28 WT 2d AGA CC cat tales a E a tan bestetenlusn E 7 29 WT ZI AGS EE CLC cat te talecrti sheet ealescaentata a a E 7 29 WT ZOD GSD AG CNC att selects sleet a a aut acheee tute alse Pauls heehee Men tess audentes etoile 7 30 DIO AS OMY Cl Crs iss feta ati wna cll ern aa E O Aer on see auto E O Malstinnsueiasea Meuseodes 7 30 Dade HOO Cl Ca chia saints ih Gea atts eater ca alloca dara ou oa ater rains Surana etna A owiascetenaeeaas 7 30 TO E e E E E S E dara cu E E E A A O 7 30 7 1 24 Distance Mode G90 and G9l1 n snnnsensseessensseesseesssesssersserssersseesseesserssersssesssersserssersseess 7 30 E2 G92 Ofis ets G92 G92721092 Zmd G92 aaee e a e a 7 31 1 1 20 Reed Rate Mode G93 G94and GIS eneret E O EE A EE AE 7 31 T 21 Canned Cycle Return Level G98 and GIO ivori oerinoar eA E E 7 32 7 8 Boulton M codiS ocarina 7 32 7 8 1 Program Stopping and Ending MO M1 M2 and M30 cc eecccceccceseeeeeeeeeeeeeeesneens 7 32 i622 sspiurdle Control MI3s Wiican MS cocci tate ech a he iin chee ete aa atic 7 33 Dee Loole e INN oes teh sheds ards E ac leetee ths tas a hase ect semi a lel 7 33 dso Coolant ControlS MMe mad MY sadenia ea heart lees a ead
156. d nor as stiff as the machine base itself If for example you place a 0 050 shim between the base of the mill and the stand you re not actually lifting the corner of the base up by 0 050 It is more likely that you are moving the mill up by 0 005 and the corresponding point on the stand down by 0 045 2 4 3 Accessories You should now try out the positioning of the screen computer and coolant sub system if any 2 5 Power to the PCNC The PCNC 1100 is powered by 230 volt single phase AC 50 or 60 Hz Auxiliary services like the control computer and coolant are separate and can be 115 or 230 volts Older coolant pumps were supplied as 115 volt only Later models can be configured to suit your auxiliary voltage Please note The Tormach Machine Controller can be run on either 115 or 230 volts For 230 volt applications be sure to flip the switch in the back of the controller to 230 The Tormach Coolant pump that comes with the Deluxe Stand is also dual voltage but comes from the factory wired for 115 volts The user must remove the cover plate on the pump motor and follow the wiring instructions inside the lid to reconfigure the pump motor for 230 volts Other products such as the Duality Lathe or companion high speed spindles are rated for 115 volts only The main machine power lead is shipped in a protective tray Terminate it with a suitable plug for the wall outlet which you intend to use 2 6 Power for Machine Acces
157. d to aid understanding e For best results especially for deep holes and blind tapping the spindle speed chosen should be checked with a tachometer to ensure it is as near the commanded S word speed as possible Goto Toolchange Position M998 Execution of M998 will send the machine to the tool change position The tool change position is defined on the Settings screen The Z axis will move first then X and Y An entry of 9999 will disable the axis Execution of this function requires the machine to be referenced Homed User Defined M codes If any M code is used which is not in the above list of built in codes then the Control Software will attempt to find a file named Mxx m1S in the Macros folder corresponding to the current XML profile name If it finds the file then it will execute the Visual Basic script program it finds within it New macros can be written using an external editor program like Notepad and saved in the Macros folder Other Input Codes Feed Rate F To set the feed rate program F Depending on the setting of the Feed Mode toggle the rate may be in units per minute or units per rev of the spindle The units are those defined by the G20 G21 mode Depending on the setting in Configure gt Logic a revolution of the spindle may be defined as a pulse appearing on the Index input or be derived from the speed requested by the S word or Set Spindle speed DRO The feed rate may sometimes be overr
158. daes 5 16 Dee OOF Siue OOM MOU gi oa5 acct access aesecsaencenas Scan A 5 16 3a Kepada Pendahle asno tier acct ge tear Merce er E od ch oe ects aco herd oar Meee ata E 5 16 6 SUC VICE WOON S ciora 6 1 6 1 Offsets and Coordinate Systems c ccccscocssssssssscvsssccssssovesscvesssovecscossssovsescsssesovessoossssooens 6 1 6 2 Tool Length Offsets and the Tool Table cccsssccsssscssssccssssccsssccsssccssscccsssceesscoeess 6 1 O21 Example Operation ob Multiple Tools s ic 2 selec tes5 ec aee e e e eea 6 1 ON Tonte TABI amp ws cchsesasancteec tat eto e sud nian Cuvetsd a tens A Sawtad casnsdiawsi 6 2 O22 Arone tO Work NESNE yc betes sles sae lesan e Seid snl e aTe e e 6 3 CLES Usmi TOON FD nenene sachs e N ERAR 6 4 ZLA ISIS OLE F TOOI 8 aean a R 6 4 6 2 1 5 Changing to a different WOrK PleCe c ccc cceccccnesecceeeeceeececseeeeseneceseeeeseeeeesnsesaenes 6 4 6 2 2 How this multiple tooling setup WOrksS ccccccccsecccceeeeceeececeeeecseseceeneeesseeeaeseeseseeeaneeeaes 6 4 6 2 3 Programming Buttons or Direct Entry s ssseessenssoesssesseesssersserssersseesssesssesssrrsserssersseess 6 5 6 3 Alternative Methods Setting Up Toolls ssccccssscssssccssscccsssccssssccssscccsssccsssccsssccessces 6 6 Ga MicaSUriImS TEC GUS bees hota a hate eles edinale elon a td aati kena ne 6 6 G45 Roll You ur Own Gauge MCh site itecett tae Ode cecebhtan Otarnnnbate tte nanana 6 7 Oad Roler Giuse Me
159. de to make this manual as complete and as accurate as possible but no warranty or fitness is claimed or implied All information provided is on an as is basis The authors publisher and Tormach LLC shall not have any liability for or responsibility to any person or entity for any reason for any loss or damage arising from the information contained in this manual Tormach PCNC1100 Personal CNC PCNC770 Personal CNC and Tormach Tooling System are registered trademarks of Tormach Windows XP and Windows 7 are registered trademarks of Microsoft Corporation If other trademarks are used in this manual but not acknowledged please notify Tormach LLC so this can be remedied in subsequent editions 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 Using Tormach PCNC 1100 Series II 1 4 31138 Rev B1 4 Preface 1 5 Nomenclature This manual uses the following typographical nomenclature Software control Refers to a Control Software soft control 1 e a Windows control on the PC screen Hardware Control Refers to a physical button or switch on the Operator s Panel of the machine G code eg GO1X34 8 Used to show G code programs Key name e g Enter Tells you to press the indicated key 31138 Rev B1 4 1 5 Using Tormach PCNC 1100 Series Il 2 2 1 2 1 1 Preparation Preparation This chap
160. devices like monitors or keyboards containing hubs USB devices can be affected by electrical noise on the computer mains power line Devices with large motors like compressors and shop vacuum cleaners should not be plugged in to a multiple outlet used by the control computer These rules minimize the chance of Windows deciding to manage USB devices when you are running cuts on the mill The machine itself requires a 230 volt single phase wall power outlet rated at 6 amps 13 amps inrush You should also provide a separate wall outlet for 115 or 230 volts depending on your locality to act as power source for the computer monitor and coolant pump if used which should be specified to suit your local voltage Learning and Training The final element of planning your installation is to consider the training that you and any other users of the machine will need 31138 Rev B1 4 2 3 Using Tormach PCNC 1100 Series II Preparation This manual will give you the basic information required to start manufacturing components with you PCNC You must however expect to have to invest time in learning how to achieve the best results The areas which you will find easy and those which will require more effort will of course depend on your background you might be most comfortable with machining or with component design or even with information technology We believe that you will find it highly cost effective to acquire additional training materials
161. dinate system whose origin is set by a G10 command may be active or inactive at the time the G10 is executed The values set will not be persistent unless the tool or fixture tables are saved using the buttons on Tables screen Example G10 L2 P1 x3 5 y17 2 sets the origin of the first coordinate system the one selected by G54 to a point where X is 3 5 and Y is 17 2 in absolute coordinates The Z coordinate of the origin and the coordinates for any rotational axes are whatever those coordinates of the origin were before the line was executed 7 7 6 Clockwise Counterclockwise Circular Pocket G12 and G13 These circular pocket commands are a sort of canned cycle which can be used to produce a circular hole larger than the tool in use or with a suitable tool like a woodruff key cutter to cut internal grooves for O rings etc Program G12 I for a clockwise move and G13 I for a counterclockwise move The tool is moved in the X direction by the value of the I word and a circle cut in the direction specified with the original X and Y coordinates as the center The tool is returned to the center e Its effect is undefined if the current plane is not XY 7 7 7 Exit and Enter Polar Mode G15 and G16 It is possible for GO and G1 moves in the X Y plane only to specify coordinates as a radius and angle relative to a temporary center point program G1 6 to enter this mode The current coordinates of the controlled point are the temp
162. drawn with virtually any program Using Tormach PCNC 1100 Series II 4 6 31138 Rev B1 4 From an idea to a part HIS Vectric Cut2D 3D View ox File Edit View Help F X y 4b X Toolpaths g J lis z Toolpath List 2 L Pocket 1 EJ Pocket 2 M Show 2D previews Toolpath Operations el Lb w tea Ok A eb lL yw Preview y Steel Bright a T Use fill C MV Animate preview M Draw tool W Preview all Toolpaths Delete Waste Material a Reset Preview F Save Preview Image Yv a 1 Ready 227 2993 Y 133 3408 Z 0 0000 Figure 4 13 Cut2D job for Motor Mount Figure 4 13 shows the drawing loaded as a Cut 2D job If your work needs powerful parametric a a a a aioli solid modeling and 3D STAIL ma o Oe Raay 508989t milling from these T a ne models then the matched A aii HF combination of Alibre vee ue Design and SprutCAM is p AC available from Tormach BE a oS Figures 4 14 through X 4 16 illustrate a part ae being designed in Alibre ry the manufacture being qla defined in SprutCAM ja and a finished test piece A oa lt 8 re Figure 4 14 Modelling a 3D part 31138 Rev B1 4 4 7 Using Tormach PCNC 1100 Series Il From an Idea to a part File Edit View Options Tools Help t RotAxis S0 Machining ha 3 O4 Be d OP0H taa GE Si SprutCAM 4 0 D RaidJunk SWParts 4th
163. drilling canned cycle cece ceeeeeee ees 7 28 G82 drilling with dwell canned cycle 7 29 G83 peck drilling canned cycle eee 7 29 G85 boring and reaming canned cycle 7 30 G86 boring with dwell canned cycle 7 30 G88 boring manual retract canned cycle 7 30 G89 boring with dwell and retract cycle 7 30 G90 absolute distance mode cceeeeeeeeees 7 30 G91 incremental distance mode 0066 7 30 G92 workpiece offsets interaction with parametePs ccecceeeeeees 7 31 G92 OSES aae lus hentdanste 7 31 G93 feedrate inverse tiMe sirieni 7 31 G94 feedrate units per minute c ceeeee 7 31 G98 canned cycle return level CO OUD Za chitan dol deed sashaon a 7 32 31138 Rev B1 4 23 G99 canned cycle return level TOUR WO aoee e E E 7 32 G code RELEE IN AEE PAE A E E A T 4 6 G code display Control cccccceccecseseceeeeeeenes 5 11 G codes s mmary tables erna i 7 12 Goto toolchange ccccceccceseeecceeeeeeesceeeneeeaenes 5 11 H Home return to G28 G30 0 cee cec cece eeeeeees 7 20 I TJ Modes S ttin 8 iscccc cccscc ech sccecsws sane ech aesecenneede 5 15 IJ mode Absolute cccccc cece ccecceeceeeeeeeeeees 7 16 IJ mode Increments ccccccecceeceeceeeeseeeeees 7 16 Inch units G2 OSC TM a Sat sal cea cee ae ctu eo aa 7 19 Incremental distance
164. e axis numbers X Y Z A usually represent positions in terms of the currently active coordinate system Any exceptions to that rule are described explicitly in this section describing G codes To go into incremental distance mode program G91 In incremental distance mode axis a numbers X Y Z A usually represent increments from the current values of the numbers sing Tormach PCNC 1100 Series Il 7 30 31138 Rev B1 4 Programming language reference I and J numbers always represent increments regardless of the distance mode setting K numbers represent increments 7 7 25 G92 Offsets G92 G92 1 G92 2 and G92 3 See the chapter on coordinate systems for full details You are strongly advised not to use this legacy feature on any axis where there is another offset applied To make the current point have the coordinates you want without motion program G92 X Y Z A where the axis words contain the axis numbers you want All axis words are optional except that at least one must be used If an axis word is not used for a given axis the coordinate on that axis of the current point is not changed It is an error if all axis words are omitted G52 and G92 use common internal mechanisms in the CS and may not be used together When G92 is executed the origin of the currently active coordinate system moves To do this origin offsets are calculated so that the coordinates of the current point with respect to
165. e correct indication but you will have to find the fault before you can move the PCNC axes under computer control Spindle An important safety interlock is that the rotation of the spindle can be disabled while maintaining axis drive power by the Spindle Lockout key switch The switch on the spindle drive door performs the same function These are used to ensure that the spindle cannot start when an R8 tool holder is being changed door open or when a tool is being changed in a collet chuck Turning the Spindle Lockout key or opening the spindle cover while the spindle is running will also stop the spindle Stopping the spindle in that way will not damage any components but it is generally a poor practice The controls to the right of the key switch are all concerned with manual control of the spindle If the Manual Auto switch is in the Auto position then none of the other spindle controls have any effect In the Manual position the computer control of the spindle is disabled 31138 Rev B1 4 Using Tormach PCNC 1100 Series II Coolant Accessory Socket 2 8 2 Preparation Switch toManual and turn the speed control knob fully counterclockwise Press the Spindle Start rocker The spindle should start turning slowly in the clockwise forward or counterclockwise Reverse direction viewed from above depending on the setting of the Forward Reverse switch You can safely switch directions while the spindle is turning Try changing
166. e spindle This ensures that the correct offsets are used by the Control Software whatever sequences of moves you perform Bore Center Jog to position the probe tip so it 1s just below the top surface of the bore to be probed and anywhere roughly near the center No precision is needed in this position Click the Find Center and Set work origin button The probe will make three pairs of exploratory moves First it goes left and right X then X and so estimates the X coordinate of the center Then it goes to the estimated X center and probes back and forward Y and Y This gives the exact Y center Finally using this it refines the X center by the final pair of moves The initial X moves off the Y center could have been slightly inaccurate because of the oblique contact of probe tip with the bore Then the current work offsets typically by default the G54 system are set so the bore center is 0 0 the X Y origin As the probe tip is in the center the X and Y axis DROs will read 0 0 Position of a Face You can set the X origin of a plane face perpendicular to X or the Y origin of a plane face perpendicular to Y The Yellow buttons X X Y and Y determine which direction the probe will move You should start within 1 2 or so of the face and with Z low Figure 8 11 enough so the tip hits the face After the probe trips it moves slightly away from the face that it has found and the control software sets the correspo
167. e 6 32 Example 2 overlaid Using Tormach PCNC 1100 Series II Offsets But when we take a closer look at the first corner we can see that the lead in came a bit short leading to a burr on the corner An adjustment of the initial lead in position is necessary to fix this Detailed issues like this are difficult to find in advance which is one of the reasons that use of cutter compensation can be time consuming to debug Programming of entry moves is critical when using cutter compensation and some debugging of a program is frequently necessary Figure 6 33 Detail of example 2 Programming Entry Considerations In general an alignment move and two entry moves are best to begin compensation correctly However where the G41 G42 compensation is only going to be used as a small correction factor it s usually possible to incorporate only one entry move plus possibly a pre entry move is needed The general method which will work in most situations is described first We programmed path 1 5 actual path Cutter Figure 6 34 General Entry Move solution Using Tormach PCNC 1100 Series II 6 18 31138 Rev B1 4 Offsets assume here that the programmer knows what the contour is already and has the job of adding entry moves General Method The general method includes programming an alignment move and two entry moves The entry moves given above will be used as an example Here is the relevant code
168. e Empty is always correct and a click on the Hi Lo button will bring the Zoff _ 0 0000 LEDs into step D 0 000 Next to the label S is a digital read out DRO of the Figure 2 19 Setting S word requested spindle speed You can change this by clicking the mouse on it It will become highlighted Type a number say 500 for 500 rpm and press Enter Figure 2 19 shows the screen just before pressing Enter If you make a mistake you can press Esc to return to the original value This technique is used for setting any DRO Remember to use Enter after any DRO change If you forget and just click on another DRO then any value you have just entered will be discarded This is designed to avoid accidental changes Now check that the machine is safe and that the motor door is closed and click on the Spindle CW F5 button The spindle will start running Clicking the button again will stop it The F5 in the caption tells you that function key F5 is a shortcut to this button it can also be used to start and stop the spindle Notice that there are two sets of screen LEDs The outer set indicates that the machine is dwelling to ensure the spindle has started and fully stopped The center LED indicates that it is running If you have connected a coolant pump to the outlet under the control box see vacant outlet in figure 2 10 then you will be able to control it by the Coolant Ctrl C button or its shortcut which is the Ctrl C key Beware of th
169. e PCNC By keeping close to general machining recommendations your tools will last longer and you will have a better cut 31138 Rev B1 4 1 3 Using Tormach PCNC 1100 Series Il Preface 1 3 2 Understanding Accuracy While a machine tool may seem absolutely rigid the truth of the matter is that everything has some elasticity Related to elasticity is the compressibility of components such as ball nuts and bearings Preloading of bearings and ballscrews can remove the physical open space between moving parts but the technique cannot eliminate compressibility The key to achieving maximum accuracy is understanding and controlling the magnitude and direction of forces Maximum accuracy is achieved when the forces are minimized as occurs in a finishing cut Maximum repeatability is achieved when the forces are repeatable both in magnitude and direction 1 3 3 Resolution Accuracy and Repeatability of the PCNC The minimum discrete position move is 0 0001 this is the resolution of motion Machine accuracy is closely related to ballscrew accuracy Our ballscrews are accurate to 0 0006 per foot but considering all the other factors that come into play we prefer to keep accuracy expectations to 0 0013 per foot Repeatability will be better than 0 001 per foot Machining is a mix of science skill and art The caveat in stating accuracy and repeatability is that these factors depend on the techniques used by the machinist A skilled machinist can
170. e Radius correction DRO which is on Settings and also the MDI screen to an estimate of the radius of the part mounted in the axis figure 8 2 This ensures that the feed rate will be correct Gear Cutting Figures 8 3 and 8 4 show the fourth axis set up for cutting a spur gear The G code for this is easily produced by hand or by a Wizard as it consists of a series of passes cutting a tooth followed by indexing by an angle say A corresponding to the number of teeth N A 360 N It is important that the gear cutter is exactly on the centerline of the gear and its mandrel A Figure 8 4 Gear cutting tailstock removed for clarity Te Figure 8 6 Ruler tilted to left at top so cutter is too high steel rule can be used to set this quite accurately figures 8 5 amp 8 6 The rule can be seen against the body of the chuck above the mandrel Notice that the test is more sensitive the smaller the diameter of the object onto which the rule is placed so the setup is done on the mandrel not on the gear blank itself If the gear cutter is mounted so that it can be inserted at the same height each time e g on an R8 holder then it may be worthwhile to set up and save a work offset giving the centerline as 31138 Rev B1 4 8 3 Using Tormach PCNC 1100 Series II 8 2 8 2 1 Machine upgrades and configuration Y 0 0 and Z 0 0 so that the setup does not need to be repeated each time the machine is switched on P
171. e a history of events Screen Selection Buttons These buttons switch the display from screen to screen You are viewing the screen whose label is blue The keyboard shortcuts are given after the names For clarity they are letters are shown in upper case You should not however use the shift key when pressing the shortcut 5 2 2 2 Axis Control Family This family is concerned with the current position of the tool or more precisely the controlled point figure 5 10 The axes have the following controls Ferd zan X 4 5000 ri saa YE 0 0000 ra san Z 40 0000 ez maA 0 0000 fes ze radius Ref XYZ 1 0000 De Ref all Figure 5 10 Axis control family Coordinate Value DROs These are displayed in the current units nch metric G20 G21 The value is the coordinate of the controlled point in the displayed coordinate system This will generally be the coordinate system of the current Work Offset initially 1 1 e G54 together with any Tool length offset and G52 G92 offsets applied If the X and Y coordinates display in red then they have been rotated by a G68 command You can type a new value into an Axis DRO This will modify the current Work Offset to make the controlled point in the current coordinate system be the value you have set You are advised Using Tormach PCNC 1100 Series II 5 6 31138 Rev B1 4 Machine controls to set up Work Offsets using the Offsets screen until you are fully familiar
172. e e es arar eri Oot toned eE 8 1 8 1 2 1 Referencing and Zeroing the Fourth AXIS sssnsssesssenssenssersssrsssesssessserssersserssersseeo 8 1 8 1 2 2 Diameter Compensation Feature sseesssesseesseesserssersssrsssessseessersserssersseessereseeo 8 1 8 1 3 Fourth Axis Applications sseeseeesseesesessrrssrrssrersrersrreseresenrssrressresseesacesaresaseseressrresseessee 8 2 S Eneravinc ondPeriphery ofa Cynder seiesima eiun EE e E 8 2 31138 Rev B1 4 v Using Tormach PCNC 1100 Series ll viContents om es E 0 Saree peer ererrren rer erererer ere nr rrr reer erer ere rerrerttr tr rere rerrrertrerre terre rr rrertrtrererrt tere 8 3 8 2 Probes Active and Passive and Tool Setters ccccccccscsscsccccccccccccccscccccecccccecsccscees 8 4 8 2 1 Introduction to Uses of Probes and Tool Setters cecccseecccseeeceeeeeeeseeeeneeeeeseeneneens 8 4 S 2 2 Probing for Work 1 OO Setting jrcoccacsnonucocusnoimessanedecnaalasimodanneduogslasmodanendecniulieucedndngdaawsalanueds 8 5 ro pie Aa ee 1010 Bs Gl od 0 0 Leen ere ee ce ee one re ee eer 8 5 of A 0 18 1 eee ne eon ee nee 8 7 Oe Comprehensive 07 VP ON aa rad rratogucatadon deowulonusnsiatneteouulnnmsnniandeaculagendutreteanuladeas 8 9 Be Probe A AOR soenoe a O OS 8 12 8 2 3 Digitizing parts from a model or for reverse engineering s essseresseresseerssseresseresseree 8 13 S24 The Probe Electrical Interiace nseries o e a aani 8 13 FS E E 1 E en eee nee
173. e intent of this design are that the straight lines should be parallel and the same length and that they form a tangent to the arc at the bottom of the slot If these constraints can be given to the CAD software then it will be possible to change its sizes e g the width of the slot by dragging the radius of the bottom arc while retaining the shape figure 4 5 If the shape is defined like this then the software can display the minimum set of dimensions required to define it figure 4 6 Finally if a dimension is changed then the part can be redrawn to correspond to the new size figure 4 7 CAM We have seen the sort of features you can get from a CAD program Figure 4 5 There are also big differences between different CAM programs Constrained and Some CAM programs accept 2D models drawings of your part size changed e g DXF files and expect you to define the Z depth of features like pickets engraved text and holes Alternatively a 3D CAM program will find all the dimensional information in the model 0 81 in RO 06 in Figure 4 6 Automatic dimensions displayed g pray Figure 4 7 Changed dimension changes drawing e g IGES file The main issues to consider are how many times you need to tell the CAM program how to machine the part and how good a visualization of the part you will be shown Suppose we decide that the inside of the keyhole slot is to be cut with a 0 125 end mill using 255 08 a Ble
174. e is a damaged Ribbon Cable J4 parallel port cable or parallel port card in the control computer Using Tormach PCNC 1100 Series II Warranty Specifications Customization and Troubleshooting Axes Drive Sub System Checklist Table 4 2 continued One axis will not move or moves in only one direction but other axes operate properly A bad motor or motor connection A blown fuse on the DC Bus Board Mechanical Problem Using Tormach PCNC 1100 Series II Power down and remove the motor leads from the Axis Drive Measure the resistance of the windings of the motor per Table 4 3 If the resistance is out of range check the wiring carefully If the wiring is good and the resistance readings are out of range the motor is bad Monitor AC Voltage from the DC Bus Board Refer to Table 4 4 Gibs too tight or too loose Oil not getting to the ways and ball screw Debris on ball screw 9 36 Simply unplug the power connector from the board Note When making resistance measurements on motors and other devices with low resistance always take a tare reading on the meter before doing the resistance measurement on the motor or device See Measuring Resistance in the Using the digital Multi meter for electrical tests section If unsure about the wiring it is best to disconnect the motor leads from the wiring and measure resistance at the motor You can also check the wiring which is now disc
175. e point Reference Point X0 YO Z5 and finally to the reference point N2 G90 G80 G40 G54 G20 G17 G50 G94 G64 safety block N5 G90 G20 N10 MO6 T7 G43 H7 N12 M03 S1000 NES GOU XA Fa Y2 NI7 Z201 N20 GOL Z 0s5 FS N29 GOL 22 ELO N30 GOO Z0 25 NSS G29 XO Y2 5 ZL Return to reference vid XO Y2Z 5 415 N40 MO6 TLO G43 H10 N45 M03 S2000 N50 G00 X2 Y2 NGA Aea Noo CUE ado ES N60 GOO Zl N65 XO YO N70 MOS N75 M30 Reference Axes G28 1 Program G28 1 X Y Z A toreference the given axes The axes will move at the current feed rate towards the home switch es as defined by the Configuration When the absolute machine coordinate reaches the value given by an axis word then the feed rate is set to that defined by Configure gt Config Referencing Provided the current absolute position 1s approximately correct then this will give a soft stop onto the reference switch es Straight Probe G31 Straight Probe Command Program G31 X Y Z A to perform a straight probe operation The probe will conventionally be tool 99 The rotational axis words are allowed but it is better to omit them If rotational axis words are used the numbers must be the same as the current position numbers so that the rotational axes do not move The linear axis words are optional except that at least one of them must be used The tool in the spindle must be a probe It is an error if Using Tormach PCNC 1100 Series II 7
176. e position of the coolant nozzle before you try this MDI for Entering G and M code Commands When you are making parts the comands othe L a 40 MS machine G and Regenerate Toolpath Jog Follow i Display Mo M codes will generally be read from a file It is however often convenient to command the PCNC directly This can be done by typing command into the Manual Data Input or MDI for short line Figure 2 20 MDI Line in use The command to start the spindle in the clockwise direction is M3 and the command to stop it is Ma Click the mouse in the bar marked MDI It will highlight You type the command in the highlighted line Unlike in DROs the Backspace Del Left and Right arrow keys are available to help you correct any typing errors 31138 Rev B1 4 2 13 Using Tormach PCNC 1100 Series Il 2 8 5 Preparation When you press Enter the command will be executed Pressing Esc abandons it and closes the MDI line You can try starting and stopping the spindle with M3 and M5 G codes Notice that the recent commands are displayed in a fly out box You can choose one of these to copy into the MDI line using the Up and Down arrow keys Figure 2 20 shows the MDI line after the spindle has been started M3 and the M5 has been typed but not yet executed by Enter There are some handy features of the MDI box It can be l Jog ON OFF Ctrl Alt ji opened by pressing Enter rather than needing a mouse click It sta
177. e result of retyping the radius of the end of the slot as 0 15 and displaying a rendered isometric view of the part The G code moved into a smaller pane for clarity on the rendered view was automatically updated to reflect the new slot width fF Se P essiawd 2 BAC mac xm Nem Bo ks Mle gig i Se X Ga E e a Ble P E T1 fem Operation 1 J 92 Y 1 7348 56306 M03 21 M08 OPERATION NAME OPERATION 1 F31 5 MILLING POCKET copay om nen 1 7249 70 amp Model 1 Paver 1 l a Figure 4 9 Rendered Isometric view of narrower keyhole slot 31138 Rev B1 4 4 5 Using Tormach PCNC 1100 Series ll From an Idea to a part 4 3 4 Running the G code 4 3 5 G01 X 0 0598 Y 3 1447 Z F Mach3 CNC Controller File Config Function Cfg s View Wizards Operator Help Opens Recent Change G Code l ReLoad Close Mil gt G15 G2 G17 G40 G20 G90 G94 G54 G43 G99 G64 G97 o i Alt J L G02 X 0 1102 Y 3 1447 Z 0 2 I L G01 X 0 1102 Y 2 1547 Z 0 2 X l 0 z 0598 a mE G02 X 0 0892 Y 1 7348 Z 0 2 I G01 X 0 0877 Y 1 7048 Z 0 2 G02 X 0 0598 Y 2 1816 Z 0 2 2 Y 2 53721 Sa Z _ 0 2000 I EE G02 X 0 1402 Y 3 1447 Z Machine Coords Override E100 0 0 G01 X 0 1402 Y 2 1816 Z 0 0 0 G02 X 0 0877 Y 1 7048 Z G01 X 0 0861 Y 1 6749 Z 0 2 Cycle Start Alt R Hi Low l ia as ps Max Speed 1750 RPM Stop Alt S S
178. e software that you use the greater will be your and the PCNC s productivity and the better the quality of the parts made A common mistake is to purchase inadequate design software and then have to discard it and the investment made in learning to use it The Control Software itself includes features for defining and cutting simple parts like keyways rectangular and circular pockets or a plane face by conversational Wizards You will be able to do useful work with these features but you will get better control and documentation of your parts be using a dedicated CAD CAM system Some software integrates the drawing CAD and G code production CAM functions but it is equally common to use different programs from different suppliers for the two functions It is perfectly possible and often efficient to design using a 3D CAD package and machine with a 242D CAM package 4 3 1 3D CAD 3D CAD software has the biggest range of purchase cost and the steepest learning curve If you want to produce true 3D parts like molds then you have no option but to buy the best package you can afford Alibre produces a good example of a mid range 3D CAD package and Alibre Design XPress is bundled with the PCNC 1100 Alibre allows you to design parts by extruding 2D shapes The extrusions can be from different planes or surfaces of the part as it is built up and can be solid material or holes Several parts can be put together into an assembly and conventi
179. e the point you want to be X 0 0 and click the Zero button by the X axis DRO on any screen Now move the table so the tool centre is above the position to be Y 0 0 and click Zero by the Y axis DRO You can if you prefer just type O followed by Enter into the DRO and Y 0 0 and There are useful techniques when more accuracy 1s required 6 5 2 With a Probe By far the most accurate and often the quickest way of setting X and Y offsets to a piece of stock material or to a part machined component is with a probe such as that illustrated in figure 6 21 Full details of the support for this accessory are given in chapter 8 6 5 3 Measuring Off an Edge Any of the above gauge methods can be used with a tool touching the edges of the stock or equally usefully the jaws of a vise used to hold the stock It is not really practicable to use a cutter because the spiral flutes do not give a clear place to gauge to A cylindrical bar e g 1 2 diameter is ideal It should be mounted in a tool holder so that it runs true It is slightly easier to feel the contact point if a spherical finder is used This is shown in the illustrations below Figure 6 22 show the measurement of the coordinates on the corner of the fixed jaw of a machine vise Figure 6 22 Measuring vise jaw Y position 31138 Rev B1 4 6 11 Using Tormach PCNC 1100 Series Il 6 5 4 6 6 Offsets The value to be use in the Touch Correction DRO or
180. each Voltage when Control Board Number Command IS on Voltage when Control Board Command IS NOT on 0 VDC 20 28 VDC un Reverse Table 5 2b Main Control Board LED Indicators for Run and Speed Commands to Drive Manual front panel switch turned to Manual Auto front panel switch turned to Auto 31138 Rev B1 4 Start button on front panel engaged Start button on computer screen engaged 9 51 Yellow LED D15 lights Brightness proportional to speed Yellow LED D15 lights Brightness proportional to speed Green LED D10 lights and blinks at a rate proportional to speed Using Tormach PCNC 1100 Series II Warranty Specifications Customization and Troubleshooting Details of the Spindle Drive Sub system Lai coe LAL COMPUT TOR nitg on cakil Extai iz BONDED TO EARTH GROIN ai 7 y Lit Y LMT TUPPER LOWER 1G EE LOR I FUTURE anama j Figure 9 32 Spindle Drive Sub system Portion of the Electrical Schematic The relevant portion of the electrical schematic is highlighted in figure 9 32 You may find it helpful to have your electrical schematic available to use along with this discussion Power is supplied to the drive through a contactor that allows power to pass when the drive is commanded to run by the user When the Mushroom Head stop button is pressed or the when Spindle Lockout Key Switch S7 is turned off or when the Spindle Drive Door is opened Contactor C2 inter
181. ean the value found in parameter 3 The character may be repeated for example 2 means the value of the parameter whose index is the integer value of parameter 2 31138 Rev B1 4 7 7 Using Tormach PCNC 1100 Series I 7 5 3 3 7 5 3 4 1 9 4 Programming language reference Expressions and Binary Operations An expression is a set of characters starting with a left bracket and ending with a balancing right bracket In between the brackets are numbers parameter values mathematical operations and other expressions An expression may be evaluated to produce a number The expressions on a line are evaluated when the line is read before anything on the line is executed An example of an expression is Piracos Ol tse a e072 IT Binary operations appear only inside expressions Nine binary operations are defined There are four basic mathematical operations addition subtraction multiplication and division There are three logical operations non exclusive or OR exclusive or XOR and logical and AND The eighth operation is the modulus operation MOD The ninth operation is the power operation of raising the number on the left of the operation to the power on the right The binary operations are divided into three groups The first group is power The second group is multiplication division and modulus The third group is addition subtraction logical non exclusive or logical exclusive or and
182. ecccseeeccneeeseeeeeeneeeseeeseeeeeseeesseeeseeeeesansesaenes 4 10 5 Machine CONOIS wescsevistccrrveusoaveceaiesvetistaveestainevetiel ceaviodiasiwiedia tosh 5 1 5 1 IMPACT OCT AU ON oeicdb asses cdicice sees tics ccdsstecacestaseccescccecsenteseccossadensesteusccacessecdenvevscccausunceartes 5 1 Dalal MODEL ALOR we Pane eoan sdanldan Aso isa tosnel Cavers Wises somelide aoe snes anne baeaoeulioes ame dor teomloatnontmeaas 5 1 Dl WO OE Maid S aor cas hace Sotlnca nee oat Acabilan sates cae iont lea satmel nea hoe aos ebnel oseaonelntoioel nea tamolengataatadg 5 3 Thek Toom o TALC 0 c datitacrsnou Souisntiien N A 5 3 PRE A a IRS TOO aa a hence anette sl cea ASooanatsae su cas Aone acanhee contsuuecsatmassess 5 3 IMZ AC hane me TES TOOS acze sara casa icaaia sence A N 5 4 JLo Spudie Speed RANDE S puin E E E E T 5 5 5 2 screen Control Panel Sissies dicsscwadeeessccdeedsecadenvsadesesisededssedenadeosdevesansseseiedadedesucedessseasdededesvaes 5 5 Jk USNE ESCE IS kon a aa E T E O ETAT ETE E T 5 5 322 Familhesof Related Controls seircciiienaierniie aa a a a a ies 5 5 5 2 21 Screen Switching Controls ses seoiatiscicesdentiecutiacevastonResubierveesteatuonubiastaedieuteomteastetes 5 5 322 2 AXIS Control Pann ly ves desseeswstieseeeut onsveiendiwhoasis EEEE EE 5 6 2 2 30 Jossins Control Family sessin EEEE ET 5 7 2 24 Spindle Speed Control Family scrierea EET 5 8 2209 Feed Control Family sisgece see doicewstonreensbuikoase EEA AA EEEN 5 9 5 2 2 6 Pro
183. ece to the next These are what we call Process Errors and have little to do with a problem residing with the machine itself The scope of this portion of the trouble shooting guide does not cover solutions to process errors It is imperative to Divide a given set up into manageable portions so one can focus on where the problem really lies is it a process problem or is it a machine problem In order to isolate machine problems from process problems the process must be removed from the set up The point of this test is to measure the machine motion explicitly thus eliminating process based problems This test is written for checking the X axis similar process can be used on Y and Z as well 1 Be sure that G40 and G49 show up in the modals list at the top of the screen 2 Mount a quality dial indicator on the mill bed orienting the plunger along the X axis Place near the end of travel 3 Orienting the axis such that the indicator plunger contacts an appropriate surface on the spindle head move the X axis such that the indicator is zeroed then zero the X axis DRO 31138 Rev B1 4 9 43 Using Tormach PCNC 1100 Series II Warranty Specifications Customization and Troubleshooting 4 After moving the spindle head away from the indicator proceed with exercising the axis This means using manual moves or a very simple G code program move the axis at varying speeds particularly rapid speed The more steps you run the ax
184. echanical engineers and billed at current hourly rates As you might expect all warranties for Tormach equipment are voided through modification 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 31138 Rev B1 4 9 1 Using Tormach PCNC 1100 Series II Warranty Specifications Customization and Troubleshooting 9 4 Specifications 9 4 1 Mechanical Table Size 34 x 9 5 Table Slots 2 drainage alignment slots 3 T Slots 0 625 5 8 center slot 0 00 0 004 outer slots 0 000 0 008 Travel X Y Z axis 18 x 9 5 x 16 5 Spindle Nose Diameter 3 Spindle Taper R8 with spindle lock for easy single hand drawbar operation Spindle Speed Range RPM 100 to 5140 Computer controlled spindle speed and direction with regenerative braking from a 1 5 hp induction motor 2 hp peak Cartridge style spindle with V belt transmission There are two overlapping speed ranges Low belt speed is 100 2000 RPM high belt is 250 5140 RPM Spindle Center to Column Face 11 Maximum Weight of Workpiece 500 Ibs Max spindle nose to table 17 Forward opening electrical cabinet This unique design allows service even when the machine is placed near to a wall Weight net shipping 1130 1325 Ibs Operating temperature range 45 to 100 F 7 to 38 C Rapid traverse
185. ember the tool is upside down now relative to when you measured it figure 6 7 e Click the Zero button on the Z Axis DRO to set the work offset figure 6 8 6 2 1 3 Using tool 2 e Set the value 2 in the T DRO e Mount tool 2 in the spindle The Z axis DRO now reads the distance between the tool tip and the work 6 2 1 4 Using other tools Repeat the above for any tool number that you have defined in the tool table 6 2 1 5 Changing to a different work piece All you have to do is repeat the Zeroing to work height process with the touch off tool when you have clamped another work piece in the vise or on the table 6 2 2 How this multiple tooling setup works As explained above the machine works with two types of coordinates Tool G43 Hn C Machine Program Machine coordinates are really an internal function of the machine It s the machine s way of hab Seer ee of Pog L nod E ng Figure 6 9 A possible way of measuring coordinates Using Tormach PCNC 1100 Series II 6 4 31138 Rev B1 4 Offsets keeping track the positions of its parts like the height of the spindle head Program coordinates are what we worry about Program coordinates are what shows up in the normal axis DROs and they are the positions that most G code commands reference The conversion between program coordinates and machine coordinates is done by the offsets They apply to all linear axes X Y Z and the rotary axis A The way
186. entered in the axis DRO is half the diameter of the probe tool plus the measurement of the gauge In the illustrated setup the ball has a diameter on 0 369 so with 0 002 foil the correction is numerically 0 1865 The same technique can obviously be used on the edges of a piece of stock clamped to the table Note You need to be careful about whether the correction is plus or minus In the case of the vise jaw it is negative the center of the tool is actually nearer to 0 0 that the touching point For the outside of a workpiece it should be positive Thus in the example illustrated the value typed into the Touch Correction DRO will be 0 1865 figure 6 23 Laser Centering Techniques If you need to setup the X and Y program coordinates to features marked on or already machined in the workpiece then a laser finder or centering microscope is very useful Figure 6 24 shows a laser finder located near a center punch mark on the stock The point of light can be more clearly seen in the close up view figure 6 25 Viewing the feature through a centering microscope has the same effect although Goto Tool Touch 0 1865 Correction 0 1 86 Gauge Block thickness etc OnfoOtt LJ Alt T Figure 6 23 Inside corrections are negative Figure 6 24 Laser finder on scribed mark the height of the Z axis is then much more important as it affects the focusing of the microscope Obviously no correction is
187. er outside a comment may be in upper or lower case without changing the meaning of a line Bo Beaxisofmachine O O o D tool radius compensation number E fedre S G general function see Table 5 H toollength offsetindex X axis offset for arcs Y axis offset for arcs TIQ H Y offset in G87 canned cycle Z offset in G87 canned cycle number of repetitions in canned cycles subroutines key used with G10 miscellaneous function see Table 7 Subroutine label number dwell time in canned cycles dwell time with G4 key used with G10 tapping depth in M871 M874 repetitions of subroutine call canned cycle retract level Figure 7 1 Word initial letters 7 5 1 Line Number A line number is the letter N followed by an integer with no sign between 0 and 99 999 999 written without commas Line numbers may be repeated or used out of order although normal practice is to avoid such usage A line number is not required to be used and this omission is common but it must be in the proper place if it 1s used Using Tormach PCNC 1100 Series II 7 6 31138 Rev B1 4 1 5 2 7 5 3 7 5 3 1 7 5 3 2 Programming language reference Subroutine Labels A subroutine label is the letter O followed by an integer with no sign between 0 and 99999 written with no more than five digits 000009 is not permitted for example Subroutine labels may be used in any order but must be unique in a program
188. er to install Click Next 10 Choose Standard PC from the listing 11 Click Next 12 Click OK O ON WD On A WO N e When you re boot Windows will have to find and load many drivers The Standard PC drivers for the video hard disk keyboard and other devices are all different than the ACPI drivers This can take a long time and it may appear to have frozen for many minutes during the process It may require re booting several times Using Tormach PCNC 1100 Series II 10 18 31138 Rev B1 4 Appendices 10 4 Revision history Rev B1 4 12 August 2011 Clarification of details correction of minor errors and reference to updated products supporting the mill Rev A3 2 11 August 2009 Major revision of description of offsets and addition of illustrations and examples in G code reference section Inclusion of information on Tormach Machine Controller and consequent update of use of other computers inane A2 2 2 November 2008 Additional troubleshooting added and various small errors corrected Rev nal 1 10 October 2008 Improved troubleshooting for spindle drive RevAl 2 Al 2 17 17 Sept 2008 2008 Initial release of Series manual release of Series IJ manual Rev lane 2 a 0 Sept 2008 E version of PCNC Series I is base manual for this documentation 31138 Rev B1 4 10 19 Using Tormach PCNC 1100 Series ll Appendices 11 Index Hint Where there is a choice most index entries are made using the name of a thing e g tool o
189. eral term for the relationship is Offsets Tool Length Offsets and the Tool Table For a given machining operation the X and Y position of the workpiece will be fixed However you will often need to use several tools and as these will be different lengths then you need to change the Z offset The control software allows you to switch tools quickly and without the need to set up the machine every time a tool is mounted Each tool and holder only needs to be measured once either offline or in the machine If you do not have enough holders for all the tools for a job then you will need to set the Z work offset each time you load a new tool Using the tool table is only useful if you can put each tool into the spindle in a fixed position Skip this section if you do not want to use the tool table The following example demonstrates a typical sequence using the Tormach Tooling System and setting up a touch off tool and 3 cutting tools in the tool table Example Operation of Multiple Tools The following example has three simple Steps 1 Fill the tool table with the tools you plan to use 2 Zero to the work height 3 Apply the tool offset Figure 6 1 The set of tools 31138 Rev B1 4 6 1 Using Tormach PCNC 1100 Series Il Offsets 6 2 1 1 To fill the table F mach3 CNC Controller File Config view Wizards Operator PlugIn Contr aodwote these are not used in Current system Config Plugins 0 0000
190. erned with manual control of the spindle If the Manual Auto switch is in Auto position then none of the other panel spindle controls have any effect In the Manual position the computer cannot control the spindle The rotary control potentiometer RPM x 100 controls the speed on the spindle when it is in Manual mode Its legend indicates approximate spindle speed in the two pulley ranges Figure 5 1 depicts a Series I control panel The speed ranges are different of Series I The Spindle Start spring loaded rocker starts the spindle and the Spindle Stop rocker stops it The direction is determined by the setting of the Forward Reverse switch Forward corresponds to clockwise rotation of the spindle You can safely switch direction while the spindle is turning H Coolant The Coolant switch controls the power from the coolant pump outlet on the underside of the control cabinet In the Off position the pump does not run In the On position it runs irrespective of the computer control In the Auto position it will run if the Control Program requests coolant Accessory Socket The Accessory socket is for connection of accessories such as a touch probe Figure 5 2 Holders in the TTS range with collet Using Tormach PCNC 1100 Series II 5 2 31138 Rev B1 4 5 1 2 1 9 1 2 2 Machine controls Tool Changing Tooling Strategy The PCNC uses a R8 spindle and so you have access to a vast range of standard tooling The main o
191. es their current values alone To set the axis offset values to the values given in parameters 5211 to 5214 program G92 3 You can set axis offsets in one program and use the same offsets in another program by programming G92 in the first program This will set parameters 5211 to 5214 Do not use G92 1 in the remainder of the first program The parameter values will be saved when the first program exits and restored when the second one starts up Use G92 3 near the beginning of the second program That will restore the offsets saved in the first program 7 7 26 Feed Rate Mode G93 G94 and G95 Three feed rate modes are recognized inverse time units per minute and units per revolution of spindle Program G93 to start the inverse time mode this is very infrequently employed Program G94 to start the units per minute mode Program G95 to start the units per rev mode In inverse time feed rate mode an F word means the move should be completed in one divided by the F number minutes For example 1f the F number is 2 0 the move should be completed in half a minute In units per minute feed rate mode an F word on the line 1s interpreted to mean the controlled point should move at a certain number of inches per minute millimeters per minute or degrees 31138 Rev B1 4 7 31 Using Tormach PCNC 1100 Series II 1 1 27 7 A Eg Ux gt SOS 7 8 SS 7 8 1 Programming language reference per minute depending upon
192. esigner The interface is presented as a 5 pin DIN socket The pin assignment is Pin number 1 is 5 Vdc useful if you have to bring power to active electronics on a probe Pin number 3 is 12 Vdc useful if you need to supply power to active electronics on a probe Pin number 4 is logic ground Do not attach to the machine ground 1 e your probe casing should be isolated from this ground 31138 Rev B1 4 8 13 Using Tormach PCNC 1100 Series II 8 2 5 8 3 Machine upgrades and configuration Pin number 5 is the signal It is internally pulled up to 5 volts in the PCNC The input is active on when this is pulled to ground Thus by jumpering 4 to 5 and you will see the probe LED change on the Diagnostics screen Other There are a number of other tools available that are less integrated than those described in this chapter but are designed to accomplish similar tasks such as our Haimer edge finders rotating lighted edge finders tool length touch off tools and off line tool length measurement devices Please review our full Tormach Tool System TTS catalog DS_TTScatalog 2 pdf for more information Auto reverse tapping The control software supports auto reverse tapping heads supplied as accessories to the PCNC PN 30612 ranges from 0 to 4 threads and PN 30613 covers 8 to 1 2 The DROs on the Settings screen are used to define the head in use and thread pitch The actual threading commands M871 M872 M8
193. et so Z 0 0 as above e Put the number of the tool you are measuring into the Tool DRO and put the tool in the spindle e Click the Setup Tool Length button The tool will move and be sensed by the setter and its length relative to the master tool be entered in the tool table To set a plane as Z 0 0 with a given tool e Load the tool in the spindle and put its number in the Tool DRO e Place the Tool Setter under the tool on the surface to be made Z 0 0 e Click the Setup Work Offset button The tool will move down onto the setter and the work offset will be reset Notes a If the setter is not directly under the tool then the probing move will miss the setter and so continue until the tool hits the table or fixture If you see this happening trip the sensor by hand or use EStop to abort the move b You can use the Setup Work Offset button and the setter for tools held by a system like ER collets where you do not know the tool length You must set up the seal a oo s setter height correctly but then click Setup Work Offset whenever you change a tool In this case the tool length does not matter everything is done by the Z work offset You must not mix this method of working for some tools Figure 8 16 Accessing the Comp with using the tool table for others because of the Probing screen differing use of the work offsets in the two methods Comp Probing Alt Comprehensive X Y Probing The simple X Y probi
194. etected by making a main probe move followed by two side steps 0 2 either side of the main move The coordinate recorded in the selected Point DROs is the point where the main move contacts the work The diameter of the probe tip is allowed for so as for simple probing it must be correctly entered for tool 99 in the tool table The probe is returned to its initial point Progress of the operation is noted on screen in the message line If Verbose Messages are selected indicated by the LED next to the toggle button then details of what the probe found will be given If the face has a radius of curvature of greater than or equal to 20 the angle of the face or tangent to the large circle it is part of will be given If the radius of curvature is less than 20 then an estimate of the radius and the center point will be displayed Clearly these will not be particularly accurate as they are derived from three points that are very close together but this information can be a useful check on the setting of the work Using Tormach PCNC 1100 Series II 8 10 31138 Rev B1 4 Machine upgrades and configuration When one point has been probed then another can be selected and the DROs set by probing another feature In some situations you may not need to probe to set the Point DROs You can just type values into then followed of course by Enter Point 1 can also be zeroed by a button Figure 8 18 shows probing for three points to find the center
195. ew tightens slide m aus ao Thick end of gib Counter clockwise on screw loosens slide mt ULL i Tapered gib Figure 9 1b Typical arrangement of gibs and screws for X Y slide dead reckoning First make sure the Lower Gib Screw is loose by a few turns this allows clearance for the Gib to be adjusted downward then tighten the Upper Gib Screw in thus pushing the Gib down until it is tight yet not hitting the bottom screw Wiggle the head while you are tightening this screw to get the gib reasonably tight this means tight but not so tight you are stripping the screw head or flexing the castings Next loosen the Upper Screw 4 full turns Now tighten the Lower Screw thus pushing the gib back up against the upper screw and creating a positive amount of Gib Clearance Now the gib should be held in place with the upper and lower screw tight on the gib Note it is important that after any gib adjustment that both adjustment screws are tight Failure to do this will result in the gib moving and all your hard work going for nothing A more precise method of adjusting the gibs is to use lost motion apparent as backlash on a dial indicator to arrive at the correct setting First loosen the Upper Screw 8 turns and tighten the Lower Screw 8 turns so that the Gib Clearance is quite loose Use a dial indicator to measure the axis backlash With a very loose gib the measured backlash is entirely attributable to
196. f label which indicates the start of the subroutine The O line may not have a line number e g N123 O777 on it The O line and the following code will normally be written with other subroutines and follow an M2 M30 or M99 so it is not reached directly by the flow of the program The L word or optionally the Q word gives the number of times that the subroutine is to be called before continuing with the line following the M98 If the L Q word is omitted its value defaults to 1 By using parameters values or incremental moves a repeated subroutine can make several roughing cuts around a complex path or cut several identical objects from one piece of material Subroutine calls may be nested That is to say a subroutine may contain a M98 call to another subroutine As no conditional branching is permitted it is not meaningful for subroutines to call themselves recursively Return from Subroutine M99 To return from a subroutine program M9 9 Execution will continue after the M98 which called the subroutine Use M47 to start program execution from the first line again Application Defined M codes Self reversing Tapping Cycles To use the Tormach Auto reverse tapping heads program M871 P or M872 M873 M874 The P word specifies the depth to be threaded relative to the current Z position which will typically be just clear of the workpiece surface The P word can be negative or positive with the same meaning Using Torma
197. ffset rather than an action e g measuring so you will get better results thinking about the part of the machine on which you want information Thus looking for Tool offset measuring will give better results than looking for Measuring tool offset For important information both entries will probably appear If you have difficulty because you tried to look something up and the index entry was missing please take a moment to e mail info tormach com with a note of a the words you were looking up and b where in the manual you found the information you wanted assuming you did 41 Absolute distance mode Co ee ee ere A ner eee ee 7 30 ADSON LEMOU C ceisiai i 7 16 Absolute machine coordinates 9 STOVE E EAA T T 7 24 PROCESS Ory SOC KCL erne E ET 2 12 on control panel sseesssessseesseesseessersssessserss 5 2 Address setting non stsetting non standard printer port 9 12 Adjustable parallel gauge ceccccecccseeeeeeeeeeees 6 7 Arc Center format cecccceccceseeeceeseeeeeseeeeeeees 7 16 Arc radius fOrMal cece eeeeceeeeeeeeeseeeeeseeeeeeees 7 15 Arc at feedrate G02 G03 defined cc eecccecesseeeeeeeeeeeeeeeees 7 14 Arc motion e 1016 eee ee eee E 7 2 Assemply Y axis Crive ccccccsececeeseeceseeeeeeeenes 2 4 Axis controls family LS MN a E E E 5 6 Axis coordinate DRO EC STING AEP E T E A T 5 6 Axis jogging control family SEE e EO E O O 5 7 keyboard
198. fool yourself into thinking there is zero backlash when the effective lost motion is within specification Understanding Preloaded Angular Contact Bearings Spacer Bearing Outer Race Cover Plate Sleeve Adjustment Nut Lock Nut Figure 9 3 Detail of bearing system Figure 9 3 shows a cross section of a typical ball screw shaft mount The ball screw shaft is in the center and the crosshatched section is the iron casting that mounts the bearings There are two angular contact ball bearings forming a preloaded pair The cover plate holds the two outer races together along with the spacer that is between them The inner races are held between the sleeve left side and the shoulder cut into the ball screw shaft The sleeve is held against the left inner bearing race by the adjustment nut and a locknut as the adjustment nut is screwed toward the bearing pair the preload increases Figure 9 4 shows how the force of preload is transmitted through the bearings from the inner race to the outer race In a preload pair this force is then transmitted back to the inner race by an opposed bearing It should be apparent that the correct orientation of the angular contact bearing 1s critical to the operation Making the Adjustment In order to make the adjustment you will need two Figure 9 5 Spanner TEER hook spanner wrenches PN 30485 in order to rotate the two nuts on the ballscrew end figure 9 5 31138 Rev B1
199. fset table for the tool 0 495 0 005 0 500 As the 1 Proper application is complex and involves a tool is sharpened and becomes large number of coding specific rules The most smaller the offset is appropriately complete reference we know of is A reduced When the offset needed is Comprehensive Guide to Practical CNC zero the tool is replaced Using this Programming in which the author describes approach the operator can us both how to apply radius offsets in 24 pages of the new and resharpened tools with the book same G amp M code program 2 Path planning is highly sensitive to lead in and lead out planning The machine controller cannot compensate under all conditions A Comprehensive Guide to Practical CNC Programming ISBN 978 0 83 1 1 3347 4 by Peter Smid is one of several advanced machining and programming books available from the Tormach web site www tormach com 31138 Rev B1 4 6 15 Using Tormach PCNC 1100 Series Il Offsets 3 There is no truly standard implementation of cutter compensation If you have experience in using cutter compensation with Fanuc Siemens GSK Haas Centroid or other control systems do not expect the Mach3 implementation to react in the same manner 4 Utility and application may be limited by the look ahead limit Cutter compensation in Mach3 cannot prevent clipping corners when going into internal cavities See the example in section 6 6 4 5 Mach3 has limitations in scope of a
200. fter consuming alcoholic beverages or taking strong medication 11 Protect your hands Stop the machine spindle and ensure that the computer control is stopped before you e Change tools e Change parts or adjust the work piece e Change the belt pulley position e Clear away chips oil or coolant always use a chip scraper or brush e Make an adjustment to the part fixture coolant nozzle or take measurements e Remove protective shields or safeguards do not reach for the part tool or fixture around a guard 12 Keep work area well lit Ask for additional light if needed 13 Keep the computer area clear of clutter Recognize that machine motion can occur when certain keys are pressed Objects falling on the keyboard can result in unexpected motion Using Tormach PCNC 1100 Series II 1 2 31138 Rev B1 4 Preface 14 Avoid getting pinched in places where the table saddle or spindle head create pinch points while in motion 15 Securely clamp the work piece in a vise on the table or in the fixture Use proper holding clamping attachments and position them clear of the toolpath Be aware of larger pieces that will be cut free during operations loose parts can become projectiles 16 Always use proper feeds and speeds as well as depth and width of cut to prevent tool breakage 17 Use proper cutting tools for the job 18 Do not use dull or damaged cutting tools They break easily and become dangerous projectiles
201. g an arc in the plane the G18 XZ plane Keep in YZ plane G19 mind that because the primary and secondary axes are reversed this arc is actually a G03 command The effects of having a plane selected are discussed in under G2 3 and Canned cycles 7 7 9 Length Units G20 and G21 Program G20 to use inches for length units and program G21 to use millimeters It is usually a good idea to program either G20 or G21 near the beginning of a program before any motion occurs and not to use either one anywhere else in the program It is the responsibility of the user to be sure all numbers are appropriate for use with the current length units 31138 Rev B1 4 7 19 Using Tormach PCNC 1100 Series ll 7 7 10 7 7 11 7 7 12 7 7 12 1 Programming language reference Return to Home G28 and G30 A home position is defined To return to home position by way of the programmed position program G28 X Y Z A or use G30 All axis words are optional The path is made by a traverse laa FON move from the current position to the programmed position followed by a traverse move to the home position If no axis words are programmed the intermediate point is the current point only one move is made Sample Program G28EX111 Workpiece Size X4 Y4 Z1 Tools Tool 7 1 Slot Drill Tool 10 1 2 HSS Drill Cutter moves on the G28 command from Tool Start Position X0 YO Z1 the start point to the intermediat
202. g letters are often given as explicit numbers Unless stated otherwise the explicit numbers can be real values For example G10 L2 could equally well be written G 2 5 L 1 1 Ifthe value of parameter 100 were 2 G10 L 100 would also mean the same Using real values which are not explicit numbers as just shown in the examples is rarely useful 66 29 N If L is written in a prototype the will often be referred to as the L number Similarly the in H may be called the H number and so on for any other letter If a scale factor is applied to any axis then it will be applied to the value of the corresponding X Y Z A U B V C W word and to the relevant I J K or R words when they are used Rapid Linear Motion G00 a For rapid linear motion program GO X Y Z A where all the axis words are optional except that at least one must be used The GOO is optional if the current motion mode is GO This will produce coordinated linear motion to the destination point at the current traverse rate or slower if the machine will not go that fast It is expected that cutting will not take place when a GOO command is executing b If G16 has been executed to set a Polar Origin then for rapid linear motion to a point described by a radius and angle GO X Y can be used X is the radius of the line from the G16 polar origin and Y is the angle in degrees measured with increasing values counterclockwise from the 3 o clock dire
203. g the Fourth Axis Referencing and Zeroing the Fourth Axis The Tormach rotary table does not have a built in home switch When you are setting it up if the initial position is important then you should use the and keys on the numeric keypad to jog it into position When in a suitable position click Zero A This will set the A DRO to zero in the current work offset system If you use multiple work offsets then you should Zero A in all of them It is possible to provide a home switch in conjunction with a fixture on the fourth axis and interface it to the PCNC using the Accessory socket on the control panel In this case the Ref A button can be used to move to this switch in the same way as the linear axes If you do this accidentally with no switch connected then the movement can be cancelled with the Esc key Diameter Compensation Feature To understand this it is useful to recall what happens on a G01 line move where two axes like X and Y are coordinated The control software will attempt to move along the line at the feed rate requested by the F word or DRO For example a move at a feed rate of 10 inches per minute from X 0 Y 0 to X 1 0 Y 1 0 will move both the X and Y axes at about 7 inches per minute By Pythagoras Theorem the diagonal speed is VWP 7 99 Now if a move of X needs to be coordinated with one of A there is a problem because A moves in degrees We only know how fast the tool is moving through the
204. g the adjustable parallels 0 0 figure 6 15 and without moving the axis you Figure 6 16 Gauge size entered to DRO would enter 0 547 into the Z axis DRO figure 6 16 The program coordinates say Z 0 547 and the tool is 0 547 above the stock so for example GOO ZO O will move the tool so it exactly touches the stock You may have noticed that in making FirstPart we cheated a little by assuming the paper gauge was zero thickness This is often sufficiently accurate and allows use of the Zero buttons rather than typing a value Using the Touch Buttons The roll you own and roller gauge methods will always give you the same measurement o to be typed in On the Offsets screen you can Length T do this once and use it each time you want to set up an offset Goto Tool C The gauge thickness is typed into the Touch le entry 1 o change Touch Correction DRO on the Offsets screen Figure i i Bj Correciinn 0 2500 6 17 shows this being set for the 14 roller Gauge Block thickness etc a AtT gauge Note the correction is also enabled as shown by the LED by the On Off button Figure 6 17 Entering roller gauge size When the gauge is in place clicking the Touch button for the axis will set the offset Figure 6 18 shows the program coordinates after Touch on Z axis Z coor 0 2500 9 8 3 0 000 0 0 623 Zero Length Ta A coord 0 0000 0 0000 0 0000 ero Touch Goto Tool Ch Offset table entry 1
205. ge Assembly use PN 30505 3 Latch Kit Assembly includes callout numbers 5 6 7 Annular Bearing Engineering Council identification D7007C DT double tandem pair ORDERED AS A PAIR gt Annular Bearing Engineering Council identification ABEC7202B P5 45 15 38 39 4l 42 43 44 15 39 35 J0 7 27 49 28 34 30 31 32 33 29 6 25 _26 24 23 54 O lt t tm lt f ef O S NA Y ny NI AN on q a am Ge t NI oly CIA st In 00 on ALAL al thal al al UO owl A AS Alo Sl Al el Al a CANLA I CA AN RAE AA S ae Awe e oian c be X L YK 15 16 20 19 18 59 21 7 52 7 17 16 13 12 40 og N og 15 50 38 51 40 53 21 il 57 56 60 54 58 55 44 43 42 24 12 10 PCNC 100 Series Il 31095 gt A o SFO VON BAG lt eo sO n R CO ID_ Number Description ID Number Description _ Screw M6x25 6 30402 NutM14x1 5 36 30431 Xaxisballscrew amp nut 8 30404 Padblock 38 30433 Shaftclamp 9 30405 Screw M6x40 39 31208 Block xaxis Bumper 30 30425 Washer8mm 60 31212 CoverPlate A ee E ee eee Annular Bearing Engineering Council identification ABEC7202AC P5 LABEL COOLANT POWER LABEL COMPUTER LABEL COMPUTER MONITOR connector on cabinet External PCNC1100 SERIES II ELECTRICAL SCHEMATIC POWER INLET OUTLET
206. gerous electrical voltages after the power has been removed Electrical Service Certain service and troubleshooting operations require access to the electrical cabinet while the electrical power is on Only qualified electrical technicians should perform such operations 1 1 2 General Operating Safety Safe operation of the machine depends on its proper use and the precautions taken by each operator Read and understand this manual Be certain every operator understands the operation and safety requirements of this machine before operating the machine 31138 Rev B1 4 1 1 Using Tormach PCNC 1100 Series II Preface Always wear safety glasses and safety shoes Always stop the spindle and check to ensure the CNC control is in the stop mode before changing or adjusting the belt pulley position tool or work piece Never wear rings watches gloves long sleeves neckties jewelry or other loose items when operating or working around the machine Long hair should be bound or kept under a hat Use adequate safeguarding around the operating envelope It is the responsibility of the employer to provide and ensure point of operation safeguarding per OSHA 1910 212 Milling Machine 1 1 3 Safety Publications Tormach recommends the following publications for assistance in enhancing the safe use of this machine e Safety Requirements for The Construction Care and Use of Drilling Milling and Boring Machines ANSI B11 8 1983 Available fr
207. ggling to the appropriate large or small LED Misc Settings Control Family Current Units This displays the units currently Current Units selected figure 5 29 nch Metric Ignore Tool Change ia i 620 G21 ___ 0 1000 Normally when the part program calls for a different tool Change depending on your G code execution will stop the Tool Set Abs IJ Setinc IJ J Incremental Change LED will flash and you Try changing I Mode if arcs cisplayicut as large circles need to press Cycle Start to continue Tool change requests Figure 5 29 Misc settings can be ignored by clicking the Ignore M6 Tool Change button This can be useful when air cutting to prove time a part program G73 Pullback This DRO defines the distance that a high speed peck drill cycle G73 will pullback when breaking the chip You may need to alter this value for metric use IJ Mode 31138 Rev B1 4 5 15 Using Tormach PCNC 1100 Series Il 5 3 5 3 1 5 3 2 Machine Controls The IJ mode defines how the I J and K words in a G02 or G03 are interpreted There is no standard for this so different CAM post processors will use different conventions The PCNC usually runs with I J and K being incremental distances from the current point You can make the Control Software treat them as absolute positions by clicking the Set Abs J button The symptoms of an incorrect setting are that small arcs can display a massive circle on the toolpath or you get an er
208. gram Running Control Family c cc ccccceccccseseccseecceesecceeceeaseeeenseeseseesenseeaes 5 10 See COMP ALAC Oni OU alll ye neose n a saomlcasidaullnntAaeeiicet saeelaon aaamcatanntls 5 11 Using Tormach PCNC 1100 Series II ii 31138 Rev B1 4 Contents IAL Fle Control geval lly Gamera ee remnree neem eenreeec E renee er weetan 5 12 5 2 2 9 Work Offset and Tool Table Control Family c ccc cecccsescccseeeeeeeeeeeeseseeneeenes 5 12 52 200 MDrand Tedcn onto PAm oea E a 5 12 Spe Alk Loop Contool Famy e emnerer nent perce nenteren rere ee rere re rente errr ener tre 5 13 5 2 2 12 Modes and Mode Alarm Control Family ccccsvesenssnseecsestceensesnaeecuatevnsasnen sees eatacneanetes 5 13 5 2 2 13 Rotational Diameter Control Family ccc ceccccseeccceeeceencecseseecenseeseseeeenseeaes 5 13 5 2 2 14 Toolchange Position Control Family cccccccceecccssecceecceesceceeseceenseeeeseseeneeeaes 5 14 5 2 2 15 Inhibits and Overrides Control Family accczescsessccanseacsaternancesnseacuatcneansncnrearuataneancetos 5 14 5 2 2 16 Feeds and Speeds Calculator salsa esset ecenioleatoan covered cntcaQnacte EE R a 5 14 5 2 2 17 Tapping Configuration Family ccccccccscccccssccceeseceeeeesesecceneeeseseceenseeeeseeseneeeaes 5 15 ILAS Mise Sethe ss Control anal catiias serrate wacacer E E E EEE 5 15 5 3 USB Jossie Pendants ioc sccsessccdcatescwessebscedsctescacseshsoeccetebsemeuebsceteetescensachseusasdesdensasehous
209. he A motion is scaled to convert it to degrees and c the radius of the cylinder is defined to ensure the correct feed rate on the surface being engraved Editing the Part program f F PMs Scale D Z 0 Ol Load the X Y engraving part program for 1 0000 _Zero your text Click the Edit button in the file control family Use the Replace function of acale O A O O the edit to change all instances of X to A 47 3600 _Zero z and then all instances of Y to X This r Er M Mac orients the engraving figure 8 1 1 2100 Scaling the Width of the Text Ta In r Ji as r The original part program will move along Figure 8 2 Scale and Radius Correction the engraving in linear units e g inches but now it is edited to use degrees the A axis needs scaling If the radius of the cylinder is R mm or inches depending on what the control program is set in then the A axis scale should be set to 57 3 R 1 e 360 2 T x R For example the radius of the disk in figure 8 1 is 1 21 so the scale for A was set to 47 36 by typing this value into the A Scale DRO on the MDI screen figure 8 2 Figure 8 3 Gear cutting Figure 8 4 Gear cutting tailstock removed for clarity Using Tormach PCNC 1100 Series II 8 2 31138 Rev B1 4 8 1 3 2 Machine upgrades and configuration Setting the Radius Correction If you are using this improvised sort of code for a fourth axis then you must set th
210. he FIX operation rounds towards the left less positive or more negative on a number line so that FIX 2 8 2 and FIX 2 8 3 for example The FUP operation rounds towards the right more positive or less negative on a number line FUP 2 8 3 and FUP 2 8 2 for example Parameter Setting A parameter setting is the following four items one after the other e a pound character e areal value which evaluates to an integer between 1 and 10320 e an equal sign e areal value e For example 3 15 is a parameter setting meaning set parameter 3 to 15 A parameter setting does not take effect until after all parameter values on the same line have been found For example if parameter 3 has been previously set to 15 and the line 3 6 G1 Using Tormach PCNC 1100 Series II 7 8 31138 Rev B1 4 Programming language reference x 3 is interpreted a straight move to a point where x equals 15 will occur and the value of parameter 3 will be 6 7 5 5 Comments and Messages Printable characters and white space inside parentheses are considered a comment A left parenthesis always starts a comment The comment ends at the first right parenthesis found thereafter Once a left parenthesis is placed on a line a matching right parenthesis must appear before the end of the line Comments may not be nested it is an error if a left parenthesis is found after the start of a comment and before the end of the comment Here is an exam
211. he parallelism of a face of a part to the XY plane may for example be found e If the probe tip radius is known approximately the parallelism of a face of a part to the YZ or XZ plane may for example be found e If the shank of the probe is known to be well aligned with the Z axis and the probe tip radius is known approximately the center of a circular hole may for example be found e If the shank of the probe is known to be well aligned with the Z axis and the probe tip radius is known precisely more uses may be made of the straight probe command such as finding the diameter of a circular hole If the straightness of the probe shank cannot be adjusted to high accuracy it is desirable to know the effective radii of the probe tip in at least the X X Y and Y directions These quantities can be stored in parameters either by being included in the parameter file or by being set in a part program Using the probe with rotational axes not set to zero is also feasible Doing so is more complex than when rotational axes are at zero and we do not deal with it here Example Code As a usable example see the code for finding the center and diameter of a circular hole For this code to yield accurate results the probe shank must be well aligned with the Z axis the cross section of the probe tip at its widest point must be very circular and the probe tip radius i e the radius of the circular cross section must be known precisely If
212. he spindle with the spindle controls in the Control Software Use the rear handle to unlock the motor mounting plate and pull the motor forwards The belt will slacken and can be moved from one set HGH E E of pulleys to the other figure 2 17 HiiLow Lou For the followi he d broid Max Speed 5140 RPM or the following tests select the low speed range by placing S 3 50 the belt on the lower pair of pulleys Retighten the belt so there is between and 4 movement between the pulleys lock the motor mounting and stow the handles in the vertical position CHANGE TOOL era t on Empty off _ 0 000 mo an anno Figure 2 18 Spindle controls Spindle C Using Tormach PCNC 1100 Series II 2 12 31138 Rev B1 4 2 8 3 2 8 4 Preparation Computer Control of the Spindle and Coolant Switch the Spindle and Coolant to Auto on the control panel Make sure the computer is displaying the Simple Run screen as shown in figure 2 15 The portion shown in figure 2 18 shows the controls for the hcn a Low ale Max Speed _5140 RPM Use the mouse to click the Hi Lo button You will see that the S 500 screen LEDs depicting the pulleys will change and the appropriate maximum speed will be displayed below them Spindle CWE5 Choose the Low setting to correspond to the PCNC pulleys m CHANGE TOOL T oam Note Just after starting the system the screen LEDs may not correspond to the indicated maximum speed The speed valu
213. here are seven different speeds 7 TAN arranged geometrically so you have instant control from Figure 5 31 X axis will be jogged the full rapid speed 65 rpm down to the slowest crawl The inner rotary control operated by fingertip has detents Each click will jog at the current feed rate by the distance defined in the Step DRO If you turn it faster than the axis can move the impossible steps will be ignored so the axis will never buffer up a backlog Keypad Pendant The keypad pendant has two modes of operation The CNC Num key toggles between these modes figure 5 32 When the Numeric LED 1s lit it is a conventional numeric pad It can be used for entering values into DROs Note that as Backspace in not available on the main keyboard during DRO entry it cannot be used on the pendant either Figure 5 32 Keypad pendant When the LED is not lit the majority of the keys are concerned with jogging the four labeled axes X Y Z and A keys 2 3 4 6 8 9 Using Tormach PCNC 1100 Series II 5 16 31138 Rev B1 4 Machine controls The 7 key will perform a Home All operation homing Z to limit switches and then X and Y The 1 key will toggle the state on the Optional Stop LED When the LED is lit MO1 is treated exactly like MOO e end program otherwise MO1 is ignored The key toggles between Continuous and Incremental or Step jogging modes In step one key press produces a single step axis movement The s
214. his is the plug that is on the end of the 4th axis and connects to the side of the PCNC cabinet PCNC 1100 Oil Lines P 3 i P 24 Table Slide Sid Y Gib Left Side Z Column Left Side P 26 Iii P 9 Z Slide and Gr ier P 10 P 29 Dovetail X Slide and Right Side P 16 Dovetail Front 2 G as 2 gt X lt E E WY Large XY Manifold Z Ballnut ele m alinu Table Slide ma Right Side Z Gib i i eh P 13 P 27 Y Slide and P 1 Dovetail Right Side P18 P14 P 15 Y Ballnut Left Side P X Slide Rear PUMP 31302 or 31373 Splitter P 2 Y Slide 32354 Left Side Inside Base Left Side tI Elbow 31311 Ferrule 31309 Gib Orifice 31408 74 4mm Nylon Tubing 31304 O Nut 31310 Ti Manifold Orifice 31370 Nut and Ferrule Bundle 31409 Tu Protective Metal Sheath 31306 Appendices 10 3 Appendix 3 Use of a Standard PC to control PCNC You are strongly advised to use the Tormach Machine Controller to run the PCNC control software If you have a particular reason to attempt to use an standard PC running Windows XP or Vista this appendix give some guidelines As such equipment is outsides Tormach s control it will not be possible to offer detailed support for its use 10 3 1 Choice of computer The system does not require a particularly powerful computer but there are certain requirements for optimal operation For Windows XP you should have A CPU
215. i a 0010 Step Jogging can be performed in two ways a using the keyboard or optional Keypad pendant or b Using the Jog Mode Num optional Tormach Jog Shuttle Controller HE Keyboard Jogging ee Ste slow Joq Rate Whenever the Jog ON OFF button is displayed on the Dn 10 jo Up current screen then the axes of the machine can be jogged Shift Jog to Override Jog bode using the jog hotkeys on main keyboard or a pendant 8 JOE y y P Figure 5 11 Jogging control keyboard family If the Jog ON OFF button is not displayed or it is toggled to OFF then keyboard jogging is not allowed for safety reasons There are two modes Continuous and Step which are selected by the Jog Mode button and indicated by the LEDs Continuous mode moves the axis or axes at the defined slow jog rate while the hotkeys are pressed The continuous jog speed is defined as shown below but this can be overridden by pressing Shift with the hotkey s A LED beside the Cont LED indicates this full speed jogging is selected The jogging speed used with hotkeys in Continuous mode is set as a percentage of the rapid traverse rate for the axis and for the Windows compatible joystick as a percentage of the feed 31138 Rev B1 4 5 7 Using Tormach PCNC 1100 Series Il Machine Controls for the given stick deflection by the Slow Jog Percentage DRO This can be set in the range 0 1 to 100 by typing into the DRO It can be nudged in 5 increments by the buttons
216. id EO 260 I0 N60 MO5 Spindle off N65 M30 Program end 7 7 5 Coordinate System Data Tool and Work Offset Tables G10 See details of tool and work offsets for further information on coordinate systems To set the offset values of a tool program G10 L1 P X Z A where the P number must evaluate to an integer in the range 0 to 255 the tool number and offsets of the tool specified by the P number are reset to the given 31138 Rev B1 4 7 17 Using Tormach PCNC 1100 Series II Programming language reference The A number will reset the tool tip radius Only those values for which an axis word is included on the line will be reset The Tool diameter cannot be set in this way To set the coordinate values for the origin of a fixture coordinate system program G10 L2 P X Y Z A where the P number must evaluate to an integer in the range 1 to 255 the fixture number Values 1 to 6 corresponding to G54 to G59 and all axis words are optional The coordinates of the origin of the coordinate system specified by the P number are reset to the coordinate values given in terms of the absolute coordinate system Only those coordinates for which an axis word is included on the line will be reset It is an error if e The P number does not evaluate to an integer in the range 0 to 255 If origin offsets made by G92 or G92 3 were in effect before G10 is used they will continue to be in effect afterwards The coor
217. idden as described in M48 and M49 above 31138 Rev B1 4 7 35 Using Tormach PCNC 1100 Series Il 7 10 2 7 10 3 7 11 Programming language reference Spindle Speed S To set the speed in revolutions per minute rpm of the spindle program S The spindle will turn at that speed when it has been programmed to start turning It is OK to program an S word whether the spindle is turning or not If the speed override switch is enabled and not set at 100 the speed will be different from what is programmed It is OK to program SO the spindle will not turn if that is done It is an error if The S number is negative Select Tool T To select a tool program T where the T number is slot number for the tool The tool is not changed automatically It is OK but not normally useful if T words appear on two or more lines with no tool change It is OK to program TO no tool will be selected This is useful if you want the spindle to be empty after a tool change It is an error if e A negative T number is used or a T number larger than 255 is used Order of Execution The order of execution of items on a line is critical to safe and effective machine operation Home change coordinate system data G10 or set offsets G92 G94 Perform motion GO to G3 G12 G13 G80 to G89 as modified by G53 Stop or repeat M0 M1 M2 M30 M47 M99 Table 7 5 Order of execution of commands on a line Items are executed in the order sho
218. ies II 10 12 31138 Rev B1 4 Appendices Modern multi core high performance computers are less likely to work well than older more modest performers The chip makers now employ a variety of power saving techniques which compromise real time performance 10 3 2 Optimizing the Windows Installation It is important that the computer used to control your PCNC does not have a large load of software running in the background Examples are the automatic update utilities for Windows and virus spam checkers Multimedia software and telephony and messaging software Such software can wake up at any time and place large loads on the computer and its disk sub system This can sometimes interfere with timing of movement of PCNC and lead to spoiled work The simplest advice is e If you are using an existing computer that has been used for some time there are likely to be a number of unnecessary programs or drivers loaded when the computer boots Windows can be hard to clean up the best solution is often to re install Windows after formatting the hard drive You may prefer to ask an IT specialist to help you with this e Install the minimum options for Windows You should include access to the Internet so you can maintain your system software and access the Tormach web site but you will normally run with the network disabled e Do not install other software packages on the computer If you wish the control computer to be dual purpose then we advise
219. ill be very different unless spindle speed is near to 1 rpm So using a feed per minute figure with feed per rev mode will probably produce a disastrous crash Feed Display The actual feed in operation allowing for the coordinated motion of all axes is displayed in Units min and Units rev If the spindle speed is not set and the actual spindle speed is not measured then the Feed per rev value will be meaningless Feed Override Unless M49 disable feed rate override is in use the feed rate can manually be overridden in the range of 20 to 100 by entering a percentage in the feed rate override DRO with a sign While it is possible to enter numbers higher than 100 the practice is not recommended The LED warns if an override is in operation The control software will apply any changes in feed rate override as quickly as possible This could be very important if you decide you have too high a feed rate for safety To optimize performance the software keeps a queue of moves ready to be implemented It is possible if you increase the federate that you will make one of these queued moves be faster than the PCNC can move or accelerate and so it will loose steps The best strategy is to write the part program to run at the highest anticipated feed rate and then use the override at less than 100 to reduce it to produce the best operating condition 31138 Rev B1 4 5 9 Using Tormach PCNC 1100 Series Il Machine Controls The FRO DRO displays
220. immediately below a Problem Resolution Checklist section For more in depth explanation of this subsystem please go to the Details section that is after the Checklist section s Disconnect Switch Figure 9 19 Power Disconnect Problem Resolution Checklist for the Power Distribution Sub system Contents of the Power distribution Sub System Problem Resolution Checklist Table 1 1 GFI in customer supply for power for the computer and coolant pump trips Table 1 2 Computer will not power up Table 1 3 Coolant Pump will not run when Coolant Switch is in the ON Position Power Distribution Checklist Table 1 1 GFI in customer supply for power for the computer and coolant pump trips Possible Cause Prob Action to identify Cause Discussion ability of Problem GFI circuit defective High Test a device such as a If the tool works the circuit is OK drill or other portable tool on the circuit Loose wires in circuit Medium Remove power from the Use the two finger tug test see machine by turning off the Loose Wires in the Frequently disconnect switch and test Found Problem list for loose wires Bad Control Board Low Remove power from the You can also unplug the power cord machine by turning off the for the machine disconnect switch Remove wires 202 and If the problem disappears a Control 205 from the Tormach Board problem is indicated You can Machine Control Board run the machine by controlling the T
221. inary motion as described above e Move the Z axis only at the current feed rate to the Z position e Dwell for the P number of seconds e Stop the spindle turning e Retract the Z axis at traverse rate to clear Z e Restart the spindle in the direction it was going The spindle must be turning before this cycle is used It is an error if e The spindle is not turning before this cycle is executed 7 7 23 7 G88 Cycle The G88 cycle is intended for boring This cycle uses a P word where P specifies the number of seconds to dwell Program G88 X Y Z A R L P e Preliminary motion as described above e Move the Z axis only at the current feed rate to the Z position e Dwell for the P number of seconds e Stop the spindle turning e Stop the program so the operator can retract the spindle manually e Restart the spindle in the direction it was going 7 7 23 8 G89 Cycle The G89 cycle is intended for boring This cycle uses a P number where P specifies the number of seconds to dwell Program G89 X Y Z A R L P e Preliminary motion as described above e Move the Z axis only at the current feed rate to the Z position e Dwell for the P number of seconds e Retract the Z axis at the current feed rate to clear Z 7 7 24 Distance Mode G90 and G91 Interpretation of the CS code can be in one of two distance modes absolute or incremental To go into absolute distance mode program G90 In absolute distance mod
222. inates This relationship is just a series of Offsets The offsets are numbers which are added by the Control Software to your program X Y Z coordinates to get the machine coordinates Figure 6 26 is a view of part of the Offsets sre You wi rat Ingen cece OX 7 0000 aaa a te th 1 4000 1 0 an en an EA 050004 roughly convert them to inches jas O O O O 0 I Ref A E E To obtain figure 6 26 the PCNC was referenced A Comection radius G amp S Rotation OH Ref XYZ notice the green referenced LEDs at right of 0 0000 screen and a tool jogged to the surface of a Figure 6 27 Axis DROs corresponding to piece of stock just touching the surface at the figure 6 26 top left corner So you can imagine it let us say that the jogging moved the Z axis down about 9 5 the tool 3 to the right and 2 5 towards the front of the machine The Zero button for X Y and Z axes was clicked we could have typed 0 into the axis DROs with exactly the same effect The Manual Data Input MDI was then used to go to the program coordinate position X 1 Y 1 4 and Z 0 5 by GUO XL 0 Yi 4 20 5 Figure 6 27 shows the axis DROs that you would see while the whole story is shown in figure 6 26 Let us use X as an example The program coordinate for the tool is currently X 1 0 we dida G00 X1 0 The offset to be added to this to get the machine coordinate is 3 Adding these two values together gives the machine coordinate value of 4
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224. ion The PCNC offers the precision of a production machine but with cost performance optimized for short run operation 1 3 Performance Expectations 1 3 1 Cutting Ability The machine is capable of cutting most materials at or near their recommended feeds and speeds For example for fast metal removal on 6061 aluminium we will run a diameter 2 flute cutter at around 18 IPM inches per minute and 3000 RPM using a full depth of cut that is a pretty good volumetric rate of metal removal so it is essential to clear chips with a flood coolant We will run smaller cutters when we are not trying to remove large amounts in a hurry For most aluminium work we use 3 3 The example above using a 14 cutter results in a surface speed of 390 SFM surface feed per minute a s cutter needs 4000 RPM to get the same surface speed well within the performance envelope of the machine Cutting steel and iron needs a lower volumetric rate thus slower feed and speed The PCNC will run best using smaller cutters when working with tougher materials For example the general machining recommendation for some oil hardening steels is 30 SFM Doing this with a 34 end mill the surface speed calculation indicates 150 RPM but that is very near the minimum spindle speed of the PCNC 1100 Series II and certainly where limited power is available By switching to a end mill the recommended spindle speed becomes 460 RPM well within the capability of th
225. ion Note The controller is shipped without the Mach3 license on its hard drive The Mach3 control program installed but without the license it will only work in demo mode limit 500 lines of code without the Mach3 license Tormach ships the Mach3 software license on a separate CD To install you license file simply insert the license CD after the controller has booted up The license file will automatically be transferred to the hard drive You can then remove the license CD and store it in a safe location Machine Controller Maintenance and Configuration Login and Software Installation The controller boots up to an automatic login with Username Operator anda blank password The Operator has rights to use the software but cannot install software or modify the MachOS configuration If you need to install software or modify configuration you must logout Operator and login again with 31138 Rev B1 4 2 9 Using Tormach PCNC 1100 Series II 2 8 2 8 1 Preparation Username Administrator Password administrator Note that the upper lower case is important The Administrator login will be necessary if you need to reinstall the PCNC software or install new software The controller is licensed as a dedicated machine controller Do not attempt to use it as a desktop computer and do not try to install general purpose software such as Microsoft Office or Microsoft Word You can install CNC related software such as CAD CAM or machining util
226. ipe Adding yeast to a soda bread recipe makes a fine mess For example here you should have the length of each tool in the tool table still set to zero You are now ready to run the program Cuiting in Air Click the Cycle Start button The PCNC will start running but almost immediately ask for tool number 1 This is already loaded so just click Cycle Start again The machine will trace the letters PCNC in the air It does this four times because they are to be cut 0 2 deep and the program is designed only to cut 0 05 each time This is conservative but runs no risk of breaking the 14 diameter tool The toolpath shows the tool as it moves by a different colored line figure 3 7 After cutting the letters the machine will stop and ask for tool number 2 Jog the Z axis up a few inches so you can put the 1 2 cutter into the tool holder Then jog down to about 2 above the material and type the value 0 into the Z DRO Do not forget to press Enter to accept the value Now click Cycle Start again The machine will use a spiral path to cut out the recess called a pocket Cutting the Actual Part You should now be ready to actually cut the part Jog the Z axis and swap back to the 4 tool You must now set this so it is just touching the surface of your material and define this as Z 0 There are many good ways of doing this and we will look at them in a later chapter For now you just need a thin sheet of paper or pe
227. is through the higher the probability that a step will be missed if there is indeed a machine problem 5 Return the axis to indicator zero and read what the DRO says Allowing for some lost motion about 001 the value indicated on the DRO should be 0 If not then the machine is indeed missing steps LL THICK LINES 1404 WIRE BLACK MOTE PUD ANO FU a E pe sa Sia n gt Figure 9 28 Axis drive subsystem portion of schematic When Control Power is on contacts from contactor C1 pass the nominal 230 VAC input power to XFM2 the DC Bus power transformer XMF2 reduces the voltage to a nominal 48 VAC which is sent to the DC Bus Board on wires L15 and L25 A full wave bridge rectifier on the DC Bus Board in conjunction with a 15 000 uF micro Farad capacitor connected wires 300 common and 301 to the DC Bus Board provide a nominal 65 VDC supply for the electronic driver modules which can be measured on wires 300 and 301 This supply is individually fused for each axis and distributed to each axis as noted in Table 4 4 above Using Tormach PCNC 1100 Series II 9 44 31138 Rev B1 4 Warranty Specifications Customization and Troubleshooting RIGHT SIDE INSIDE BOX INSIDE DOOR OUTSIDE DOOR 5 S ere a INTERFACE FOR See detail on page 3 Figure 9 29 Machine Cabinet Component Locations for the Axis Drive Subsystem Control signals to move the axes are created by the Mach3 software in the control co
228. ith Mach CNC control software Under most circumstances no modification to the configuration is needed Modification to the configuration of the operating system can disable the controller Starting the controller The Controller is configured to boot immediately upon the application of power This allows you to turn on the computer using a remote power switch such as the power switch marked COMPUTER on the front of the PCNC mill control panel You can also start the controller using the power button on the front panel For the present just power the Controller and your monitor from a wall outlet PCNC control software Mach3 will start immediately after the Controller boots If you need to exit the control program you can restart it using the desktop icon Stopping the controller The controller should be stopped by clicking on the Start gt Shutdown function on the lower left corner of the computer screen It is not a good idea to simply turn off the controller it should be allowed to shutdown properly After you have shutdown the computer turn off the computer power using the switch on the front panel of the mill This will allow you to use the power switch to turn the computer back on If you forget to turn off the power then you will not be able to turn it on using a quick off on cycle of the computer power switch The computer needs to be off for 30 seconds before the function of Boot upon Power will work Mach3 License Installat
229. ity programs such as Machinist s ToolBox Connecting and Running the PCNC You have now completed the installation and merely need to connect the PCNC to the computer Now close down MachOS and switch off the Controller Connect the parallel port of the computer figure 2 13 socket 11 to the D25 connector on the underside of the PCNC control cabinet The cable provided to connect the computer to the mill meets IEEE 1284 specifications This provides a high level of immunity to electrical noise which is important to reliable operation Do not use inferior cables Now power the Controller from the outlet near the D25 connector and if relevant power the monitor from the connector adjacent to it below the PCNC control cabinet Viewed from behind the inlet is on the right next to two outlets for computer and monitor The coolant pump outlet is to the left of these figure 2 11 Main Switch and Control Panel The rotary main switch on the right hand side of the control cabinet disconnects the mains power from the PCNC itself and isolates computer coolant 115 230 VAC outlets that are on the bottom of the cabinet Warning You should not open the control cabinet until the mains power to the machine and to the computer coolant pump are both removed from the wall outlet Live parts may be exposed even when the main switch is in the off position Computer On Off 7 Figure 2 14 Control panel layout Switch the main switch ON and switch
230. ive but none of the motors and drives are powered up Turn Control Power on when your desire to run the machine by pressing the start PB push button and turn off Control Power by pressing the stop PB when you are not running The stop PB is a twist lock device The button must be released by turning the button clockwise until the button pops out The machine LED illuminates when Control Power is on You will find listed immediately below a Problem Resolution Checklist section For more in depth explanation of this subsystem please go to the Details section that is after the Checklist section 9 27 Using Tormach PCNC 1100 Series Il Warranty Specifications Customization and Troubleshooting Problem Resolution Checklist the Control Power Sub system Control Power Sub system Checklist Table 2 1 Control Power Cannot be Turned On Possible Cause Prob Action to identify Cause Discussion ability of Problem Stop button is in the High Twist the head of the locked position button to release Breaker turned off in Medium Check the breaker Turn it on if required electrical wall cabinet supplying PCNC Check the switch Turn it on if required Measure for Disconnect Switch in off position 230 VAC nominal between wires L1 Low and L2 if required Fuse FU1 and or FU2 Low Measure for 230 VAC Turn off Disconnect Switch before blown nominal between wires checking or replacing fuses L11 and L21 Measure for 115 VAC Turn off Disc
231. ive the highest tapping torque As the machine is applying the feed any rotational slippage will cause problems 1 Tapping can be done using the M871 M872 etc cycles tapping code generated by CAM systems such as SheetCAM and of course hand written G code The recommended sequence is the same in each case figure 8 26 Feed the Z axis down at a rate corresponding to the pitch of the thread and the spindle speed The distance of this move will be the depth to be tapped plus the initial Z clearance Rapidly retract the tapping head As the tap is held in the thread this will pull the spindle out of the head and engage reverse gear Feed the Z axis up at a rate corresponding to the pitch of the thread and the geared up speed of the reverse running tap The distance of this move should be sufficient to ensure the tap completely leaves the thread Optionally position the Z axis at the initial Z clearance height Tapping with M871 M874 Macros The M871 M874 tapping macros use 4 Z moves Feed down at the tapping feed rate to tapping depth Rapid retract to reverse the tapping head Feed up at the tapping reverse feed rate to clear the tap Rapid down to the starting point PWN Pp Call using one parameter M871 Px xxx Px xxx Z start Z final See sample procedure below mimmi a N a N ee ee m a mm m m a Z start l 3 mn oo O Ce eee Z final Figure 8 26 Moves in tapping a hole 2 The M871 M872 etc cycles
232. k exe running in the background can kill it and there will be other programs which you probably are not even aware are on your system that can do the same Windows can and does start many processes in the background some appear as icons in the systray and others do not show themselves in any way Other possible sources of erratic operation are local area network connections which may be configured to automatically speed detect You should configure these to the actual speed 10 Mbps or 100 Mbps of your network Because of these factors it 1s important that you test your system when you suspect something is wrong or you just want to check that the install went well Navigate by Windows Explorer to the PCNC folder usually C PCNC3 Double Figure A3 1 The DriverTest program display click the file DriverTest or if you display file extensions DriverTest exe figure A3 1 You can ignore all the boxes with the exception of the Pulse Frequency It should be fairly steady around Using Tormach PCNC 1100 Series II 10 14 31138 Rev B1 4 10 3 3 4 10 3 3 5 Appendices 24 600Hz but may vary even wildly on some systems This does not necessarily mean the pulse timer is unsteady it may mean that the computer is heavily loaded or slow to begin with since the Control Software takes the highest priority in the system the clock may be shunted down to a priority slow enough that its one second is a variable length of time Since the p
233. k to set rotation of program axes Zero 1 Adjust probe from 2 and 3 swns elWork offset 1 G54 curved or inclined faces Verbose Messages fal i RESET C PCNC3 Temp tap Clear Initialization Macro Called on reset PCNC M3 R2 7 SRev 6 23 G Cod es M Co des Simple Run CtLAlt 1 Comp Run Alt 1 MDI Alt 2 Toolpath Alt 3 Offsets Alt 5 Settings Alt6 Diagnostics Alt 7 XN Probe Ctl As Z Probe Alt 9 Figure 8 17 The two areas of Comp X Y Probe screen The probing and recording function is done using the yellow buttons and the DROs enclosed in the red box of the figure The offset setting is done with the DROs and green buttons enclosed in the blue box Probing to Set Point DROs Before probing you should set which Point will be used to record the probed coordinates by clicking Select 1 Select 2 or Select 3 The adjacent LED will indicate the currently selected point The circular central yellow button will set the Point to the centre of the circular hole in which the probe tip is placed Ensure that the Z axis is lowered sufficiently so contact is made on the equator of the tip The cross pattern of square buttons probes in the two X directions and the two Y directions Unlike on the simple X Y Probing screen the face being probed does not need to be square on to an axis and can be a circular arc segment This is indicated by the graphic on the buttons The angle and possibility of an arc are d
234. l be guided through the usual installation steps for a Windows program such as accepting the license conditions and selecting the folder for the control software Accept all the defaults You will now be told to reboot before running the Control Software Your installation will come with a second CD which contains your license file Follow the instructions to put a copy of your numbered license file and the working license into the PCNC folder This stage is most important or you will not be able to run programs longer than about 500 lines and various features are disabled 31138 Rev B1 4 10 13 Using Tormach PCNC 1100 Series I 10 3 3 2 10 3 3 3 Appendices Vital Re boot After you have initially installed the Control Software program you must re boot your computer This reboot is vital If you do not do it then you will get into great difficulties which can only be overcome by using the Windows Control Panel to uninstall the driver manually So please reboot now If you are interested in knowing why the reboot is required then read on otherwise skip to the next section Although the Control Software will appear to be a single program when you are using it it actually consists of two parts a driver which is installed as part of Windows like a printer or network driver and a graphical user interface GUI The reasons for this division are complex but the driver is the most important and ingenious part The Control Software must be a
235. le factors The scaling is the first thing done with the values and things like feed rate are always based on the scaled values The offsets stored in tool and fixture tables are not scaled before use Scaling may of course have been applied at the time the values were entered say using G10 31138 Rev B1 4 7 1 Using Tormach PCNC 1100 Series Il Programming language reference 7 1 5 Controlled Point The controlled point is the point whose position and rate of motion are controlled When the tool length offset is zero the default value this is a point on the spindle axis often called the gauge point that is some fixed distance beyond the end of the spindle usually near the end of a tool holder that fits into the spindle The location of the controlled point can be moved out along the spindle axis by specifying some positive amount for the tool length offset This amount is normally the length of the cutting tool in use so that the controlled point is at the end of the cutting tool 7 1 6 Coordinated Linear Motion To drive a tool along a specified path a machining system must often coordinate the motion of several axes We use the term coordinated linear motion to describe the situation in which nominally each axis moves at constant speed and all axes move from their starting positions to their end positions at the same time If only the X Y and Z axes or any one or two of them move this produces motion in a straight li
236. lel to the Z axis to 5 7 4 2 e a traverse parallel to the Z axis to 5 7 4 8 The second repeat consists of 3 moves The X position is reset to 9 5 4 and the Y position to 12 7 5 e a traverse parallel to the X Y plane to 9 12 4 8 e a feed parallel to the Z axis to 9 12 4 2 e a traverse parallel to the Z axis to 9 12 4 8 The third repeat consists of 3 moves The X position is reset to 13 9 4 and the Y position to 17 12 5 e a traverse parallel to the X Y plane to 13 17 4 8 e a feed parallel to the Z axis to 13 17 4 2 Using Tormach PCNC 1100 Series II 7 28 31138 Rev B1 4 Programming language reference e a traverse parallel to the Z axis to 13 17 4 8 Execute the following to observe the G81 drill cycle Remember the G81 command follows a certain sequence Sample Program G81EX18 Workpiece Size X4 Y3 Z1 Tool Tool 6 3 4 HSS Drill Tool Start Position X0 YO Z1 N2 G90 G80 G40 G54 G20 G17 G50 G94 G64 safety block N5 G90 G80 G20 N10 MO6 T6 G43 H6 N15 MO3 1300 N20 GOO XL YL N25 Z209 No0 G81 Z27029 RO 120 FS Drill cycle Invoked N35 X2 N40 X3 N45 Y2 N50 X2 NSO X1 N60 G80 GOO Z1 Cancel canned cycles N65 X0 YO N70 MO5 N75 M30 7 7 23 3 G82 Cycle The G82 cycle is intended for drilling Program G32 xy YX Ze As R De pP e Preliminary motion as described above e Move the Z axis only at the current feed rate to the Z position e Dwell for the P n
237. ler for jogging the probe position because it combines precision with speed If you hit anything while jogging the machine does not stop and although the devices have some over travel there is a risk of damage Probing a Z Surface If the Control Software knows the length of the probe relative to the master tool then you can set the current work offset so any surface you probe is Z 0 0 conversely if you have a Z 0 0 surface then you can set the length of the probe in the tool table The pane that does this is shown in figure 8 14 We describe setting the tool length first although it needs to be done very infrequently e g if the probe tip is changed or the master tool length has to be altered The yellow button is semi transparent to reflect the infrequent use and visually draw you to the Set Work Offset button e Put the master tool in the spindle and type its number traditionally tool 0 or 1 into the T DRO Jog Z so it just touches the table or any flat Z surface Zero the Z axis DRO You can use this or any of the standard setup processes for the Z work offset for details revise offsets and in particular sections 6 1 and 6 3 e Load the probe into the spindle e Click the button Move and Set Tool length so the probe trips on the same surface you used to touch the master tool This will set the length of Tool 99 the probe relative to the master tool In everyday running you can now set any surface to be Z 0 0 Just put
238. line at the programmed feed rate and X3 provides an argument value the value of X should be 3 at the end of the move Most commands start with either G General or M Miscellaneous The words for these commands are called G codes and M codes The language has two commands M2 or M30 either of which ends a program A program may end before the end of a file Lines of a file that occur after the end of a program are not to be executed in the normal flow so will generally be parts of subroutines 7 4 2 Parameters The CS maintains an array of 10 320 numerical parameters Many of them have specific uses The parameters that are associated with fixtures are persistent over time Other parameters will be undefined when The CS is loaded The parameters are preserved when the interpreter is reset Parameters 1 to 1000 can be used by the code of part programs 7 4 3 Coordinate Systems The machining system has an absolute coordinate system and 254 work offset fixture systems You can set the offsets of tools by G10 L1 P X z The P word defines the tool number to be set You can set the offsets of the fixture systems using G10 L2 P X Y Z A B C The P word defines the fixture to be set The X Y Z etc words are the coordinates for the origin of the axes in terms of the absolute coordinate system You can select one of the first seven work offsets by using G54 G55 G56 G57 G58 or G59 Any of the 254 work
239. ll also apply to lost steps Possible Cause Prob ability Improper use of tool offset G43 Work offset G54 59 or cutter compensation G41 42 Spindle tooling not properly locked down Z axis only Motor Coupling loose or cracked Holding Brake not releasing Z axis only Computer or Software problem Obstruction or excessive friction gibs not adjusted properly or poor lubrication or high load in the mechanical system Using Tormach PCNC 1100 Series II Action to identify Cause of Problem See Machine Position Test described after this table Inspect to insure the cutter is not slipping in the holder or that the tool holder is not pulling out of the collet Inspect Z will usually move down properly but will not move up Restart the application software first If no success then restart both the computer and the application software Re install Mach 3 after downloading current version from the Tormach website for your machine configuration Jog the axis with the jog shuttle control and carefully observe the motion 9 42 Discussion By far the most common cause of a perceived loss of position or lost steps 1s user error Please refer to Chapter 7 for details on using machine offsets in Mach You may find it useful to run the axis with the cover removed A paint line from shaft through coupling to screw can be used to see if there is any movement ove
240. load and backlash will be excessive This test should be done with the lock nut tight It is best to support the box on its dowel pins when adjusting the nuts to avoid damaging the ballnut or risking bending the screw f Finally remount the box and motor ensuring that the coupling is symmetrically fitted to the motor shaft and the screw end and is fully tightened figure 9 7 amp 9 8 9 5 7 Adjusting Mating Surfaces The mating surfaces between components are pinned with tapered metric dowels The dowel holes are drilled after the parts have been aligned The pins help maintain alignment during a tool crash and allow restoration of original alignment in case the parts have to be disassembled Alignment between components can be adjusted with shims In most cases any adjustment will only require a few thousandths of an inch and will not require a full disassembly Normally the bolts can be loosened the alignment dowels left in place and the shim stock inserted in a small opening Often the machine motion can be used to open the space to insert the shim stock If alignment needs to be changed and requires removal of a dowel pin the recommended procedure is to over drill and ream for the next large size dowel pin after adjustment Each dowel pin has a small metric threaded hole in the center that can be used to extract a dowel 9 5 8 Speed Calibration This procedure is not necessary for operation of a machine it is only recommended as an impr
241. luable information If calling Tormach Technical Assistance make sure you know what version number of software machine profile and screen you are running and have recorded information from the diagnostic screen and the error line 31138 Rev B1 4 9 19 Using Tormach PCNC 1100 Series Il Warranty Specifications Customization and Troubleshooting HGH a Low on M ax Speed 5140 RPM gt O z Licensed to J Prentice E Spin Version R3 042 029 HANGE TO mpty Alphabetically Z Off D Displ i isplay Mode If your name is not listed in the box above but a serial numbered license please C amp gtact us at license machsupport com for a personalised license in your name ei tap Simple Run CtLAlt 1 Comp Run Alt 1 MDI Alt 2 Toolpath Alt 3 Offsets Alt 5 Settings Alt6 Mal Ala Ai Figure 9 i7 Location of version numbers 9 6 3 3 Tools The following are the minimum tools one should have on hand for troubleshooting e Good lighting so you can truly see what you are looking for a trouble light or a headlamp or a flashlight e A digital multi meter that can test for AC volts up to 300 V DC volts up to 100V and Resistance from 0 to IMQ Q is the common symbol for ohms e Assorted screwdrivers 2 and if possible a 3 Phillips 1 4 and 16 flat blade e A wire stripper e Measuring tools Tape measure Calipers Dial Indicator Optional 9 6 3 4 Using the digital multi meter for elect
242. made a serious error in setting up tool offsets you should save them or you will have to enter them again next time you run the Control Program Using the T DRO on a screen is a very easy way of changing a tool The process is more complex in a part program This is because the RS 274 standard part programs can run on large 6 10 31138 Rev B1 4 Offsets CNC systems with complex automatic tool changers The RS 274 process consists of choosing the next tool to use with a T word Loading the tool with M06 and applying its offsets with G43 The required commands will be generated by CAD CAM systems and the Wizards We strongly advise you to put all three stages T M06 and G43 H on one line in you program and to check that the post processor of your CAM system does this If you do not follow this Triplet Rule then you will encounter problems if you mix using tool lengths in the tool table and just setting the work offset when you change a tool 6 5 Setting X and Y Offsets The X and Y offsets allow the actual position of you work on the table to be converted to the machine coordinates whenever a movement is required It is usual to the top left coner of the work piece to be used in the G code as X 0 0 Y 0 0 If your code uses another convention then set 0 0 to the place used in your code 6 5 1 By eye It is sometimes quite acceptable to define the program coordinate zeros by eye as was done for FisstParc Move the tool to be abov
243. mpensation G40 G41 and G42 Note Cutter compensation is an area of active development for the Mach3 control software The current version of Mach3 implements a primitive version of cutter compensation G41 G42 which we do not recommend for most applications The demonstration example in section 6 8 does work and G41 G42 can be used successfully under certain conditions never the less there are enough exceptions to make programming with G41 G42 and exercise in frustration All modern CAM programs support path planning for tool offsets which offer a more practical solution at this time To turn cutter radius compensation off program G40 It is OK to turn compensation off when it is already off Cutter radius compensation may be performed only if the X Y plane is active Using Tormach PCNC 1100 Series II 7 22 31138 Rev B1 4 7 7 14 A li 7 7 15 7 7 16 Programming language reference To turn cutter radius compensation on left 1 e the cutter stays to the left of the programmed path when the tool radius is positive program G41 D To turn cutter radius compensation on right 1 e the cutter stays to the right of the programmed path when the tool radius is positive program G42 D The D word is optional if there is no D word the radius of the tool currently in the spindle will be used If used the D number should normally be the slot number of the tool in the spindle although this is not required It is OK for the
244. mputer The computer sends the axis commands via the parallel port to the Tormach Machine Control Board which massages these signals and distributes them to the individual axis commands through a ribbon cable which plugs into the axes drives The X Y and Z Axes each have 1 limit switch which actuates at the end of travel in each direction These limit switches are used to stop the travel of an axis before the mechanical limit is reached The limit switches are also used to stop an axis near its extreme travel position during a reference procedure Sensors such as limit switches are usually the biggest source of problems on a machine By necessity they need to be mounted out on the machine where they are detecting events such as end of travel This makes them vulnerable to damage They can get fouled by coolant chips or by physically being contacted Sticking is also a common problem as is wire damage The PCNC electronics are such that if any one limit switch is actuated or the Control Board thinks the switch is actuated the other limit switches will not function to stop travel even though the respective end of travel limit switch is contacted Additionally if one switch is actuated the Reference All button will not cause all of the axes to be referenced The limit switches are all wired normally closed Therefore a broken wire or bad connections results in the Control Board detecting a limit switch is actuated The diagnostic screen
245. ncluding transformations e There is very little standardization of the functions of this code across different CNC controls so careful checks should be made on code written for other machines e Jogging always takes place in the direction of the machine axes The toolpath display frame is oriented to the physical axes and will show the part at the angle at which it will be cut 7 7 21 Canned Cycle High Speed Peck Drill G73 The G73 cycle is intended for deep drilling or milling with chip breaking See also G83 The retracts in this cycle break the chip but do not totally retract the drill from the hole It is suitable for tools with long flutes which will clear the broken chips from the hole This cycle takes a Q number which represents a delta increment along the Z axis Program 31138 Rev B1 4 7 25 Using Tormach PCNC 1100 Series II Ko GSN U 7 17 22 7 7 23 Programming language reference Gis X Xo Aa Ar Re D Oe e Preliminary motion as described in G81 to 89 canned cycles e Move the Z axis only at the current feed rate downward by delta or to the Z position whichever is less deep e Rapid back out by the distance defined in the G73 Pullback DRO on the Settings screen e Rapid back down to the bottom of the current hole but backed off a bit e Repeat steps 1 2 and 3 until the Z position is reached at step 1 e Retract the Z axis at traverse rate to clear Z It is an error if the Q number is negative or ze
246. nd ball screw figure 2 9 As an alternative to adjust the Y axis to the front position before you fit the stepper motor you can temporarily clamp a length of 1 2 bar into the coupling and turn the bar with a pair of slip joint pliers figure 2 10 When you are ready to lift the machine you should remove the nuts from the four screws holding it down to the pallet 2 4 2 Fixing to Stand Unlike very large mills the level of your mill does not significantly alter machine accuracy Leveling should be sufficient to provide proper coolant drainage but precision leveling is not necessary The supports under the corners of the base of the mill are important to Figure 2 9 Manual moving table by back of old machine accuracy Despite the toothed belt apparent stiffness of the base casting it will respond to the weight of the machine The result will be errors in the left right tram of the mill For best accuracy add shims under the left front or right front corners of the machine as Using Tormach PCNC 1100 Series II 2 6 31138 Rev B1 4 Preparation needed such that the left right tram is within your desired tolerance Something like 0 002 is usually all that 1s needed however it is certainly possible to do even better A welded steel stand is unlikely to be flat Furthermore if it is flat sitting on its own it will sag down as the 1300 Ib machine is placed on it Be aware that welded steel stands are neither stress relieve
247. nd spacing piece in which the tools stand When measuring online you have to consider one of your tools to be the reference or master tool Measuring techniques Now it is time to go from the theory of coordinate systems to the very practical choice of the best ways of finding where a tool is in relation to stock which you want to machine We will look at ways of measuring tool position and then how you use these measurements to set up the PCNC We will concentrate for the present on the position of the Z axis There are several reasons for this e The Z dimension is often the one Figure 6 11 Roll your own gauge in use with the highest accuracy constraints because the stock is often oversize in both dimensions in X and Y and is at any event not easy to locate precisely on the table e The Z direction is not only important for setting the initial position of the stock it needs to be accounted for when using several tools which are almost inevitably of different lengths Note We assume that the top surface of your work piece is the plane Z 0 0 Using Tormach PCNC 1100 Series II 6 6 31138 Rev B1 4 6 3 1 1 6 3 1 2 Offsets Roll Your Own Gauge Method This is a time honored machinists method which traditionally used Rizla or similar cigarette paper as a gauge The plastic foil from candy wrapping is a good substitute Both materials are fairly strong and around 0 002 in thickness Jog the tool
248. nd the machine will stop Click on Reset and very carefully jog the other way Take care not to mechanically hit the limit doing this in the wrong direction You will lose the referenced status if you trip a limit switch You might find the directions of movement are unexpected Figure 2 22 shows the tool above a work piece The positive X Y and Z directions are marked by arrows If you press the Right arrow key then the tool will move in the positive X direction 1 e to the right of the work Similarly the Up arrow moves the tool in the positive Y direction i e towards the PCNC column Of course this actually happens on the PCNC by the table moving under the tool but you must Figure 2 22 Jogging is to move the tool relative to work imagine what it would look like if you were sitting on the table and watching the tool Using Tormach PCNC 1100 Series II 2 14 31138 Rev B1 4 Preparation You should jog around until you are quite confident which way the machine moves when you press any key Notice that the values in the Axis DROs change as you jog the tool around Jogging the Z axis is done by using the Page up and Page down keys Here of course it is the tool that moves so Up is indeed up 2 9 Summary This chapter has covered a lot of basic ground Much of it only has to be done once You may however wish to revisit the latter parts if you are not fully confident with using buttons DROs the MDI and jogging
249. nding current work offset so that the face is coordinate 0 0 This is typically useful to set the two edges of a piece of material to be the origin of their axes i e the corner will be 0 0 0 0 There are occasions when you actually want to set both X and Y offset values to the location of the point probed To do this toggle the green button Set X AND Y before making the probe move figure 8 11 Two different moves will not of course be meaningful if they use Set X and Y as the second overrides the first The probed face should not be significantly angled to the X or Y axes and should be flat Any errors here will be reflected in the accuracy of the probed position If you need to probe r AO inclined and or radiused faces then you ao F d Jaw width need to look at the Comprehensive X Y h _ inches Probing screen E S Corner of Vise It is very quick for machining a small batch of parts that can be held in a vise to align the stock by feel to the corner of the fixed jaw This function allows you Using Tormach PCNC 1100 Series II 8 6 31138 Rev B1 4 Figure 8 12 Vise jaw corner 8 2 2 2 31138 Rev B1 4 8 7 Machine upgrades and configuration to find the back left corner which 1s a typical choice for X 0 0 Y 0 0 Jog the probe to 4 to 1 2 down and to the left South West of the corner of the fixed jaw The Z height make the probe tip be below the top of the jaws Set the Jaw width DRO to the size of
250. ne hence the word linear in the term In actual motions it is often not possible to maintain constant speed because acceleration or deceleration is required at the beginning and or end of the motion It is feasible however to control the axes so that at all times each axis has completed the same fraction of its required motion as the other axes This moves the tool along the same path and we also call this kind of motion coordinated linear motion Coordinated linear motion can be performed either at the prevailing feed rate or at rapid traverse rate If physical limits on axis speed make the desired rate unobtainable all axes are slowed to maintain the desired path 7 1 7 Feed Rate The rate at which the controlled point or the axes move is nominally a steady rate which may be set by the user In the Interpreter the interpretation of the feed rate is as follows unless inverse time feed rate G93 mode is being used e For motion involving one or more of the linear axes X Y Z and optionally A B C without simultaneous rotational axis motion the feed rate means length units per minute along the programmed linear X YZ ABC path e For motion involving one or more of the linear axes X Y Z and optionally A B C with simultaneous rotational axis motion the feed rate means length units per minute along the programmed linear X YZ ABC path combined with the angular velocity of the rotary axes multiplied by the appropriate axis C
251. needed for the position as the beam is where the center of the tool will be How Work Offsets work We have shown you several uses of offsets This section gives a summary of how they work internally As explained above the PCNC keeps track of the absolute position of all axes If it has been referenced then these will be measurements relative to the home switches on the X Y and Z axes It it has not been referenced then the machine coordinates will be arbitrary Machine coordinates are useless for programming the machine as you will not Using Tormach PCNC 1100 Series II 6 12 Figure 6 25 Close up of spot of light 31138 Rev B1 4 Offsets know when designing a part what they will be at a datum position e g one corner of the part This is why you define a relation between the Program Coordinates and Machine Cordinates Program coord lt Work Offset gt G52 G92 Offset lt Tool o gt Machine coord G54 _Offset On Off ial Set offsets to Lathe Zero Em X coord 1 0000 3 0000 0 000 ae Diameter x 4 0000 Zero Touch 0 0000 f Ref X Ycoord 1 4000 25000 0 000 Applied wih 64142 y 1 1000 Zero Touch in Program Coord Ref Y Z coord 0 5000 _ 9 5000 00000 0 0000 z 9 0000 Zero Touch Length Touch RefZ A coord 0 0000 0 0000 T 0 0000 A 0 0000 Zero l Touch Goto Tool Change Home key Ref XYZ Ref A Figure 6 26 Illustrating Program and Machine coord
252. ng for a plug in card then the card name will probably appear in the title 31138 Rev B1 4 9 13 Using Tormach PCNC 1100 Series Il Warranty Specifications Customization and Troubleshooting a ice Manan Device Manager File Action View Help e MEERA JAP ATHLONE4 W Computer S Disk drives 2 Display adapters 2 DVD CD ROM drives 4 Floppy disk controllers 33 Floppy disk drives ig Human Interface Devices IDE ATA ATAPI controllers IEEE 1394 Bus host controllers H 5 Keyboards E E E E e oF ECP Printer Port LPT1 Properties General Port Settings Driver Detai SURE A EEN ioj xi lt EN n Linke Resources 3 ECP Printer Port LPT1 i Resource settings Resource type fe iii 1 0 Range 8 0 Range DMA Setting based on Current configuration Configure PONCE Profile Open Fratile ESPCNCANPCNC M3 W aml CAUTION Do not run this utility when machine Control Software is running or you will loze your changes when you close the Control Software Printer Port Printer port address in Hex cpa Joes not need Ox in number Spindle Calibration Spindle steps per unit are 1000 0 willbe 999 929 3E wf lt gt Mach X Pulsing Engines E H Y Mice and other pointing devices H Monitors ni By om lo a8 Processor Network adapters HY NVIDIA Network Bus Enumerator EY Ports COM amp LPT CP Pri
253. ng screen is designed so that the one click does everything needed to set the required offsets This imposes the limitation that the moves are performed by the software rather than by the operator For example while you can find the center of a circular bore you cannot find the center of a circular protruding boss even though the basic geometry is identical A Comprehensive Probing screen is provided to overcome this limitation The screen is accessed by a button on the simple X Y probing screen figure 8 16 Figure 8 17 shows the Comp X Y Probing screen It gives the operator the required flexibility by separating the actions of probing for feature on the work and setting work offsets from the features The interface between the operations is the X Y coordinates of three points which are stored and displayed in a bank of DROs 31138 Rev B1 4 8 9 Using Tormach PCNC 1100 Series Il Machine upgrades and configuration F mach3 CNC Controller File Config View Wizards Operator Help Mil gt G15 G80 G17 G40 G20 G90 G94 G54 G49 G99 G64 G97 x 0 0000 F 6 00 Y 0 0000 Tiere Z 0 0000 2 0050 ster Test probe EL Lo before move Cont Step Set point by moving Probed points Click to set work offset 1 2 3 so point is origin ta Xx _ 0 0000 _ 0 0000 _ 0 0000 a Y 0 0000 0 0000 0 0000 Panes 4 A Select 1 a Select 2 E Select 3 E i ies Suitable for touching Center of rotation Clic
254. ng the Clear Rot button by typing O into the angle DRO or by using a G69 command Probe Calibration For the probe readings to be meaningful the center of the probing tip ball needs to lie on the centerline of the spindle The Tormach probe has three set screws which are used to adjust this alignment Most other probes will have similar features although the pitch of the threads and the orientation of the screws may differ and so require alteration to the details of this procedure To align the probe tip you need a hole about 1 2 diameter and 34 or so deep machined in a block of material so that it is perpendicular to the bottom face of the block Aire 8 20 Point 3 Cable left The hole should be as circular as possible so ideally be reamed or bored on a lathe If it is produced on a lathe then having a through hole and facing the end provides the accurate bottom face A rough setting can be made using the TTS Measurement Fixture p n 30140 although its bore is not finish machined e Insert the probe in the machine spindle in the collet with which it will be used so that the connector and cable are on the right X direction Leave the spindle lock on Probed points e Work using the Comp X Y Probing screen Zero the Point 1 DROs as it is not used Select Point 2 and use the round yellow centre finding button to record the center of the alignment bore This is illustrated in figure 8 19 e Rotate the spindle
255. nt outside of the Intended Use Statement are supported through consulting engineering not through our free support policy There are no limits to the applications that Tormach products can be used for or to the modifications that can be applied to the Tormach machinery Tormach designs use standard industrial components and incorporate the principles of Open Architecture specifically to allow and promote these variations With Open Architecture controls industrial engineers will find Tormach products cost effective to incorporate into larger manufacturing systems or with easily separable base column and head sections manufacturing engineers looking to design specialized in house equipment will find they can use the base as a low cost motorized XY table Some machinists may want to convert a stepper mill to servos or some software engineers may want to replace the Tormach approved software with something of their own creation All of the technical information and insight required to support these variations from the intended use cannot possibly be foreseen If the extensive documentation provided does not supply all the information you need we can provide additional information and engineering support required for your project on a consulting engineering basis We are actually very good at this If you have your questions well organized we can normally provide all the information you need in short order Consulting engineering is done by electrical and m
256. nteen significant figures will be retained however enough for all known applications e A non zero number with no sign as the first character is assumed to be positive Notice that initial before the decimal point and the first non zero digit and trailing after the decimal point and the last non zero digit zeros are allowed but not required A number written with initial or trailing zeros will have the same value when it is read as if the extra zeros were not there Numbers used for specific purposes by the Control Software are often restricted to some finite set of values or some to some range of values In many uses decimal numbers must be close to integers this includes the values of indexes for parameters and carousel slot numbers for example M codes and G codes multiplied by ten A decimal number which is supposed to be close to an integer is considered close enough if it is within 0 0001 of an integer Parameter Value A parameter value is the hash character followed by a real value The real value must evaluate to an integer between 1 and 10320 The integer is the parameter identification number Think of it as the number of a pigeon hole and distinguish this from its real value which is whatever number is stored in it The character takes precedence over other operations so that for example 1 2 means the number found by adding 2 to the value of parameter 1 not the value found in parameter 3 Of course 1 2 does m
257. nter Port LPT1 Conflicting device list No conflicts COM1 4 SCSI and RAID controllers H A Sound video and aame controller pi profiles provide a way for you to set up and store i Figure 9 13 IO address in Resources 8 IV Use automatic settings Chane Fr when 5 2000 Digital spindle WFD w APA TAG Sees a Help 2008 Tormach LLC All nights reserved PCN CContig Rew 3 0a lt Figure 9 14 Entering port address Choose the Resources tab and take note of the first number under Setting that corresponds with the first Resource Type I O Range figure 9 13 This shows the standard value for a motherboard port A PCI post will not start with a zero it will probably be something like CD80 as it is a hexadecimal number it can have digits A B C D E or F in it Write down the four numbers and or letters This is your Printer port address in Hex Finally run the PCNCConfig program and open the PCNC3 profile details in section 9 5 8 above and enter this number under the Printer Port heading figure 9 14 1 Machine Config is for PCNC770 2 Open Profile C APCNC3SPCNC1100M 31 xml 3 Now configure data in the panels below e _ _ __ dag Steps CAUTION Do not run this utility when machine Control Software is running or you will lose your changes when you close the Control Software Printer P
258. number is missing and the same canned cycle was not already active e The R number is less than the Z number When the XZ plane is active the Y number is sticky and it is an error if e The Y number is missing and the same canned cycle was not already active e The R number is less than the Y number When the YZ plane is active the X number is sticky and it is an error if e The X number is missing and the same canned cycle was not already active e The R number is less than the X number Preliminary and In Between Motion At the very beginning of the execution of any of the canned cycles with the X Y plane selected if the current Z position is below the R position the Z axis is traversed to the R position This happens only once regardless of the value of L 31138 Rev B1 4 7 27 Using Tormach PCNC 1100 Series II 7 7 23 2 Ka amp S Gs Programming language reference In addition at the beginning of the first cycle and each repeat the following one or two moves are made e A straight traverse parallel to the XY plane to the given XY position e A straight traverse of the Z axis only to the R position if it is not already at the R position If the XZ or YZ plane is active the preliminary and in between motions are analogous G81 Cycle The G81 cycle is intended for drilling Program G81 X Y Z A R L e Preliminary motion as described above e Move the Z axis only at the current feed rate to the Z position e Retr
259. o remove the machine from its pallet e Un strap the stepper motor from its transit position figure 2 5 e Remove the sheet steel cover from the Y axis drive coupling box at base of column behind the machine Figure 2 5 Y axis motor as shipped and mounting flange Using Tormach PCNC 1100 Series II 2 4 31138 Rev B1 4 2 4 2 4 1 2 4 1 1 Preparation e Remove the four cap head screws from the back face of the coupling box and loosen the two screws in the shaft coupling on the end of the Y axis ballscrew 4 mm or 5 32 hex wrench e Use the cap screws to mount the motor on the back face of the coupling box The wiring runs downwards from the motor It is important to ensure that the motor flange can pull up flush to the machined face of the coupling box Remove any paint that could cause mis alignment After tightening the cap screws back them off 1 4 turn so the motor is free to self align e Ensure that the coupling is centrally positioned on motor shaft and the machined end of the ballscrew and tighten the cap screws on the coupling Then tighten the cap screws holding the motor figure 2 6 Check that the axis turns with no tight spots The smooth 1 e outside face of an old auto engine timing belt or poly vee auxiliary drive belt which has been cut to make a strip can be used to turn the coupling between the stepper motor and ball screw figure 2 9 If it does feel tight then you need to recheck
260. of a feature that could not be located by the simple X Y Probing screen Setting Offsets from Points Once you have a point or some points you can use them to set work offsets by using the green buttons Figure 8 18 Finding a tricky center Origin X Y or X and Y from a point The buttons outside the circle use just one point If you only want to set the X offset use Point 1 If you want to set just the Y offset use Point 2 To set both X and Y use Point 3 Origin X and Y are center of an arc Set all three Points to lie on the circle or arc Click the Origin is Center button Although the picture on the screen implies the points are roughly equally spaced around the circle and this will give the greatest accuracy you can work with a small segment of arc drawn from a large circle whose center is outside the machining envelope by many feet As the points can be centers of holes it can find the center of a set of holes on a pitch circle like a pipe flange Origin X and Y are at intersection of line and perpendicular from a point Again you set all three Points Points 2 and 3 define the line and Point 1 from where the perpendicular is to be dropped Click the Origin is corner button Lib ipa i LAM The picture implies that the perpendicular should intersect the line between the probed points but this is not necessary The corner can be on any projection of the line This function is a generalization of the vise jaw locator on
261. of the Control Software disappears unexpectedly If you have a troublesome system then you might find it worthwhile to create a shortcut for DiverTest exe and drag it onto the Desktop for easy access Manual Driver Installation and Un installation You only need to read and do this section if you have not successfully run the DriverTest program The driver Mach3 sys can be installed and uninstalled manually using the Windows control panel e Open the Windows Control Panel and double click on the icon or line for System 31138 Rev B1 4 10 15 Using Tormach PCNC 1100 Series I Appendices e Select Hardware and click Add Hardware wizard As mentioned before the Control Software s driver works at the lowest level in Windows Windows will look for any new actual hardware and find none e Tell the wizard you have already installed it and then proceed to the next screen e You will be shown a list of hardware Scroll to the bottom of this and select Add a new hardware device and move to the next screen e On the next screen you do not want Windows to search for the driver so select Install the hardware that I manually select from a list Advanced e The list you are shown will include an entry for Mach x pulsing engine Select this and go to the next screen e Click Have disk and on the next screen point the file selector to your directory C PCNC3 by default Windows should find the file Mach3 inf Select this file and click Open
262. ofessional edition or Microsoft Windows 7 Our experience is that the more modern and high performance the motherboard in your computer is the less reliable the performance running a real time task will be This is due to many power saving and temperature control tricks used by the chip manufacturers The Tormach Machine Controller is specifically designed for real time applications Details of the computer requirements and software installation for a standard PC can be found in Appendix 3 Setting Up Your Controller Positioning the Controller The controller should be positioned where it will remain clean and dry It can be placed vertically or horizontally When vertical it should be resting on the rubber pads When horizontal it should be resting such that the CDROM drive is above with the power button on the lower right corner Do not allow anything to block the vented cabinet holes The steel cabinets design for PCNC series mills have storage sections intended for the controller The cabinet storage areas are large enough to provide adequate cooling without the Figure 2 12 Front of TMC need for additional fans The controller remains well protected in the machine stand but access to the controller is less inconvenient This isn t a concern if you power the controller through the computer outlet on the PCNC mill see the section below Operating the Controller Starting the Controller and if you extend the USB ports using USB B
263. offsets work in Z is shown in figure 6 9 In the image above it should be clear that the following equation applies Program Coordinates Work Offset Tool Length Machine Coordinates The tool length comes from the tool table The work offset comes from the work offsets table also sometimes called the fixture table There 255 different work offsets available The first few are called by G54 through G59 You can do virtually all straightforward machining using just the one default work offset system G54 You only need multiple systems if you decide to use more than one vise or other complex fixturing clamps We will talk more about the work offsets later When we used the Z axis Zero button with the tool touching the top of the work what happened is that current value of the Program Coordinate was added to the current work offset For example if we had the following before pressing the Zero button Program Coordinate Work Offset Tooloffset Machine Coordinate 3 2 4 9 Then after the Zero button was pressed we would have the following result Program Coordinate Work Offset Tool offset Machine Coordinate 0 5 4 9 so making the program coordinates of the top of the work be zero as is conventional for most programs Figure 6 9 shows the top of the table as being machine zero This is arbitrary We could have chosen the top face of the stand and the diagram would have looked very similar just that the work offset
264. often deliver accuracy that exceeds the accuracy specified by the machine builder while an inexperienced machinist may have difficulty delivering the expected accuracy With this understanding we cannot tell you what accuracy you will be able to achieve in your own work Nevertheless the accuracy specified by a machine builder remains an important reference point 1 4 Scope and Intellectual Property This document is intended to provide sufficient information and detail to allow you to install setup and use your Tormach mill It assumes that you have appropriate experience and or access to training for any Computer Aided Design Manufacture software that you intend to use with the machine This document also assumes familiarity with typical Microsoft Windows applications programs as the control software for the PCNC runs under the Windows operating system Tormach LLC is dedicated to continual improvement of its products so suggestions for enhancements corrections and clarifications will be gratefully received Tormach LLC Art Fenerty and John Prentice assert their right to be identified as the authors of this work This work is copyrighted by Tormach LLC The right to make copies of this manual is granted solely for the purpose of training courses related to evaluation of and or use of the PCNC It is not permitted under this right for third parties to charge for copies of this manual beyond the cost of printing Every effort has been ma
265. oftware 5 Open the PCNCConfig software program located under Programs on your Start menu This will have been installed when you installed the control software Click the Open Profile button and choose the machine profile you wish to modify figure 9 10 The profile for the PCNC 1100 Series II is C PCNC3 PCNC1100M3 II xml A OpenProfite P PENO IPCNCIIDOMJHI eri 3 Now configure dala in the panels below x CAUTION Do rt rien tiy o pou wal owe roa chores YT G e CAUDO Local Disk C3 PENCS gt 3 seach rcncs 2 Pritat Past Prete por scdhersin Hee Crganize w sew foide L Fanontet jo EE Dassen NNW koan Fi Spinde Calibration Ti Deures Gpandio seps perunt w gt I Recent Passe Run zonde n low pan wih S werd a fi E asno VED Feresdngi f 8 teres DIL 2 LPM 17 2011 2 13 eM WAIL LLIPH 21772011 2 13PM STOL 211 Pm JNN Awe X17011 2 OPH 2 17 2011 2 13 PH Probe Loge Serres f a Ej CD Gene 2 Batt_ex Probs mates amut on tous aa PATRIOT Q Bh Ari Honing ge are HG DHTREF D N Harig deabied Ga dave TSt N G pubic 1 TORMACH GER YER P 4 T ATUH Q PUH OCenfigAer 4 2 Figure 9 10 Opening the profile 6 Next under the Speed Calibration heading enter the frequency you recorded earlier figure 9 11 The software will display a new Spindle steps per unit value 7 At this point you should click the Save Profile button If you are sure
266. ogramming ccccecseseeeeeeeeees 4 8 Coolant COMER olo uriena acu shee teins aval A 7 3 control panel SWIC iiwtesxccwetentieundicriwncteatienns 2 12 Importance of in CNC cc eccceecccceeeeeneeeeneneees 2 2 IMO MISC ON isis dard oeGa ties a a a 7 34 MOS Hood Onenaren narinaa 7 34 MOQO e a aoactegeGateaheceds 7 34 Coolant controls ON CONULO pane harr aA 5 2 Coordinate rotation by probing setting coordinate rotation cccseeeceeeeeeees 8 11 Coordinate system rotation G68 setting and G68 clearing 7 25 Coordinate systems IG OM CUS Ei e e eei 6 1 TELCrENCe CEMMITIONS ai 7 5 Co ordinated linear motion LSN aT Gl A E E E E eaeeeea 7 2 Current position sa HU S a E ee eee ene een E ES 7 3 Cutter compensation tool diameter entry move BSTC FAM E E EA E dances trtet teen E 6 18 Cutter diameter compensation through CAD CAM ccceecceeeceseeeseeeeeeees 6 14 Cutter radius compensation G40 G41 G42 defined cc eeccccceeseeeeeeeees 7 22 Cycle Start Dutton rea neenon enie aa nihai 5 10 D Demonstration program PONNE a ee enue oer art On re ae vee ere ante 3 2 Diameter compensation LED described rsa uis hse udaeld a 5 7 Diiin zer RODS 53a belt chee a E EE 8 4 Digitizer probe interface ccccceeeeeeseeeeeeeeees 8 13 Using Tormach PCNC 1100 Series II Index 22 Direction Of JOPEING ccccceececseeeceeeeeeseseeeeeeens 2 15 Display mode button
267. oise If extension cables are used frequently there are exposed metal parts on the connectors If these metal parts contact other metal objects such as the machine frame noise problems have been observed Taping off the exposed metal parts of the connectors to prevent contact has proven to be effective 9 6 5 Which sub system should I troubleshoot l Proceed to the No ower on the machine ee p Sub section Can you turn on Control No Proceed to the Power Machine LED is gt Control Power on Sub section Yes No Can you turn on the PTOCERG 1O Ne 4 gt Computer Control computer LED Sib Section Proceed to the gt Axis Drive Sub section Are the X Y Z and A Axes No Function Properly Yes Is the Spindle Drive No 5 spindis ie i 5 Functioning Properly Sub eecic Yes CD Figure 9 18 Deciding which sub system to troubleshoot The flowchart in figure 9 18 will guide you where to start troubleshooting the electrical system 31138 Rev B1 4 9 23 Using Tormach PCNC 1100 Series Il Warranty Specifications Customization and Troubleshooting 9 6 5 1 Computer and Coolant Power Distribution Sub system Overview User supplied electrical power is run through the disconnect switch on the machine This switch turns on and off all the electrical power to the entire machine and the computer system You will find listed
268. ol is located there are two basic rules to follow for safety s sake If the Z value represents a cutting move in the negative direction the X and Y axes should be executed first If the Z value represents a move in the positive Hil direction the X and Y axes should be executed last a g oT Example N25 GOO X275 Y4 75 Rapid CO XZ2 57 14 75 N30 20 1 Rapid down to 20 1 As this diagram shows if the basic rules are not followed an accident 7 7 2 Linear Motion at Feed Rate G01 CAN TESH opens Or GCO often occurs because clamps are not taken into consideration Following the basic rules will reduce any chance of error a For linear motion at feed rate for cutting or not program G01 X Y Z A where all the axis words are optional except that at least one must be used The GOI is optional if the current motion mode is G01 This will produce coordinated linear motion to the destination point at the current feed rate or slower 1f the machine will not go that fast b If G16 has been executed to set a polar origin then linear motion at feed rate to a point described by a radius and angle G00 X Y can be used X is the radius of the line from the G16 polar origin and Y is the angle in degrees measured with increasing values counterclockwise from the 3 o clock direction 1 e the conventional four quadrant conventions Coordinates of the current point at the time of executing the G16 are the polar origin
269. ol number to use G43 says that a tool length offset must be be applied with H giving the offset length to use this is usually the same as the number of the tool you have chosen As an example if you want to change to tool 21 the command would be M T21 G43 HZ1 If you re creating a G amp M code program by hand in a text editor this sort of line will be needed when your code intends to command a switch from one tool to the next If you develop your code using a CAM program your CAM program will automatically insert this line Alternative Methods Setting Up Tools The previous section showed you how to measure tools and set up the tool table if you have the Tormach Tooling System TTS and its touch tool Working this way is easy to explain and understand as well as allowing you to set up tools for the next job while using the machine to run a job Offline measurement is common in professional toolrooms but TTS is one of the few systems making it available to small shops This section describes ways of using the mill itself to measure tools and is applicable to standard R8 tooling which is difficult to measure offline It can of course also be used with TTS if you do not wish to measure offline You must however be consistent with the method you use You cannot measure some tools offline and some online The reason for this is that any measurement is based on a reference or datum position In TTS the datum is the cylindrical grou
270. ols cool but it does little for clearing chips Flood coolant will cool the cutting tools while clearing chips but is more challenging to contain The table of the PCNC has drain slots and a hole tapped for a pipe fitting to allow coolant collection as is common on most small mills Nevertheless CNC machining operations commonly produce so many chips that you simply cannot keep the table drain running At times you may need a coolant flow that is simply too much for the table drain The little drain tray that is common under manual machines or the open frame setup of a Bridgeport style knee mill just does not make it We strongly recommend that you plan your setup with a full motion tray such that coolant will be captured as it overflows the machine table within the full operating envelope of the machine Another reason to use a full motion tray is to reserve the space that will be required when the machine moves If you use a narrow drip tray or none at all you should plan for full machine motion plus some human space when you place the machine in your workshop You do not want to locate it where you can create crush points between the machine table and a wall When in operation the X Y and Z motions will not stop when they hit something The machine will move with hundreds of pounds of force enough to punch through a wall tip over the machine or crush someone in the way Machine safety is the responsibility of the operator This includes all
271. olumn They are scraped in as a set and neither the saddle nor the column can be had as a replacement component Likewise the base XY saddle and machine table are scraped in as a set The slide ways have tapered gib plates also hand scraped where the position of the Gib Plate controls the tightness and friction in a slide way For example in figure 9 1b the Y axis Gib Plate is part of the Saddle and is held in position on both front and back via the Gib Screws see cutaway in figure 9 1b Adjustment Procedure The adjustment procedure is similar for all three axes The Z axis is described in detail The Gib Plate is tapered down When the Gib Plate is moved down relative to the Z axis Saddle the slide way will become tighter when it moves up the slide way will become looser With the machine is turned on move the Z axis up to near the top of its travel Remove the screws that attach the way cover to the Z axis Saddle in order to gain access to the lower Gib Screw Figure 9 1a Upper Z gib screw It is difficult to assess the correct clearance for the Gib as a very small force on its end can via the shallow taper apply a large force to the dovetail Too tight a gib results in zero gap and very Using Tormach PCNC 1100 Series Il 9 6 31138 Rev B1 4 Warranty Specifications Customization and Troubleshooting high friction since there is no longer space for an oil film The easiest method is by a form of Clockwise on scr
272. om The American National Standards Institute 1430 Broadway New York New York 10018 e Concepts and Techniques of Machine Safeguarding OSHA Publication Number 3067 Available from The Publication Office O S H A U S Department of Labor 200 Constitution Avenue NW Washington DC 20210 1 1 4 Safety Precautions 1 Do not run this machine without knowing the function of every control key button knob or handle Refer to the manual or contact Tormach if any function is not understood 2 Protect your eyes Wear approved safety glasses with side shields at all times You should never use compressed air to remove chips or to clean the machine An air blast will often launch a metal chip into a place it should not be 3 Ear protection should be used on any operations that exceed sound levels of 85dBa 4 Avoid moving parts Before operating this machine remove all jewellery including watches and rings neckties and any loose fitting clothing 5 Keep your hair away from moving parts 6 Take off gloves before you operate the machine Gloves are easily caught in moving parts or cutting tools 7 Never operate with unbalanced tooling or spindle fixtures 8 Remove all tools wrenches chuck keys etc from the spindle and machine surface before you begin Loose items can become dangerous flying projectiles 9 Use adequate work clamping Do not allow your work piece to become a projectile 10 Never operate a milling machine a
273. on the upper part of the spindle You will have to turn the spindle a little to get it to line up The locked spindle is shown in figure 5 7 Figure 5 6 ER32 collet tool holder 31138 Rev B1 4 5 3 Using Tormach PCNC 1100 Series Il Machine Controls To remove any installed tools e Wipe any debris from the spindle nose and the tool being removed to avoid any risk of it getting into the spindle bore e Using the supplied 13 mm wrench on the squared end loosen the drawbar by about one turn Tap the end of it with a copper faced hammer to disengage the R8 taper e While holding the tooling in one hand fully unscrew the drawbar and remove the tooling To insert a new tool e Check that the R8 taper on the tool holder collet is quite clean e Insert the tool holder collet into the spindle turning it to ensure that the drive keyway engages with the key in the spindle Start the drawbar thread to retain the tool holder collet e If you are using a tool holder then the drawbar can be tightened Otherwise using the drawbar to prevent the collet jaws from closing in the spindle taper insert the TTS holder or tool into the collet Then tighten the drawbar ie e Finally disengage the locking forks and close the door Figure 5 7 Spindle lock fork engaged 5 1 2 3 Changing TTS Tools For more information on the Tormach Tooling system please review the TTS manual from the Tormach web site titled 31866_TTS_Manual
274. onal orthographic engineering drawings more or less automatically produced from the model High end programs like Solidworks and Pro ENGINEER also work in the same way and can be used to design for manufacture with the PCNC A 3D CAD program will typically allow the export of solid models IGES or STL format for input to a 3D CAM program or DXF Figure 4 2 Keyhole format files for use in 2 2D CAM 4 3 2 2D CAD In a 2D CAD program you represent parts by drawing the individual views of the engineering drawings A vast range of software is available much of it free We advise that you use software that allows you to express the intent of your design in the drawings rather than just drawing a set of lines As an example let us assume you want to l l Figure 4 4 Joined make a key hole shaped slot in a block of Figure 4 3 Line moved points material This can easily be drawn as two BU eee arcs and two lines with the hole that accepts the key s shank being highlighted figure 4 2 How useful this drawing is depends of how intelligently the CAD program can interpret the lines As drawn they are probably separate and can be moved independently figure 4 3 Most software will allow joining the lines so they move together figure 4 4 This however does not really reflect what the part is like 31138 Rev B1 4 4 3 Using Tormach PCNC 1100 Series Il 4 3 3 From an Idea to a part The important things about th
275. onnect Switch before nominal between wires checking or replacing fuses 102 and 100 Transformer XFM1 bad Low First ensure fuse 3 is not Turn off Disconnect Switch before blown then measure for replacing transformer 115 VAC nominal between wires 102 and 100 Fuse 3 or 7 blown Details of the Control Power Sub system Find the relevant portion of the electrical schematic highlighted below You may find it helpful to have your electrical schematic available to use along with this discussion LAAR COM LAPEL COMPUTER MONTOR gameder eg sagt Ever DITS VAC ow 7 K H ADDY on A xs Hs A el a ETERS te i eels JA 22 Figure 9 23 Control Power Sub system Portion of the Electrical Schematic Using Tormach PCNC 1100 Series II 9 28 31138 Rev B1 4 Warranty Specifications Customization and Troubleshooting The Control Power circuit is that circuit which is energized when in a ready to run state and which de energizes when the red stop button PB1 is in the depressed position The circuit does not energize until the Stop Pushbutton is released and the start Pushbutton PB2 is momentarily depressed When Control Power is off the machine is in an off state however some components in the electrical cabinet are still energized including the main fuses FUI and FU2 the Control Power Transformer XFM1 fuse FU3 and wires 102 and 103 on the Stop and Start Pushbuttons Additionally the Filter is powered b
276. onnected for shorts wire to wire and wire to ground and also for wire breaks Note that a blown fuse usually is the result of a bad drive If you replace a fuse and it immediately blows suspect a bad stepper drive or wiring to the drive Adjust using procedure in section 9 5 5 Note Too tight results in too much friction in the system Too loose can cause binding Investigate oiling system for lack of oil and or plugged lines Refer to Service Bulletin SB0031 Oil residue from long term Repeatedly pump oil and slowly jog storage axis OF axes Clean ball screw 31138 Rev B1 4 Warranty Specifications Customization and Troubleshooting Table 4 3 Stepper Motor Winding Resistance To To To Q Probe Probe Probe Tare 308 309 312 313 316 317 320 321 310 314 318 322 311 315 319 323 310 311 314 315 318 319 322 323 0 5 2 0 Q ew as e a O a ma Ground Ground Ground Ground gt 1 MQ Bar Bar Bar Bar Table 4 4 DC Bus Power Distribution The DC Bus Board contains 4 fuses which are used to individually fuse power to the stepper driver modules A 5 fuse is provided on the Supply Boards for the Z axis Brake Fuses are noted on the circuit board Note that the control power circuit must be on Machine LED LED1 is on Fuse Number Function Wire Numbers to Voltage when DC Bus is OK on DC Bus Monitor with Common and when fuse is good Board Lead 0V listed first 31138 Rev B1 4 9 37 Using Tormach PCNC 1100 Series
277. or try to seek out networks New computers are often laden with freebee 2 System Configuration Utility General SYSTEM INI WIN INT BOOT INT Services Startup versions of programs fe E M pI ESTAA J ae lege E i RAdobe LM Service Unknown Stopped that are loaded when C autodesk Data Manage Unknown Running the computer starts CI Autodesk EDM Server Unknown Running Autodesk Licensing Service Linknown Stoppe Thi 0O desk kn d ngs to remove O ttd_stringt 6e44F930 Unknown Running include QuickTime J FLExnet Licensing Service Unknown Stopped CJ tnstallriver Table Manai Unknown Stopped RealPlayer AOL C Machine Debug Manager Unknown Running messenger O SOL Server AUTODESK Unknown Running QuickBooks Instant 0O NVIDIG Display Driver Se NVIDIA Corporation Running O Remote Solver for COSM Unknown Running Messenger Camera C Sophos Anti virus status Unknown Running F video software music SE ra software and just about Hide All Microsoft Services Enable Al CESEN any application SS _ Se Eee OK Cancel App Help software that you do C3 not use or recognize Figure A3 3 Disable Services Your mill computer should be lean and clean and void of any unnecessary programs 1 Click Start button 2 Click Run 3 Type MSCONFIG and press Enter 4 Click Services tab 5 On the lower line check the box for Hide All Microsoft Services step 1 then Disable All
278. orary center Program G15 to revert to normal Cartesian coordinates GO XA YAU normal GO move to 2 0 2 0 G16 start of polar mode CLO X10 Y45 thas WLLL move to X 2 7071 Yo 2 707 whieh Tsa spot on a circle of radius 1 0 at 45 degrees from the Tne LL Coordinates Of 2077 0 This can be very useful for example for drilling a circle of holes The code below moves to a circle of holes every 90 degrees on a circle of radius 2 5 center X 0 5 Y 0 6 and high speed peck drills to Z 0 6 GOr 20 0 Oey OLS goto the center point G16 enable Polar coordinates Gol oF oc O20 ROL Aa 6 FS Using Tormach PCNC 1100 Series II 7 18 31138 Rev B1 4 Programming language reference in G16 mode the X becomes the offset from center and the Y becomes the degrees of rotation from the center KZ eo YIU MZ ea LLOG XZ26 Y270 G15 cancels the g16 G80 cancels the canned cycle GO 20 0 XO 00 M30 Note 1 You must not make X or Y moves other than by using GO or G1 when G16 is active 2 This G16 is different to a Fanuc implementation in that it uses the current point as the polar center The Fanuc version requires a lot of origin shifting to get the desired result for any circle not centered on 0 0 7 7 8 Plane Selection G17 G18 and G19 Program G17 to select the XY plane G18 to select the XZ plane or G19 to select the YZ plane A circular tool move in the G17 An example of an arc cut in Tool cuttin
279. order of importance for most users You should however note that all the screens of your system do not include all the controls of a family This may be to increase readability of a particular screen or to avoid accidental changes to the part being machined in a production environment sid i RESET C PCNC3 Temp tap E PCNC M3 R26 SRev6 8 Program R 5 2 2 5 2 2 1 Clear Initialization Macro Called on reset G Code M Cod es Simple Run Ctl Alt 1_ Comp Run Alt 1 MDI Alt 2 Toolpath Alt 3 Offsets Alt 5 Settings ans Diagnostics Alt Figure 5 9 Screen switching control family Families of Related Controls Screen Switching Controls These controls appear on each screen They allow switching between screens and also display information about the current state of the system figure 5 9 31138 Rev B1 4 5 5 Using Tormach PCNC 1100 Series Il Machine Controls Reset This is a toggle When the system is Reset the LED glows steadily Error and Profile Information The Machine OK LED indicates that the PCNC is started The intelligent labels display the last error message the current modes the file name of the currently loaded part program if any and the Profile that is in use The Clear button clears the text from the error line The entries written to the error line are logged in the file C PCNC3 LastErrors txt This can be opened and inspected with a text editor like Notepad if you want to analyz
280. ordinate System G54 to G59 amp G59 P To select work offset 1 program G54 and similarly for the first six offsets The system number G code pairs are 1 G54 2 G55 3 G56 4 G57 5 G58 6 G59 To access any of the 254 work offsets 1 254 program G59 P where the P word gives the required offset number Thus G59 P5 is identical in effect to G58 It is an error if one of these G codes is used while cutter radius compensation is on See relevant chapter for an overview of coordinate systems Sample Program G54EX19 Workpiece Size X8 Y5 Z2 Tool Tool 6 3 4 HSS Drill Tool Start Position X0 YO Z1 Workpiece Coordinate system 2 X1 Y1 Z0 Workpiece Coordinate system 3 X5 Y1 Z0 N2 G90 G80 G40 G54 G20 G17 G50 G94 G64 safety block N5 G90 G80 G20 N10 MO6 T6 G43 H6 N15 MOS S1300 N20 G55 GOO XL 0 Y1 0 Rapid to Xli Y1 of work coordinate System z N29 AU N30 GEA A02 RUTIS Pa ES Noo YZ N40 X2 N45 Y1 Using Tormach PCNC 1100 Series II 7 24 31138 Rev B1 4 Programming language reference N50 X15 kyo N60 G80 GOO Z1 N65 G56 GOO X1 0 Y1 0 Rapid to X1 Y1 of work coordinate system 3 N70 20 5 N75 Gor 20 25 ROIS PL FS N80 Y2 N25 X2 N90 Y1 NOS Aleo Ila N100 G80 GOO Zl N105 XO YO N110 MUS N115 M30 7 7 19 Set Path Control Mode G61 and G64 Program G61 to put the machining system into exact stop mode or G64 for constant velocity mode It is OK to prog
281. orrection Diameter multiplied by pi where T 3 14152 1 e the declared circumference of the part e For motion of one rotational axis with X Y and Z axes not moving the feed rate means degrees per minute rotation of the rotational axis e For motion of two or three rotational axes with X Y and Z axes not moving the rate is applied as follows Let dA dB and dC be the angles in degrees through which the A B and C axes respectively must move Let D sqrt dA dB dC Conceptually D is a measure of total angular motion using the usual Euclidean metric Let T be the amount of time required to move through D degrees at the current feed rate in degrees per minute The rotational axes should be moved in coordinated linear motion so that the elapsed time from the start to the end of the motion is T plus any time required for acceleration or deceleration 7 1 8 Arc Motion Any pair of the linear axes XY YZ and XZ can be controlled to move in a circular arc in the plane of that pair of axes While this is occurring the third linear axis and the rotational axes can be controlled to move simultaneously at effectively a constant rate As in coordinated linear Using Tormach PCNC 1100 Series II 7 2 31138 Rev B1 4 7 1 9 7 1 10 7 1 11 7 1 12 7 1 13 7 1 14 7 1 15 Programming language reference motion the motions can be coordinated so that acceleration and deceleration do not affect the path If the
282. ort Printer port address in Hex 378 does not need Ox in number Help r Spindle Calibration Spindle steps per unit are 1178 0 will be 1178 0 Run spindle in low gear with S word as f 000 VFD Fr reading is Quick settings PCNC3 Default Small steps finch Small steps rm or type in the sequence you want For safety avoid a big change from last back to first TEPER Help Probe Logic Sense Probe makes circuit on touch Tormach standart ss 4th Axis Homing Homing disabled v 4 Save Profile PCNCConfig Rev 4 2 2008 09 Tormach LLC All rights reserved Done Fiqure 9 15 Step sizes in PCNCConfig 9 5 10 Defining Your Own Sizes for Step mode Jogging When Step jogging either by keyboard or the Jog Shuttle controller the size of step that will be take is in the Step DRO You can put any value you like into here For safety avoid large movements The control software has a table of standard increments and you can go through these one by one and put them into the Step DRO using the Jog Step button The values in this list can be configured using PCNCConfig Using Tormach PCNC 1100 Series II 9 14 31138 Rev B1 4 9 5 11 9 5 12 9 5 13 Warranty Specifications Customization and Troubleshooting You can either setup your own sequence in the indicated boxes or use a sequence of two small steps Buttons are pr
283. otate and measuring the torque required to do this a For adjusting the X axis position the table near the right hand end of its travel 1 e X near to zero This ensures that the bearing is near to the ballnut to minimize bending of the screw during tests b Slacken the two screws clamping the coupling between the stepper shaft and ballscrew end c Remove the four cap screws holding the stepper motor Figure ee Cee eee to the coupler box Remove the stepper This is the tightening the lock nut Using Tormach PCNC 1100 Series II 9 10 31138 Rev B1 4 Warranty Specifications Customization and Troubleshooting reverse of the process for coupling the Y axis drive shown in section 2 3 d Ne Remove the four cap screws holding the motor coupler box to the table X axis or frame of the machine Y and Z axis Move the axis so the mounting box comes free of its pins The screw and box are supported on the ballnut so take care not to apply forces that could bend the screw figure 9 6 e You can now rotate the box by hand and get a sensitive feel for the torque caused by the preload on the bearings Rotation should be smooth with a small perceptible drag this corresponds to a medium preload of about 150 lbs If the rotation feels tight you have too much preload and will dramatically shorten the life of the bearings If the rotation is free and or the box can be rocked perpendicular to the screw axis then you have little on no pre
284. otational axis words are allowed in canned cycles but it is better to omit them If rotational axis words are used the numbers must be the same as the current position numbers so that the rotational axes do not move Using Tormach PCNC 1100 Series II 7 26 31138 Rev B1 4 7 7 23 1 Programming language reference All canned cycles use X Y R and Z numbers in the NC code These numbers are used to determine X Y R and Z positions The R usually meaning retract position is along the axis perpendicular to the currently selected plane Z axis for XY plane X axis for YZ plane Y axis for XZ plane Some canned cycles use additional arguments For canned cycles we will call a number sticky if when the same cycle is used on several lines of code in a row the number must be used the first time but is optional on the rest of the lines Sticky numbers keep their value on the rest of the lines if they are not explicitly programmed to be different The R number is always sticky In incremental distance mode when the X Y plane is selected X Y and R numbers are treated as increments to the current position and Z as an increment from the Z axis position before the move involving Z takes place when the YZ or XZ plane is selected treatment of the axis words is analogous In absolute distance mode the X Y R and Z numbers are absolute positions in the current coordinate system The L number is optional and represents the number of repeats L
285. ovement to spindle speed accuracy The spindle speed in your PCNC is factory calibrated but your computer is not calibrated to your machine The variations among PCs will affect the precision of the computer generated spindle speed To improve spindle speed accuracy your computer needs to be calibrated to your PCNC The PCNC uses a printer port of a standard PC for its machine control The procedure described below will calibrate the PCNC to a specific computer The procedure should be repeated any time the machine control computer is replaced While the there is no electrical work involved the procedure does require access to the electrical cabinet while under power Points within the cabinet will contain high voltage Exercise caution whenever opening the cabinet if the machine is under power 1 Turn on the machine and control computer and then open the PCNC control software program 2 Set the belt to the LOW speed range and set the S word to 500 either by MDI of S500 or typing the value into the S DRO followed by Enter gt EMERSON 3 Start the spindle 4 Inspect the value displayed on the panel of the VED It should be around 35 Hz See figure 9 9 Figure 9 9 VFD frequency E 31138 Rev B1 4 9 11 Using Tormach PCNC 1100 Series Il Warranty Specifications Customization and Troubleshooting this photo was shot with the machine running near top speed Record the frequency shown Shut down the PCNC Control S
286. ovided for metric steps 2 microns and 20 microns or imperial steps 0 0001 and 0 001 If you choose your own steps you should take care that there is no unexpected jump going from the end of the list to the start Defining Probe Type The accessory port on the user panel can be used as an input port for a digitizing probe The Tormach Probe closes a contact when a touch is made and consequently is the default setting in the Probe Logic Sense portion of the PCNCConfig program A number of aftermarket probes require the opposite logic for proper function opens a contact on touch If an aftermarket probe of this sort is to be used change the Probe Logic Sense using the indicated pull down menu figure 9 15 Please note that it is up to the user to ensure that proper wiring and source voltages are recognized Please refer to section 8 2 4 for more information Enabling 4th axis homing To enable the optional 4th axis homing kit please refer to figure 9 15 and select Homing Enabled Configuring to start in Metric units The PCNC is designed based on the imperial inch system of units Thus one step of each axis is exactly 0 0001 It is however equally capable of working in metric units The only limitation you will encounter is that if you look at the raw tool and work offset tables you will see that they are always in inches Everything else on the screens is automatically in the units you have currently got selected In order
287. p n 30669 in use on a tooling plate There are two main uses for the measurements taken a They can be used to set up the offsets in the Control Software so that the cutting defined by the part program is in the correct place relative to the stock material or part machined component b They can be recorded to allow the shape of an existing model object to be input to a computer aided design CAD program We refer to the first application as probing and the second as digitizing Using Tormach PCNC 1100 Series II 8 4 31138 Rev B1 4 8 2 2 8 2 2 1 Machine upgrades and configuration Note Our Probes and Tool setters have changed in appearance a bit from the ones pictured in the following sections All instructions and descriptions still apply ZU led lede leo lotto lado lobe Probing for Work Tool Setting The basic operation of the probe is controlled by the G31 Probe code q v In practice you will not want to write z programs to set up a job so a series of interactive screens is provided to perform probing operations These are divided into measuring probing X and or Y positions and probing Z positions To make effective use of these screens you need a basic understandings of the concepts 0 000 of Work Offsets and the Tool Length offset You will have used Work Offsets already in setting up any work a Toushil on the table even if only unconsciously by using the axis Zero buttons Figure 8 9 Data for P
288. ple of a line containing a comment G80 M5 stop motion An alternative form of comment is to use the two characters The remainder of the line is treated as a comment Comments do not cause the machining system to do anything A comment contains a message if MSG appears after the left parenthesis and before any other printing characters Variants of MSG which include white space and lower case characters are allowed Note the comma which is required The rest of the characters before the right parenthesis are considered to be a message to the operator Messages are displayed on screen in the Error intelligent label 7 5 6 Item Repeats A line may have any number of G words but two G words from the same modal group may not appear on the same line A line may have zero to four M words Two M words from the same modal group may not appear on the same line For all other legal letters a line may have only one word beginning with that letter If a parameter setting of the same parameter is repeated on a line 3 15 3 6 for example only the last setting will take effect It is silly but not illegal to set the same parameter twice on the same line If more than one comment appears on a line only the last one will be used each of the other comments will be read and its format will be checked but it will be ignored thereafter It is expected that putting more than one comment on a line will be very rare 7 5 Item Order
289. pplication of cutter radius compensation We advise against using cutter compensation in combination with subroutine programming canned cycles macro programming polar mode with run from here function and with multiple work offsets The complexity of application for cutter compensation can lead to hours of programming debugging Given the nature of the problem Tormach cannot provide program debugging support nor resolve application specific questions regarding the use of cutter compensation 6 8 4 Examples of Operation The program below plans cutting a rectangle which is 2 x 2 The graphic below shows two paths On the left in a solid line we see the path described by the G code program On the right in the dashed line we see the actual path that is followed by the Mach3 controller when tool 1 is programmed with a 0 5 diameter Actual Tool Path with Cutter Compensation aaa EE MD D Oo gt G Code Path lt lt I lji S begin at X1 50 Y 1 255 end at X1 Y 1 5 begin at X1 50 Y 1 25 J i bi lt oes at X1 25 Y 1 5 Figure 6 29 Toolpath in Example 1 Example 1 G17 G20 G40 G49 G50 G64 G90 G94 M6 T1 G43 H1 Select Tool 1 and offset 1 GO Z1 M3 S1000 Start Spindle X1 5 Y 1 25 Move to lead in position Gl z 5 50 Z down to cutting level G41 Turn on cutter compensation G1 X1 Y 1 Cut around block which is 2x2 in dimension
290. ptions Open to you are e Tormach Tooling System TTS this allows you to have all the tools that you commonly use mounted in low cost tool holders and to change them very quickly The working length of each tool is accurately maintained each time it is loaded into the spindle so it can be used for cutting with no further setup Tool lengths can be setup and checked in a stores or inspection area without using the PCNC figures 5 2 amp 5 3 e R8 tool holders offer similar features to TTS holders but need to be setup once in the machine and are slower to exchange figure 5 4 Figure 5 3 TTS presetting e Screwed shank cutter collet chuck Clarkson Posilok type allows you to exchange a cutter while maintaining a known length as the center hole at the back end of the cutter registers in the chuck figure 5 5 e ER or similar collet accepts a l Figure 5 4 L R8 tool holder wide range of cutter diameters but the length of the tool is not accurately repeatable so the offset needs to be reset after each tool change figure 5 6 e R8 collet gives the shortest overhang from the spindle nose but requires an individual collet for each tool diameter and as with ER collets length is not repeatable The tool changing procedure is slightly different depending on the tool holders you have Changing R8 Tools Open the spindle drive cover Swing the spindle locking fork so it engages with the flats
291. r should not change them Block Delete Control If the block delete control is ON lines of code which start with a slash the block delete character are not executed If the switch is off such lines are executed Optional Program Stop Control The optional program stop control works as follows If this control is ON and an input line contains an MO1 code program execution is stopped at the end on the commands on that line until the Cycle Start button is pushed Tool File The CS maintains a tool file for each of the 256 tools which can be used Each data line of the file contains the data for one tool This allows the definition of the tool length Z axis tool diameter for milling and tool tip radius for turning Part programs Language Overview The language is based on lines of code Each line also called a block may include commands to the machining system to do several different things Lines of code may be collected in a file to make a program Using Tormach PCNC 1100 Series II 7 4 31138 Rev B1 4 Programming language reference A typical line of code consists of an optional line number at the beginning followed by one or more words A word consists of a letter followed by a number or something that evaluates to a number A word may either give a command or provide an argument to a command For example G1 X3 is a valid line of code with two words G1 is a command meaning move in a straight
292. r the Spindle Drive Sub system Contents of the Spindle Drive Sub System Problem Resolution Checklist Table 5 1 Spindle will not turn in Manual or Auto Table 5 2 Run and Direction Commands to Drive 3 Table 5 Spindle Will Not Run At High Speed Spindle Drive Sub System Checklist Table 5 1 Spindle will not turn in Manual or Auto Possible Cause Prob ability No Power to Spindle oy No Power to Drive Using Tormach PCNC 1100 Series II No Power to Drive because Contactor C2 is not energizing This can be checked by checking the voltage across L16 and L26 at the drive Meter should read 200 250 VAC Action to identify Cause of Problem The drive has power if the digital display lights up Discussion If the display on the drive is on proceed to Belt is Loose or Broken Note When power is removed the drive display will remain active until the internal capacitors dissipate their energy usually about 15 seconds or SO Spindle Lockout key 115 VAC measured from wire 100 to switch off or defective wire 105 when OK Spindle Cover Door not holding Belt Guard switch closed or switch defective Loose wires in circuit Tormach Machine Control Board not providing run command or holding contact on C2 between wires 106 and 107 bad In manual mode press the stop rocker switch With the door open press the start rocker switch and listen for a soft audible click on the control board If you hear
293. r time Use caution keep away from the rotating parts You should be able to hear motor cogging whenever you tell the axis to move It should be noted that usually the brake alone does not have the torque to cause a loss of step Typically a condition such as poor lubrication combined with a bad Z brake are required to actually lose position It may be required to swap out the computer especially if you have observed other glitches with the computer It is possible the computer being used is not up to the task of running real time machining software such as Mach If the wrong version of Mach 3 is being used for your particular machine configuration loss of position is possible It has happened on rare occasion that Tormach mistakenly sent out versions of Mach 3 with an improper configuration file downloading the latest version from our website will eliminate the possibility of this problem If you lose steps it is normally many steps You should be able to hear the motor cogging Mechanical issues most often result in losing a large number of steps or stalling Typical mechanical issues include an increase in friction due 31138 Rev B1 4 Warranty Specifications Customization and Troubleshooting to lack of oil at the way surfaces or ball screw and or improperly adjusted gibs They also come from excessive load on the system due to chips or debris on the way surfaces or ball screw a sticking Z axis brake or an
294. r will switch sides 6 8 5 Look Ahead Issues There can be problems with cutter compensation related to the lack of foresight on the part of the controller The program below plans cutting an edge using cutter compensation shown in the graphic as CDEFGHIJ The segments AB and BC are entry segments as described above G17 G20 G40 G49 G50 G64 G90 G94 M6 T1 G43 H1 GO0O X 1 Y2 21 M3 SLO00 position above Starting point Gl 2 025 30 14 down Co cutting Nergnt G41 X 1 Y1 Making the first entry move to point B G3 X0 YO R1 Doing the entry arc to point C GL XL C6uceiInG Gor Point D Vola COUL CING CO TONE E Xa CUEING tO polne F Yeso Aga YO Xov D G40 GO Z1 M5 M30 In figure 6 35 we can see how a tool will cut this The process is successful but only because of the small diameter of the cutter 31138 Rev B1 4 6 19 Using Tormach PCNC 1100 Series II Offsets gt a gt 2 4P ay lt gt S x b Ov Figure 6 35 Compensating a small tool If we change to a 0 787 cutter common 20 mm end mill we see the results in figure 6 36 Figure 6 36 Compensation fails with large tool Using Tormach PCNC 1100 Series II 6 20 31138 Rev B1 4 Offsets What has happened here is that the cutter is too big for the channel in the pocket As it is cutting path DE it s removing the sidewall of IH Likewise on the way out it will destroy a segment of wall DE while it
295. ram for the mode that is already active These modes are described in detail in 7 1 15 above 7 7 20 Coordinate system rotation G68 and G69 A rotation transformation can be applied to the controlled point coordinates commanded by a part program or by the MDI line To do this program G68 X Y R The X and Y words specify the center about which the rotation is to be applied in the current coordinate system R is the angle of rotation in degrees with positive values being counter clockwise If X or Y are omitted then zero is assumed A and B can be used as synonyms for X and Y respectively To cancel rotation program G69 If a G68 is used while rotation is in operation a G69 is implied before it In other words successive G68s are not cumulative and the X and Y points are always in an un rotated system When a rotation is in use the X and Y axis DROs will be red to remind the operator that these values are program coordinate values which will be rotated This function can be used to compensate for work not exactly aligned on the table to rotate the operation of a part program if it is coded with Y travel greater than X and so the work will not fit on the table or as software vise soft jaws Note e G68 may only be used in the XY plane G17 mode e The effects of changing work offsets when a rotation transformation is in effect will be non intuitive so it is wiser not to program this Indeed care should be taken proving any program i
296. ration Computer Mounting Arrangement Keep the computer in a clean location preferably inside the stand of the milling machine Resist the temptation to expose the computer in any way Providing access to floppy disks CDs or direct computer controls will also open the computer to contamination and risk Tormach offers accessories that will allow you to operate the system without exposing your computer While there are many possible configurations for your machine control computer we suggest the following figure 2 2 1 USB bulkhead panel mount cable This allows you to mount a USB socket directly on the side of the cabinet You can use a standard USB flash drive to transfer G code programs and other files to the machine controller This is Tormach PN 30278 USB bulkhead mount cable 3 Version 2 0 USB A to A extension M F 2 USB extension cable extending the short cable normally found on keyboards and other USB devices Tormach PN 30279 LOFT USB 2 0 A to A Male Female Extension Cable 3 USB mini keyboard This is about the size of most laptop keyboards The keyboard includes a key which will power down the computer allowing a convenient way to shutdown the system This is Tormach PN 31371 Mini Keyboard The keyboard can be protected against coolant or chips by addition of Keyboard Cover PN 31384 4 A Tormach USB jogging pendent is a very useful accessory for jogging manual operations and machine setup Two options are available
297. re shown in figure 7 5 Program Stopping and Ending M0 M1 M2 and M30 To stop a running program temporarily regardless of the setting of the optional stop switch program MO To stop a running program temporarily but only if the optional stop switch is on program M1 It is OK to program MO and M1 in MDI mode but the effect will probably not be noticeable because normal behavior in MDI mode is to stop after each line of input anyway If a program is stopped by an MO M1 pressing the cycle start button will restart the program at the following line To end a program program M2 or M30 M2 leaves the next line to be executed as the M2 line M30 rewinds the G code file These commands can have the following effects depending on the options chosen on the Configure gt Logic dialog e Axis offsets are set to zero like G92 2 and origin offsets are set to the default like G54 e Selected plane is set to XY like G17 e Distance mode is set to absolute like G90 e Feed rate mode is set to Units per minute mode like G94 e Feed and speed overrides are set to ON like M48 e Cutter compensation is turned off like G40 e The spindle is stopped like M5 e The current motion mode is set to G1 like G1 Using Tormach PCNC 1100 Series II 1 32 31138 Rev B1 4 7 8 2 Programming language reference e Coolant is turned off like M9 No more lines of code in the file will be executed after the M2 or M30
298. recisely follow the commanded path Constant velocity will overlap acceleration in the new direction with deceleration in the current one in order to keep the commanded feed rate This implies a rounding of any corner but faster and smoother cutting This is particularly important in routing and plasma cutting The lower the acceleration of the machine axes the greater will be the radius of the rounded corner In Plasma mode set on Configure Logic dialog the system attempts to optimize corner motion for plasma cutting by a proprietary algorithm It is also possible to define a limiting angle so that changes in direction of more than this angle will always be treated as Exact Stop even though Constant Velocity is selected This allows gentle corners to be smoother but avoids excessive rounding of sharp corners even on machines with low acceleration on one or more axes This feature is enabled in the Configure Logic dialog and the limiting angle is set by a DRO This setting will probably need to be chosen experimentally depending on the characteristics of the machine tool and perhaps the toolpath of an individual job Interpreter Interaction with Controls Feed and Speed Override controls The CS has commands which enable M48 or disable M49 the feed and speed override switches It is useful to be able to override these switches for some machining operations The idea is that optimal settings have been included in the program and the operato
299. replaced If the LED takes 5 seconds or more to extinguish the capacitor is good A DC voltage of a nominal 65 VDC 55 75 indicates the capacitor is OK A DC voltage of a nominal 40 VDC 35 45 indicates the capacitor 1s defective There have been cases of a noisy axis relating to a bad driver This may be temperature dependant Some versions of Mach 3 release by Tormach are not compatible with all machine configurations A Flaky computer or one that is not suited to run real time software such as Mach3 will not produce smooth step signals for good axis motion 31138 Rev B1 4 Warranty Specifications Customization and Troubleshooting Loose Sheet Metal Feel for vibrating sheet Often loose sheet metal is mistakenly metal diagnosed as a noisy stepper motor On some systems certain stepper motor speeds can cause excessive vibration in the sheet metal stands Identify the problem areas and treat with silicone caulk Squeaky Z axis brake Z Low Noise will be noticed Removing the brake Caution the axis only coming from the brake brake wires are short and somewhat canister fragile lift the brake canister off the motor with caution and placing a dab of grease on the motor spindle shaft and on the shafts mating surface on the under side of the brake will remove excess noise without compromising the brake s function 31138 Rev B1 4 9 39 Using Tormach PCNC 1100 Series II Warranty Specifications Cu
300. requires re programming To exit this mode push and hold the M button until the display reverts Check that all cables are seated properly in their connectors on the board Attempt to run the drive If the display reads Fr xy z or Ld xy z where xy and z are numbers between 0 and 9 the Control Board is sending a run enable signal to the VFD A reading of rd 0 0 indicates the drive is ready but not receiving a run command Note that the drive may be displaying numbers on the left side of the display If the digits on the right side of the display are flashing momentarily press and release the M button just below the display to cause the left side digits to flash With the left side digits flashing press and hold the M button for 3 seconds and the display will change to Fr Ld or rd as described above 9 50 Turn off Disconnect Switch before investigating If the drive displays a trip condition that does not clear with removal of power it is possible the drive is bad A drive reprogram is a simple operation but requires a programming key from Tormach If the display reads rd 0 0 measure DC voltage per Table 5 2 below Be sure to measure at the Control Board and at the drive to determine if there is a problem with the wiring It is not critical that the measurement for reverse be made as it is not required to make the Spindle turn however it may aid in further trouble shooting If your measurements match
301. resting to look at other issues which affect the accuracy of your work The PCNC is a rigid machine and is fitted with precision anti backlash ballscrews and laser aligned in the factory so is inherently very accurate You do however need to consider the following points e You are measuring at one point on the stock If its surface in not flat or it 1s not clamped exactly parallel to the table then the height at other places will be different e Achange of 40 F in the temperature of a ballscrew say between early morning in the winter and when the shop and machine has heated up in the afternoon will amount to a difference of around 0 004 when the tool is near the table at the bottom of the Z axis General Accuracy Issues Machining is a mix of science skill and art The caveat in stating accuracy and repeatability is that these factors depend on the techniques used by the machinist A skilled machinist can often deliver accuracy that exceeds the accuracy specified by the machine builder while an inexperienced machinist may have difficulty delivering the expected accuracy With this understanding we cannot tell you what accuracy you will be able to achieve in your own work While a machine tool may seem absolutely rigid the truth of the matter is that everything has some elasticity Related to elasticity is the compressibility of components such as ball nuts and bearings Preloading of bearings and ballscrews can remove the physical open spa
302. rhaps a plastic wrapper from a candy packet Using Tormach PCNC 1100 Series II 3 4 31138 Rev B1 4 Making your first part Jog the Z axis down to 4 or so above the material If you are using keyboard jogging change the Slow Jog DRO from 10 to 2 The Tormach Jog Shuttle Controller allows you to control the speed depending on how far you turn the ring Then with the paper below the tool carefully jog down until the paper just gets trapped by the tool You must avoid ramming the tool into the material you want to just touch the paper figure 3 8 When in position type 0 and Enter into the Z axis DRO You now have the Work Offsets set to suit your material thickness and length of tool Make certain you have properly shut the door protecting the motor and spindle belts or the spindle will not start and a non rotating tool will try to cut the work Click Cycle Start The program will stop for a tool change to tool 1 Just click Cycle Start as you have tool already in the spindle The PCNC will cut the letters in four passes Figure 3 9 shows this process in pass two When the text is done the machine will stop and request a change to tool 2 Jog up so you can change the tool to the 1 2 cutter If you hold the Shift key down when jogging the jog will take place at full speed rather than the 2 used for very careful positioning Change the tool and jog down with the paper under the tool Type 0 and Enter into the Z
303. rical tests Almost all Digital Multi meters have the capability of measuring AC Volts DC Volts and Resistance These are the important functions use when troubleshooting a Tormach PCNC Two test leads are required to measure these three functions While many meters have more than 2 receptacles in which to plug leads for our purposes the leads will always remain in the same 2 receptacles One receptacle is almost universally labeled COM for Common and the black lead is to be plugged into this receptacle The other lead most often red in color is plugged into the receptacle labeled VQ for volts and ohms Measuring DC voltage V DC voltage has polarity so if the common lead on the meter is not placed on the common signal the voltage will read as a negative number This will not harm the meter but could be confusing in certain cases We will strive to define the common terminal when asking you to take a measurement Select the DC voltage scale on the meter The scale may be labeled DCV or Measuring AC voltage V There is no polarity to AC voltage so either lead can be placed on either location we are having you measure Select the AC voltage scale on the meter The scale may be labeled ACV or Measuring Resistance Q is the symbol for ohms which are the units in which resistance is measured Select the resistance scale on the meter most often labeled Q Using Tormach PCNC 1100 Series II 9 20 31138 Rev B1 4 9 6 3 5 9 6 4
304. ring at the Control Board Diagnostic Screen Inputs Status Reported X Limit and Home light is always on even though the switch is not actuated Y Limit and Home light is always on even though the switch is not actuated Z Limit and Home light is always on even though neither the up or down limit switch is not actuated X Limit and Home light is never on even though the switch is actuated Y Limit and Home light is never on even though the switch is actuated Z Limit and Home light is never on even though either the up or down limit switch is actuated Jumper J2 1 to J2 4 Jumper J2 2 to J2 4 Jumper J2 3 to J2 4 Remove wire J2 1 Remove wire J2 2 Remove wire J2 3 If the light does not go out when the terminals are jumpered the Control Board is defective If the light goes out when the terminals are jumpered the wiring has a break or the limit switch is defective Remove power from the machine disconnect wires from the switch and tie the two wires together and tape over to prevent short circuits Apply power If the diagnostic light is off the wiring is OK and the switch is bad If the diagnostic light is on the wiring has a break or bad connection If the light does not go on when the wire is removed the Control Board is defective If the light goes on when wire is removed the wiring has a short or the limit switch is defective Remove power from the machine
305. ro The following sample program demonstrates the G73 command Sample Program G73EX20 Workpiece Size X4 Y3 Z1 Tool Tool 3 3 8 HSS Drill Tool Start Position X0 YO Z1 N2 G90 G80 G40 G54 G20 G17 G50 G94 G64 safety block N5 G90 G80 G20 N10 MO6 T3 G43 H3 N15 MOS S1200 N20 GOO X1 Yl N25 G73 Z 04 753 R0129 00 0623 FS Invoke G73 cycle N30 X24 N35 X3 N40 Y2 N45 X2 N50 X1 N55 G80 GOO Z1 Canned cycle cancel N60 X0 YO N65 MO5 N70 M30 OOO CO Cancel Modal Motion G80 Program G80 to ensure no axis motion will occur to terminate canned cycles etc Note that it cancels the current G2 or G3 mode so this must be re established for the next move that is required This particularly affects people adapting a CAM postprocessors from another machine as this behavior varies between different CNC controls It is an error if e Axis words are programmed when G80 is active unless a modal group 0 G code is programmed which uses axis words Canned Cycles G81 to G89 The canned cycles G81 through G89 have been implemented as described in this section Two examples are given with the description of G81 below All canned cycles are performed with respect to the currently selected plane Any of the three planes XY YZ and ZX may be selected Throughout this section most of the descriptions assume the X Y plane has been selected The behavior is always analogous if the YZ or XZ plane is selected R
306. robe T 99 in In Program coord The screen buttons all use the current feedrate F DRO We recommend using 20 IPM As they do not involve Tool length offsets we will describe the X Y Probing screen first Before this there is one bit of configuration to do e Locate the effective diameter of your probe tip usually made of ruby to avoid wear in the inspection certificate supplied with the probe The standard tip diameter is around 4 millimeter 0 1575 e Enter this diameter for Tool 99 on the Offsets screen figure 8 9 Ignore the Length for now and if it is zero then the Offset On Off LED will not be lit This is unimportant Note The geometry of probing is complex and the certified effective diameter will be different from the actual diameter that you can measure Simple X Y Probing This screen figure 8 10 allows you to set the origin X 0 0 Y 0 0 point to some feature of the stock material or a partly finished component The three pictures represent the three operations on this screen a Finding center of a bore b Finding a plane surface and c Finding the corner of the fixed jaw of a vise The convention is on all screens is that a al xj Fle Config Yew Wiss Operator Hep yellow screen button Mil gt G15 G10 G17 G40 G20 G90 G G54 G49 G99 G64 G97 will make the PCNC z move the probe x 0 000 eee looking for the part a 0 000 Obviously two things 0 000 Sey ide Huni i are necessary The
307. robes Active and Passive and Tool Setters Introduction to Uses of Probes and Tool Setters If you mount a switch in the spindle instead of a cutting tool and connect the switch to the control computer so that the software can read it then you can use the machine for measuring instead of cutting The switch is usually arranged so it operates when a probe tip is moved horizontally in any direction or pushed up Figure 8 7a shows a probe from the Tormach range of accessories p n 30668 probing the top of a partially machined part The Tormach probe has a standard TTS 34 shank and is best used in the 34 R8 collet p n 30146 Figure 8 7a Tormach probe Note We advise you to mark the spindle pulley with a dot of paint and always to insert the probe with the spindle in the same position This eliminates any errors caused by random positioning Keep the spindle lock ON when the probe is in This will prevent any accidental startup of the spindle motor which would rip the cable out of the probe body Figure 8 7b Some probe packaging options A Renishaw or other standard probe can be interfaced using an appropriate cable Interface details are given below The other possibility is to have a tool in the spindle and replace the work with the switch This allows measurement of the length of the tool and setting the coordinates of the plane on which the switch is standing Figure 8 8 shows the Tormach Tool Setter
308. rofile PCNCConfig Rev 4 2 2008 09 Tormach LLC Done All rights reserved Figure 9 11 The measured frequency 9 12 31138 Rev B1 4 Warranty Specifications Customization and Troubleshooting is a z a aan CorelDRAW 6 Inkscape f gt ae View Favorites Tools Help visual Stud MET 200 Realbraw Ross ey T eo ph P Low Back ov P Search ear Folders gt News Row address Control Panel Go tsa Fia ae G ud Microsoft nad hane e visual Ba Corel Adobe am Contral Panel Fonts Add ct HOTO PAINT Photoshop 5 Ta Game Controllers Add re fos ae asm ri LE E G Switch bo Category view internet Options Config PRS amp p lava JayalT eat Microsoft z n riena 15 x File Action wiew Help i System Restore Auton akasa Remote lt E Ee B Mic General Computer Hame C Hawe D Advanced E Mice and other pointing devices j E a Monitors Device Manager Ee Network adapters Micrc F The Device Manager lists all the hardware devices installed a gt NVIDIA Network Bus Enumerator Wie on your computer Use the Device Manager to change the 4 Ports COM amp LPT m properties of any device ae i Sigi S r Pinpin ET ae oe OM1 _ Caen Fae Processor F lt SCSI and RAID controllers se p Driver Signing lets you make sure that installed divers are ES compatible with Windows Windows Update lets you set up
309. ror message about the radius of an arc being different at the start and end of a cut USB Jogging Pendants Optional accessories purchased by many users are the USB jogging pendants These provide access to the main axis jogging controls on a unit that can be positioned for use while touching off the tool position They are not resistant to coolant and for safety reasons do not have controls for starting and stopping machining The pendants should be plugged into USB ports on the computer motherboard We have found connections through hubs can lower responsiveness Figure 5 30 Jog Wheel pendant Jog Shuttle Controller The Jog Shuttle Controller is a low cost but very precise and fast way of jogging the four axes There are five buttons and two rotary controls figure 5 30 The buttons allow you to select which axis you wish to jog The chosen axis is indicated by a LED next to the corresponding DRO For example figure 5 31 shows that the X axis is the one to be jogged If a Jog Shuttle Controller is not installed then all the LEDs will be dark The Step button will cycle through a set of jog step SIZES lose J Wilezio15 G80 Gee C in the Step DRO in the Jogging family The available preset step sizes can be customized with XMLTweak see x m O OC chapter 9 Tai ai The outer rotary shuttle control is spring loaded Turning Y z O OC it will jog the selected axis at a speed proportional to the Zero E amount it is turned T
310. rotational axes do not move but the third linear axis does move the trajectory of the controlled point is a helix The feed rate during arc motion is as described in Feed Rate above In the case of helical motion the rate is applied along the helix Beware as other interpretations are used on other systems Coolant Flood coolant and mist coolant may each be turned on independently They are turned off together Dwell A machining system may be commanded to dwell 1 e keep all axes unmoving for a specific amount of time The most common use of dwell is to break and clear chips or for a spindle to get up to speed The units in which you specify Dwell are either seconds or Milliseconds depending on the setting on Configure gt Logic Units Units used for distances along the X Y and Z axes may be measured in millimeters or inches Units for all other quantities involved in machine control cannot be changed Different quantities use different specific units Spindle speed is measured in revolutions per minute The positions of rotational axes are measured in degrees Feed rates are expressed in current length units per minute or in degrees per minute as described above Warning We advise you to check very carefully the system s response to changing units while tool and fixture offsets are loaded into the tables while these offsets are active and or while a part program is executing Current Position The controlled point is alw
311. rstPart cut in Chapter 3 is an example of a simple 2 2D component A 2D product has no changes in depth This might be a mechanism link cut out of a sheet of steel or lettering cut out of vinyl sheet 2D products can be milled but are usually produced on specialist machines e g a laser table or plasma cutter Design and particularly production of a 3D shape is much more time consuming than something which is 212D If the pocket in FirstPart had a dished shape with a fillet in the corners then it would have been cut with a ball nosed tool and would have required many passes a few thou apart rather than the passes about 0 3 apart that could be used with the flat end mill In addition the design process is complicated because the pocket cannot be defined by a single number 1 e its depth 1f it is 3D With current CAD software you will probably find it is easiest to design 212D parts with a 2 2D CAD package or with a full 3D one running in 2 2D mode Software for CAD CAM This section gives some guidance on things to consider when choosing software It is a very big topic whose surface we try to skim Using Tormach PCNC 1100 Series II 4 2 31138 Rev B1 4 From an idea to a part The two most important points are that a the PCNC because of its open and standard architecture will run the part programs produced by virtually all Computer Aided Design Computer Aided Manufacture CAD CAM software and b that the more comprehensive th
312. running at least 1 GHz with at least 512 megabytes of RAM Intel and AMD processors are both satisfactory Video of 1024 x 768 Certain low cost computers with integrated video have shown problems In those situations the best solution is to disable the motherboard based video and install an inexpensive video card in an expansion slot Laptop computers are unsuitable and any which can be eventually be made to work will only do so by re installing Windows without the APCI Advanced Power Configuration Interface This will cripple the machine for normal portable use You need a parallel printer port 25 pin D socket A USB to printer adaptor cannot be used in place of this If this port is on the motherboard then the standard configuration will use it PCI parallel ports from many manufacturers can however be used You will need to consult Chapter 9 for details of the configuration process for cards which do not use the standard port address of 0x378 Some motherboards based on the Via chipset have proved incompatible with the control software If you are buying such a board please ensure your supplier will take it back and refund the cost in the unlikely event that you have problems A CD ROM or DVD drive is essential for software installation We advise you to use a USB storage device for transporting small files like G code programs to the machine tool These devices are variously known as flash thumb jump or key
313. rupts power to the VFD and prevents the motor from running Note After a power down the VFD will only power back up when first commanded to spin in either manual or auto The VFD will not power up simply upon pushing the green start button on the Operator Panel Once the VFD is powered up it will stay powered until one of the above conditions occurs Control signals are sent to the drive from the Tormach Machine Control Board which gets commands from the computer in Automatic mode or from the Operator Panel in Manual mode When Manual is selected with the Manual Auto Rocker Switch the start and stop Rocker Switches the forward reverse Rocker Switch and the Speed Pot are used to control the Spindle speed In the Auto mode none of these controls are functional and all control for the spindle is provided by the Computer and machine control software The Tormach Machine Control Board provides a contact closure between wires 106 and 107 to cause power to be applied to the drive It also provides a run command a direction command and an analog voltage in the range of 0 5 VDC to wires J1 1 com and J1 2 proportional to desired speed See the Problem Resolution Checklist for the Spindle Drive Sub system Table 5 1 and Run and Direction Commands Table 5 2 above The display on Series II machines provides valuable information for troubleshooting The display will provide diagnostics which include Using Tormach PCNC 1100 Series II 9 52 31138 Re
314. s are specific to the PCNC These repeat offenders are important to keep in mind when troubleshooting Loose Wires Try as we might it seems that on occasion we find a poor wire connection This can be the wire in a screw clamp terminal where the clamp is loose a problem with a crimp spade or ring connector where the connector is tight in the screw clamp terminal but the wire is loose in the crimp connector This is most frequently found during the initial startup of the machine The vibration that occurs during ravel tends to loosen connections Use the 2 finger pull test grasp 31138 Rev B1 4 9 21 Using Tormach PCNC 1100 Series II 9 6 4 2 9 6 4 3 9 6 4 4 9 6 4 5 9 6 4 6 9 6 4 7 9 6 4 8 Warranty Specifications Customization and Troubleshooting the wire close to its termination point between your thumb and index finger and gently but firmly tug each wire If the wire comes loose re terminate it before moving on to other wires One of the graybeards at Tormach recalls industrial customers in the paper industry who were so plagued by problems caused by poor connections that they shut their entire operation down for days and checked virtually all connections This act solved many problems for them Wire Hairs Sometimes with stranded wire we find that a wire hair from the stripped end of the wire may be sticking out from the wire and touching another wire or the machine frame This can cause short circuits Poor
315. s colored rectangular indicators referred as LEDs on various screens to indicate output or functional status The Diagnostics screen also has indicators for X Y and Z home limit switches and accessory input status These are useful to determine if the input is operational There are also various physical LED indicators within the electrical cabinet Among these are e DC Power LED Indicates voltage on the DC bus power to axis drivers e X Y Z and A axis drivers Indicate power to each individual drive e Control Board LED1 Indicates power to the control board e Control Board D10 Blinking indicates speed signal from software Manual speed demand is not shown e Control Board D15 Brightness indicates speed signal to spindle driver Beyond the obvious problems of broken limit switches blown fuses and damaged motor cables we suggest contacting Tormach directly for advice on diagnosing or correcting electrical problems Preparation for Transport It will generally be straightforward to transfer the machine to a pallet and transport it in one piece The Z axis should be lowered and the spindle supported from the table on a box or solid block of timber The Z axis should be under a relatively neutral force not under stress by being parked with a high downward force nor held up by the ballscrew Run it down to a wooden block but do not crunch it hard into the block If required the stepper motors for the axes can be
316. s sort of trouble but intentionally leaves the responsibility of referencing to you You can repeat the referencing operation at any time if you have reason to suspect that the PCNC is in the wrong position e g an error in a depth of cut has stalled the machine Despite the advantages of having the machine referenced you can still use it without for example if one of the home switches fails or becomes unreliable We advise you to treat this as a crippled mode for use until you can get the switch fixed The Goto toolchange position macro M998 will not work if the machine is not homed but you can ignore the error message and jog the axes by hand to get clearance to change the tool The Control Software now knows exactly where the PCNC axes are and has called this home position X 0 0 Y 0 0 and Z 0 0 You probably think that this position is not very convenient and you are correct The Control Software will let you define any other place to be 0 0 O when you are running a part program but will always keep a record of the machine position using home as machine zero Normally the axis DROs will show your coordinates for the position but you can see the Control Software machine coordinates by clicking the Machine Coords button A big flashing LED warns you that you are not looking at your version of the coordinates Loading a Demonstration Program The system comes with a demonstration lt a Nf program in the file 2 rae C PCNC3
317. s that are intended for the computer and monitor This is provided for convenience In some applications the computer monitor might be powered directly from a wall outlet and this computer circuit left unused or used for other functions such as to powering a work light 31138 Rev B1 4 5 1 Using Tormach PCNC 1100 Series II Machine Controls Start and EStop The Start button will energize the circuits for the axis drives and for the spindle motor The Stop button which locks in once pressed stops all motion and is the Emergency Stop EStop control The Stop button is released by a turning the button head a quarter turn clockwise Machine start is protected by a no volt relay from failure of the mains supply The PCNC requires Start to be pressed on re application of power Status LEDs The Machine LED indicates that the Start button has been pressed When it is lit then the Machine OK LED on the computer screen should be solid green The Computer LED indicates that the Control Software is running Spindle An important safety interlock is that the rotation of the spindle can be disabled while maintaining axis drive power by the Spindle Lockout key switch The switch on the belt guard door performs the same function These are used to ensure that the spindle cannot start when an R8 tool holder is being changed door open or when a tool is being changed in a collet chuck The controls to the right of the key switch are all conc
318. s that you should not remove ballscrews bearings or separate sliding joints For example in reference to the head and column exploded view drawing D40134 you should not separate item 82 Z axis slide from item 75 column Instead you should separate item 19 Head Casting from item 82 Z axis slide Detailed advice should be sought from Tormach support Using Tormach PCNC 1100 Series II 9 56 31138 Rev B1 4 Appendices 10 Appendices 10 1 Appendix 1 Not Used 10 2 Appendix 2 Exploded Parts Views The following pages identify the mechanical and electrical components of the PCNC cross referenced to part numbers 31138 Rev B1 4 10 1 Using Tormach PCNC 1100 Series II 2 we 23 37 38 91 3940 41 22 23 21 42 43 44 45 46 47 48 49 50 51 24 Se 17 18 cjs 34 ao n Oo SEA h Ler AANA paa ie MN WU IE a FERT ol 4 OMES VAR Ww 33 de cj 30 L3 28 8D er 26 e3 24 eg ee Ci 20 l ili ei el el el e 000 AA u oc N o wl NIEI al Jo my y mM 78 19 80 88 87 49 94 10 79 86 84 83 82 81 389 90 Column and Head Assembly July 2009 D40220 PCNC 100 Series II 31095 Parts List for PCNC 1100 series Il Drawing D40202 Upper Exploded June 2011 ID Number Description ID Number Description 1 30303 Lower spindle bearing 49 30353 Screw M6x3
319. sacicesasssseseededsstsscesscascdesseddesecessessucsesessacuceesdeesciseeds 1 3 Contine ADINI enra ne bontheheoatdoibsosntsedsacuiobbeouenebsecins 1 3 Understandind FC CU Cy nsss e rE 1 4 Resolution Accuracy and Repeatability of the PCNC sseesseesseessensseessersssesssersserssersseess 1 4 Scope and Intellectual Property ssccessecssecccecccecsccosscosccocscosssecssecsceoscecscessscesscecssesssessseo 1 4 INGIMETICIA TAIN O serrin aaeoa ais 1 5 Propa AUN ON oo cscs cece cet ete EEE EE EE 2 1 Planning for Your CNC paces ceccssecsescescateccscesususevsssecdeasarsssesueueccssssacsdvabeseseusssuceseeecsesseess ss 2 1 jettere neker ie Qe 01 1 68 01 Career a ere ere eee 2 1 Loc on ad MOU esses poise sctnacs pence E E sacnaunbessunee teacesoneee 2 1 Computer Mounn Ari OCC I esa EEEE E E 2 3 Can E E E E A E E 2 3 Receiving Unpacking and Checking Shipment essssecssseccsssesossecsssecsssesosseessssessssesso 2 4 Mormone E he ee er eee eon een ee eee eT re te eer ere eee rarer Ter rarer 2 4 LB faves es muavegeei0y Wl ists o s 6i ON ae nere Ree ete Renee rene nee ne Weren nT enn nee Rrrene tr rere eee rene en eee rere te 2 4 Assempine Y axis DrIVO sesiis votes ars cases sivecavecuvenses EEE ENSE ERSS 2 4 Mopin He PCN sesoses aea A E eE EaR 2 5 EEN R S L EE E O E sees cans E AE P EN A N E A 2 5 L rOn DEO AE EAE EAEE E A EEE E 2 5 E a OPE A DON oere EEE A AEA EEE 2 6 FO CAN it AE EE E EAE EAE EE A AE 2 6 PS SONS as esr A AAE A EEEE AEEA
320. sensecsusecseecessuseeseusesseseesusesaenss 9 15 9 5 13 Configuring to start in Metric UNItS ec cecccceeccceeeecceececeneeceeeecssneecaseesenseeseeesenseeaenes 9 15 9 6 MT OUT OS MOO NG obs cceccs tenses ccescstersssecssassecacecssacstacevecstrcecseseassbocsteesdsusecassscotevorseseacscscetresees 9 16 Ao ral GE 21 E en oe TE OTe E EE E E E ip eae ne eek vn ease 9 16 962 Philosophy Of TroubleShOOuUn viinccccccicccievaiensessvivecaseviarasanelesenseeasessseeseseaaianaceeseasaswavernnss 9 16 9 6 3 Tips and Tools for Troubleshooting Equipment and Procedures cccccseeeceeeeeeeeees 9 19 OM igre ci steatosis ashe om epee AAA A pe ace sa sue oe epee NE 9 19 9 6 3 2 Tip on Computer Diagnostics ccc cecccceeccceeccceeeeeceeeeeaeeecsenceeseeeeseseeseseeseneeeaes 9 19 Using Tormach PCNC 1100 Series II vi 31138 Rev B1 4 Contents DIO TOO E EEE AE E EE EE AA ENTON E EIO 9 20 9 6 3 4 Using the digital multi meter for electrical tests ccc eeccccescccseeeeeeeeeeseeeeeeneeeaes 9 20 063 5 Contacting Technical SUppof lesne E teed oletendals 9 21 9 6 4 Frequently Found Problems Repeat Offenders nssenssessonsseesssesssessserssersserssersserssseo 9 21 ok EOSO W IES aeea a E E EEE 9 21 DOER Wea aeoe A E 9 22 90 43 Poor Cabe Connec UON Senor sensi ecetold ainsi net ena at ollsmatonseeadalss 9 22 BLOM SOWIE RESI ooreen an a EAA E E 9 22 9 6 4 5 Sensors on the PCNC the End of Travel Sensors
321. set table There are two ways to use cutter radius compensation The most obvious way is to have the offset stated in the tool table to be the diameter of the tool In theory this would allow the G code program to simply define the geometry of the actual part to be machined with the machine controller left to calculate the tool paths necessary to compensate for cutter diameter In practice the problem is far more complex and can lead to a great deal of trouble in debugging the G code program Another way to use cutter compensation is as a small correction factor where the tool path planning is done outside of the machine and the offset is used to only to make minor adjustments This approach can be used to make fine adjustments for tool wear part tolerance or final finish cuts for rough cutting to finish cutting Wear Compensation Example Suppose a shop prefers to resharpen cutting tools not disposing of a tool until it is more than 0 005 reduced in diameter In this situation a programmer could do his CAM work and create a G amp M code with 6 8 3 Caveats in the Use of Cutter Compensation a tool path that assumes a 0 495 diameter for a 1 2 diameter tool While the concept has useful applications there are When the tool is new and has a true many pitfalls in actual practice This is not a programming technique for beginners A few of the issues are listed below 0 500 diameter the operator will put 0 005 in the of
322. shed by clicking the Reset button in the Mach3 software when the Machine OK indicator in on the Mach3 screen is solid green This will cause the bar indicator above the Reset button to change from flashing green to solid green and will also turn on the computer LED on the machine operator panel Once communication is established the Mach3 software can control machine operation Note The Spindle can be controlled via the computer or manually via the operator panel controls see figure 9 22 The manual auto rocker switch must be in the auto position for computer control of the spindle 31138 Rev B1 4 9 31 Using Tormach PCNC 1100 Series II Warranty Specifications Customization and Troubleshooting 9 6 5 4 Axes Drive Sub system Control H Axis Command DC Tormach Bus Board Machine Control Board Control Signal Control Signal A Axis Command Control Signal Parallel Por Cable with25 Pin D Connector Controller Computer Figure 9 26 Axis drive arrangement Overview of the Axis Drive Sub system DC Stepper Motors are used to move the X Y Z Z axis vertical travel not rotation and A axis The motors are powered by electronic driver modules also referred to as axis drivers or stepper drivers which receive control signals from the Tormach Machine Control Board The electronic driver modules get power from the DC Bus Board Motion is limited in the extremes of travel by end of
323. shows the status of the switches The axes are driven by stepper motors that have no feedback It 1s possible that an axis can be commanded to move but will not move as far as it is commanded to This is commonly referred to as loosing steps Excessive friction or load in the mechanical system will cause loss of steps When loosing steps it is usually possible to hear a cogging noise from the motor The probability of losing a single step or just a few steps from a mechanical problem is very low Mechanical issues most often result in losing a large number steps or stalling the motor Tormach has found that loosing steps is usually due to the software or the computer Appearing to lose steps on the Z axis is frequently due to the tool holder being pulled out of the collet or the cutter slipping in the holder 31138 Rev B1 4 9 45 Using Tormach PCNC 1100 Series Il Warranty Specifications Customization and Troubleshooting 9 6 5 5 Spindle Drive Sub system Overview The Spindle on the PCNC is powered by an AC motor whose speed is controlled by a variable frequency drive VFD Electrical Power IL Black Wirir es Contactor 2 A Black Wiri es FO Variable Frequency Drivel Black Witir es Spindle hl ot o lt S Computer UserFPanel Conteal Signals Blue Sires Ribbon Cable Farallel Port able 25 Pin D Connector Bulkhead onnector In Bottom of abinge Figure 9 30
324. si Bene ME a kind on canned cycle TFI or Pitch mm QO 00 Q 00 0 00 Q 00 Auto reverse tapping parameters Each macro is set up for a Select Large Small Teggle B wi Toil i Ta particular pitch of thread tapping head E L fi a and choice of tapping head Tapping Mode Dwen E pwen E pwen wen This information is provided by the Tapping Figure 5 28 Tapping Configuration Configuration family of controls figure 5 28 The TPI or Pitch DRO is interpreted in a different way depending on whether the part program calling its macro is running in Inch G20 or metric G21 mode In G20 mode the value is a number of threads per inch and in G21 mode it is the pitch of the thread in millimeters It is perfectly possible to change modes within a program and so have a job with mixed thread standards Fortunately Inch numbers are unlikely to be pitches and vice versa The control software checks that the chosen pitch can be cut at the current spindle speed when the macro is called so there is little chance of damage to a tap If you select Dwell mode then the macro will use an alternative movement algorithm which dwells pauses at the bottom of the thread This gives a more accurate depth but slower tapping and more wear on the mechanism of the tapping head Both tapping heads have a high speed reverse feature to minimize tapping time As the gear ratios are different for each head you must define which is going to be used by to
325. site www tormach com In addition to the Auto Reversing Tapping head Tormach also offers a fully featured Tension Compression or Floating tapping head Please review our full Tormach Tool System TTS catalog DS_TTScatalog 2 pdf for more information Using Tormach PCNC 1100 Series II 8 16 31138 Rev B1 4 9 Warranty Specifications Customization and Troubleshooting Warranty Specifications Customization and Troubleshooting 9 1 9 2 9 3 Intended Use Statement The PCNC is intended for use as a general purpose CNC milling machine The intended use includes cutting conventional non abrasive materials such as unhardened mild or alloy steels aluminum plastics wood and similar materials in fact any material that can be cut with a rotating cutter The PCNC is intended to be used with the software configuration files provided by Tormach Support Tormach provides free technical support through multiple channels The methods are listed below in order of preference The quickest way to get the answers you need is normally checking in order of preference e This manual ALWAYS the first place to check e Related documents found at hitp www tormach com documents html e Our website at www tormach com e Email to info tormach com e Telephone Tormach at 608 849 8381 e Fax Tormach at 209 885 4534 Outside of the Scope of Intended Use Applications for the equipment or modifications of the equipme
326. sories There is an IEC inlet on the bottom of the control cabinet for the computer coolant This should be connected to a GFI Ground Fault Interrupt wall outlet This separate supply like the main machine supply is controlled by the main power switch but allows use of 115 volt accessories on a 230 volt mill The 115 VAC outlet under the panel that is furthest from the column feeds the coolant pump and is controlled by the CNC Figure 2 11 Power and interface connectors software The pair of similar outlets nearer the column is switched by the Computer switch on the front panel Both the 115 VAC power and ground are autonomous from the main machine power and ground 230 VAC in order to allow correct operation of the ground fault interrupter GFI The computer control of the coolant outlet is accomplished by an isolated relay Refer to the upper portion of the circuit diagram in section 10 2 for details wire numbers 200 through 207 31138 Rev B1 4 2 7 Using Tormach PCNC 1100 Series Il 2 1 2 7 1 2 7 2 2 7 2 1 2 7 2 2 2 7 2 3 Preparation Tormach Machine Controller and Software Installation Control Computer We recommend that you purchase a Tormach Machine Controller as part of the mill package as the whole system will be covered by the Tormach warranty If in exceptional circumstances you wish to provide your own computer it needs to run the 32 bit version x86 of Microsoft Windows XP Home or Pr
327. ss than 0 0004 of lost motion attributable to the ball nut Bearing Pair Bearing Adjustment Nuts Ballscrew Motor y i i A Wo 4 N LEXAR AM eee A Ee fon Aj al Figure 9 2a Section view of X axis mount The ball screw mount bearings are at the motor end of the ball screws These are preloaded angular contact bearings and are user adjustable They are typically adjusted for 0 0003 to 0 0013 of lost motion Bearings are available individually and two are needed for each ball screw If the Bearing Adjustment Nuts are not set properly then there will be either excessive backlash in the machine too loose or rapid wear and excessive friction Figure 9 2b Photograph of X axis mount Using Tormach PCNC 1100 Series II 9 8 31138 Rev B1 4 9 5 6 1 9 5 6 2 Warranty Specifications Customization and Troubleshooting too tight Figure 9 1 shows the X axis bearings ballscrew and motor The Y axis and Z axis are similar The recommended procedure for checking backlash is to observe motion at the table or head via a dial indicator while moving the machine using the axis motors Tormach recommends adjusting the backlash on X and Y to something between 0 0004 and 0 001 The recommended backlash for Z axis is 0 0006 to 0 001 Checking backlash by pushing or pulling on the axis is a less accurate method The push pull method will normally show a smaller backlash value You can
328. st bar for slinging the lift the machine These should be solid steel bars mill 31138 Rev B1 4 2 5 Using Tormach PCNC 1100 Series II Preparation not pipes and be 34 or in diameter 2 4 1 2 Lifting from Above The alternative way to mount your PCNC to a stand involves lifting from above The eye in the top of the column is suitable for lifting the machine but it is not in line with the center of gravity The machine will tilt when lifted solely from the eye The alternative is to sling the machine using a combination of the eye and an eye in a T nut on the table using a Tormach special tool part number 30576 Machine Hoist Bar figure 2 7 Figure 2 8 shows the geometry of the slinging The table should be as far away from the column and as far to the right as possible to optimize the balance It is most important that the machine is not lifted by the control cabinet or by any of the protruding stepper motors or the head or the table Incorrect rigging of the sling will likely result in serious damage to the PCNC The optimal balance for lifting should be checked with the machine an inch or two off the floor The X Y and Z axes can easily be moved by hand if the covers on their coupling boxes are removed The smooth i e outside face of an old auto engine timing belt or poly vee auxiliary drive belt which has been cut to make a strip can be used to turn the coupling between the stepper motor a
329. stem is displayed 5 2 2 7 Toolpath Control Family The currently loaded part program is displayed in the G code window The current line is highlighted and can be moved using the scroll bar on the window figure 5 16 The Toolpath display shows the path that the controlled point will follow in the X Y and Z planes When a part program is executing the path is over painted in green This over painting is dynamic and is not preserved when you change screens or indeed alter views of the toolpath On occasions you will find that the display does not exactly follow the planned path This occurs because the Control Software prioritizes the tasks it is doing Sending accurate step pulses to the machine tool is the first priority Drawing the toolpath is a lower priority It will draw Regenerate Display Mode points on the toolpath display whenever it has spare time and it joins these points by straight Jog Follow lines So if time is short only a few points will Ki 0 0000 3 7262 be drawn and circles will tend to appear as f 2 3921 0 0000 polygons where the straight sides are very Z 0 5000 1 000d noticeable This is nothing to worry about A 0 0000 0 0000 The Simulate Program Run button will execute Absalute Motion Extremes the G code but without any tool movement and allow the time to make the part to be estimated simulate Program Run The Absolute Motion Extremes data allow you Estimated Program Run Time
330. stomization and Troubleshooting Axes Drive Sub System Checklist Table 4 6 Cannot Reference all Axes or End of Travel Limits don t Work aka Limit Switch Problems Possible Cause Prob Action to identify Cause Discussion ability of Problem Limit Switch Stuck in High Consult the Diagnostic See Table 4 7 the on state Screen in the Mach3 Software to see if a Limit Or Switch is being reported as actuated even though no axis 1S at the end of its Limit Switch wire travel broken or wire connection bad Limit Switch contacts Medium Consult the Diagnostic See Table 4 7 stuck in the off state Screen in the Mach3 Software to see if a Limit Switch is being reported as not actuated even though the axis is at the end of its travel Limit Switch not being Medium Check to see if the limit If it looks like the switch is being contacted at end of switch loose or if the actuated properly but the diagnostic travel actuating cam is actually screen does not report the switch as contacting the switch being made go to next step Control Board Low See Table 4 7 A defective control board will report Defective no change in the state of the limit switch even though the switch and wiring are functioning properly Using Tormach PCNC 1100 Series II 9 40 31138 Rev B1 4 Warranty Specifications Customization and Troubleshooting Axes Drive Sub System Checklist Table 4 7 Testing Limit Switch Problems Test to Perform Results and Conclusions on Wi
331. stop to running the spindle but leave the VFD power on and cool power electronics down to let the power electronics cool down prevent failure Heat sink temperature is too You are working the spindle motor too hard or it is high because the VFD is too hot in your shop Stop running the spindle but working too hard and needs to leave the VFD power on and let the power electronics stop to cool power electronics cool down Check to see 1f the fan on the VFD is down to prevent failure Cabinet running and check your filters on the cabinet Cool may also be too hot your shop down 1f required Hf 29 Cooling fan not cooling Failed drive 31138 Rev B1 4 9 53 Using Tormach PCNC 1100 Series ll Warranty Specifications Customization and Troubleshooting The drive can also provide parameter information This is information from the Tormach program of the drive and is usually not important from a user standpoint If the drive is displaying this sort of information which always has 2 digit numbers displayed on the left side of the display the user must take action to allow the drive to display the diagnostic information above If the right side digits are flashing momentarily press and release the M button just below the display to cause the left side digits to flash Now with the left side digits flashing press and hold the M button for 3 seconds and the display will change to display diagnostics If frequency is displayed and it is desired
332. strainer at the top of the reservoir is only a screen it is not a filter Note e The pump is spring loaded where the spring force creates a very light hydraulic pressure You can get the oil out quicker by pushing a bit but apply too much force and you can pop off one of the oil lines e You will have a more uniform distribution of oil if the machine is moving when the hydraulic pressure is applied e The pump sucks up oil from the reservoir on the pull stroke and delivers it to the machine on the push stroke If at some point the oil pump seems much easier on the push stroke then make certain that you do not have a broken oil line e Extreme axis positions can expose the oil distribution channels that are cut into the way support saddle surfaces If the pump is used in those positions the hydraulic force of the oil will not apply it throughout the machine as intended Instead the oil will simply squirt out at the point where the oil channel is exposed e After a long period of inactivity or in cold conditions the oil system may become clogged See SB0031 Flushing the Lubrication System in the Event of a Clog Way Covers Way covers are important to keep abrasive debris out of the slide ways Inspect the way covers frequently and replace as necessary Tormach stocks replacement way cover Axis Gib Adjustment The slide ways are hand scraped as part of the manufacturing process This means that the Z axis saddle is fitted to the c
333. tened to the CS Linear Axes The X Y and Z axes form a standard right handed coordinate system of orthogonal linear axes Positions of the three linear motion mechanisms are expressed using coordinates on these axes Rotational Axes The rotational axes are measured in degrees as wrapped linear axes in which the direction of positive rotation is counterclockwise when viewed from the positive end of the corresponding X Y or Z axis By wrapped linear axis we mean one on which the angular position increases without limit goes towards plus infinity as the axis turns counterclockwise and decreases without limit goes towards minus infinity as the axis turns clockwise Wrapped linear axes are used regardless of whether or not there is a mechanical limit on rotation Clockwise or counterclockwise is from the point of view of the workpiece If the workpiece is fastened to a turntable which turns on a rotational axis a counterclockwise turn from the point of view of the workpiece is accomplished by turning the turntable in a direction that for most common machine configurations looks clockwise from the point of view of someone standing next to the machine Scaling Input It is possible to set up scaling factors for each axis These will be applied to the values of X Y Z A I J and R words whenever these are entered This allows the size of features machined to be altered and mirror images to be created by use of negative sca
334. tep size is displayed in a DRO The key labeled Size cycles through the available Increment Step sizes 31138 Rev B1 4 5 17 Using Tormach PCNC 1100 Series II 6 6 1 6 2 6 2 1 Offsets Using Multiple Tools This chapter explains how you can configure the PCNC to use several tools without having to waste time at each tool change defining the length of the new tool It also covers techniques for simplifying machining of work in a vise or other fixture Offsets used are often considered as advanced features but the design of the PCNC Control Software should make them easy to use You will find it worthwhile to master this chapter even if it needs more than one reading to do SO Offsets and Coordinate Systems If you made the FirstPart then you will already have met and used the ideas explained in this section When you Reference the PCNC when it is started the X Y and Z axes are moved so that they are just off the home switches and the machine coordinates are set to 0 0 We saw that this is not useful when you want to run a part program as the program will have its own view of where zero should be in the case of FirstPart this is the top left corner of the material for X 0 Y 0 and the top surface for Z 0 By moving the tool to this position and zeroing the axis DROs you defined relationship between the Machine Coordinates and the coordinates which the part program would use the Program Coordinates The gen
335. ter describes the work required to unpack and to commission the hardware and software of the PCNC It contains a lot of detail but can be completed in one or two hours by a person familiar with CNC machines Enough detail is given here so that a beginner should be successful but some users may prefer to arrange for a machine tool expert to do this work If your machine has already been set up then you can skip this chapter Planning for Your PCNC Electrical Connection The PCNC 1100 Series II is shipped with a 3 wire cord and no electrical plug There are several different NEMA National Electric Manufacturers Association and non NEMA plug patterns that can be used Straight blade patterns are common in household use twist lock patterns are more common in industrial locations Power required is 200 to 250 VAC 50 or 60 Hz Continuous current is below 15 amps but a 20 amp breaker or slow blow fuse is recommended Both primary and secondary power inputs must be grounded During installation it is not enough to assume that the ground line of a wall outlet is properly grounded Check continuity between the machine frame and true earth ground water pipe or similar to ensure a good ground connection Location and Mounting People experienced with CNC machining will undoubtedly have ideas as to how they want to setup their PCNC figure 2 1 While the machine can be configured in many different ways there are a few limitations Many fully
336. th one leg of the 2 current carrying conductors grounded Normally a 115 VAC circuit would be supplied in North America A third wire ground must also be provided The ungrounded leg of this supply is connected to a third pole on the disconnect switch described in the paragraph above Running this circuit in this manner allows the coolant pump outlet to be controlled either automatically by the machine under computer control or manually depending on the position of the Coolant switch SW5 on the operator panel The circuit also provides power to 2 outlets which can be used for the computer and monitor These outlets are controlled by SW6 labelled Computer on the operator panel This allows turning off the computer when power is still applied to the main machine Turning the disconnect switch to the off position removes power to the coolant and computer outlets Control Power Sub system Overview Control Power enables running of the machine When Control Power is on some components IORMACH www tormach com on off auto computer Oh machines CAUTION Read and understand the manual before operating this machine Wear eye protection and use safe machining practices at all times ott coolant computer manual start stop forward RPM x 100 stop i i ai TEN auto spindle reverse XY Personal CNC 100 SEE machine LED stop PB Figure 9 22 Operator Panel start stop and machine LED functions in the cabinet are l
337. the alignment of the coupling e A final check of alignment should be made when the machine is under computer control This involves loosening the motor retaining screws 4 turn and jogging the axis The motor should show no signs of wobbling If it does wobble or move relative to the coupling housing then the coupling screws should be slackened and retightened and the motor rechecked for movement When alignment is perfect retighten the motor fixing screws and refit the coupling box cover Mounting the PCNC Figure 2 6 coupling the Y drive motor Lifting onto Stand The machine can be lifted onto an operating stand by either of two methods from below using the base connection points or from above using a slinging technique In either case caution and common sense are needed for the protection of the machine and the people involved Lifting up tol000 Ibs can be simple with proper preparation and good equipment but it is never trivial and the dangers involved should be taken seriously The work of lifting and placing heavy equipment is called rigging If you are not trained or prepared then you should seek the advice of those who are Professional riggers can be found in most areas Lifting from Below The base of the machine has four holes By sliding two steel bars into these holes at least 32 in length you end up with some outrigger wings that can be used in combination with a fork lift truck to Figure 2 7 Hoi
338. the moved origin are as specified on the line containing the G92 In addition parameters 5211 to 5214 are set to the X Y Z A axis offsets The offset for an axis is the amount the origin must be moved so that the coordinate of the controlled point on the axis has the specified value Here is an example Suppose the current point is at X 4 in the currently specified coordinate system and the current X axis offset is zero then G92 X7 sets the X axis offset to 3 sets parameter 5211 to 3 and causes the X coordinate of the current point to be 7 The axis offsets are always used when motion is specified in absolute distance mode using any of the fixture coordinate systems Thus all fixture coordinate systems are affected by G92 Being in incremental distance mode has no effect on the action of G92 Non zero offsets may already be in effect when the G92 is called They are in effect discarded before the new value is applied Mathematically the new value of each offset is A B where A is what the offset would be if the old offset were zero and B 1s the old offset For example after the previous example the X value of the current point is 7 If G92 X9 is then programmed the new X axis offset is 5 which is calculated by 7 9 3 Put another way the G92 X9 produces the same offset whatever G92 offset was already in place To reset axis offsets to zero program G92 1 or G92 2 G92 1 sets parameters 5211 to 5214 to zero Whereas G92 2 leav
339. the backlash in the angular contact bearings and the ball nut On a newer machine the value should be under 0 0014 on the Z axis note under 001 on X and Y Next tighten the Gib by one turn by loosening the Lower Screw first then tightening the Upper Screw Measure the backlash again Repeat this procedure until the measured backlash increases this is the point 31138 Rev B1 4 Backlash versus turns of adjusting screw Backlash in Backle 0 0 5 1 a 2 2 5 3 3 5 4 5 Number of turns of adjusting screw 0 is loose 5 is tight Figure 9 1c Changes in backlash with gib tightness 9 7 Using Tormach PCNC 1100 Series II Warranty Specifications Customization and Troubleshooting at which the gib setting has started to induce lost motion in the axis Back the adjustment off to the point just before you saw the increased backlash That is the ideal setting for the axis see figure 9 1c For the X axis the Gib tightens with the Gib Screw on the left No covers need to be removed For the Y axis the Gib tightens with the Front Gib Screw The front and rear Y way bellows need to be removed where they screw to the Saddle 9 5 6 Adjusting Ballscrew Preload The ball screw itself is of the double nut preloaded design The preload is set at the factory via a precision ground spacer placed between the two ball nuts They are not user adjustable Under typical conditions there is le
340. the calculated result of applying the percentage override to the set feed rate 5 2 2 6 Program Running Control Family These controls handle the execution of a le Start AN R EEES Set Next Line loaded part program or ee CHANGE TOOL T 2 the commands on an Line o Two flute ballnose MDI line figure 5 15 Stop Alt S Run Ecol ase 2 000 D 0 ON Cycle S Rewind Ctrl W seei ycle Start Goto Tool Change Edit Save Table How Safety warning Note Single BLK Alt N E Work Offset 54 that the Cycle Start button will in general Pause spc Block Delete E i Optional Stop start the spindle and Ignore Blocks M01 Break axis movement X x Figure 5 15 Program running family Stop Stop halts axis motion as quickly as possible Unless used when Paused it may result in lost steps especially on stepper motor driven axes and restarting may not be valid Rewind Rewinds the currently loaded part program Single BLK Single BLK is a toggle with indicator LED In Single Block mode a Cycle Start will execute the next single line of the part program Pause Pause brings the current move to a controlled stop applying deceleration etc Although jogging while paused is possible we do not recommend doing it The best sequence is to Pause and then press Stop Resume by editing the program or using the Run From Here feature Line Number Line DRO is the ordinal number of the current line in the G code display window st
341. the computer power on at the PCNC control panel figure 2 14 Using Tormach PCNC 1100 Series II 2 10 31138 Rev B1 4 Preparation The computer will power up and run the Control Program figure ald xj fie Coty ruen cfe Yew Winds Cperstor PaginGerd Heko 2 15 Spams Rocant Edit ciosa Fee nl gt G E 317 G40 G20 GAO GO G55 G43 GSS G4 GBF ae a A X 107 5171 Jea aena This will allow you to perform all z l oC oe Yi 21 1235 eee the important functions onthe ss wa I 31917 aL Ka standard machine If you have the Mu 2 F __6 00 Ath axis or want to use G code oes i features like Optional Stop then cycle set anit outeni you may wish to use the VUE Comprehensive Run screen pe mre figure 2 16 In this case click ee 1 the Comp Run button to change __Loslaat Cube D gee regener ne Topai seare Display Model the display a p E A Machine OK The screen Light Emitting Diodes LEDs in this manual by the Reset button will be flashing as will the Machine OK LED Now returning to the operator s panel Start and EStop The Start button will energize the circuits for the axis drives and for the spindle motor The Stop button stops all motion and is the Emergency Stop EStop control The Stop button locks in the off position once it has been pressed as safety feature It can be released by a turning the button head a quarter turn clockwise Note Once the stop b
342. the probe tip above the surface that is to be Z 0 0 and click Move and Set Work Offset This is the best way to set the Z work offset if the probe is in the spindle for setting X and Y too Setting a Tool or Z Surface The other pane on the Z probing screen is used with the tool setter It is shown in figure 8 15 Here there are three quantities and provided two are know the third can be quickly set The height of the tool setter sensor is essentially a constant so needs to be put into the DRO once after each installation or upgrade of the Control Software We first describe setting the sensor height e Put the master tool in the spindle and put its number in the Tool DRO sO e Touch it on a flat Z surface like iA 3 9300 TEA Tool length the table of tooling plate and set the current work offset so Z 0 0 sections 6 2 and 6 3 give a range of methods e Jog the master tool so it is above the sensor Tests its wiring by 7 e depressing the top and checking sanea 31500 that the Test Probe before move mM Setu me Height inches LED lights and click the Setup E Ty Sensor Height button This will set the persistent DRO recording the sensor height To set tool lengths in the tool table you work as follows Figure 8 15 Tool setter Using Tormach PCNC 1100 Series II 8 8 31138 Rev B1 4 8 2 2 3 Machine upgrades and configuration e Select the master tool Touch a Z surface with the master tool and set work offs
343. the speed using the rotary control knob The actual speed will depend upon which of the two pulley ratios you have selected Pressing the Spindle Stop rocker will halt the spindle The Coolant switch controls the power to the coolant pump outlet on the underside of the control cabinet In the Off position the outlet is not powered and the pump will not run In the On position power is applied to the outlet and the pump will run until the switch is switched to either off or auto positions In the Auto position outlet power is under program control the pump will run if the Control Program requests coolant Ci The Accessory socket is for connection of accessories such as a touch probe See Chapter 8 for details of the interface Changing the Spindle Speed Range The PCNC has two speed ranges The low range 100 to 2000 RPM is suitable for most machining operations with ferrous and other tough materials The high range 250 APN to 5140 RPM is suitable for small i i diameter cutters plastics and non Figure 2 17 Changing spindle pulleys ferrous materials The range change is performed by moving the V belt from the upper pair of pulleys high speed range to the lower pair low speed range Open the spindle drive door The interlock will prevent the motor from running Note Opening the spindle drive door will also stop a running spindle however this is a safety hazard and should not be used as a substitute for stopping t
344. those in Table 5 2 the Control Board and wiring to the drive are good 31138 Rev B1 4 Warranty Specifications Customization and Troubleshooting Defective Tormach Machine Control Board or cables between the Control Board and drive Defective Motor Attempt to run in manual with the Speed Pot in a mid range position Determination of Defective Drive or Control Board Power down the drive using the Key Switch Wait 30 seconds and measure resistance between the leads of the motor which are wire numbers 400 401 and 402 Remember to take a tare reading with your meter See the section on using your multi meter in the Tips and Tools section following the Philosophy of Troubleshooting 2 3 5 VDC measured on the Control Board between wires J1 2 common and J1 1 indicates the Control Board speed output signal is OK Turning the pot from minimum to maximum should cause the voltage to range from lt 1 to gt 4 5 VDC Return Pot to mid position If the voltage measurements in the two tests above are not good the Control Board is defective if correct the drive is bad Resistance should be in the range of 2 4 QO 0 Q would indicate the winding is shorted and gt 1M Q would indicate the winding is open both cases indicate a defective motor or compromised wiring to the motor from the drive Table 5 2a Run and Direction Commands to Drive Command Monitoring Points Voltage Measured From Card One Probe on
345. through a code sometimes in combination with M1 optional stop statements Additional guidance can be had from Programming of CNC Machines by Ken Evans Refer to section 4 pages 250 to 261 31138 Rev B1 4 6 21 Using Tormach PCNC 1100 Series II Offsets CNC Programming Techniques by Peter Smid Refer to chapter 4 pages 46 to 66 Both of these reference books are available through the Tormach web site www tormach com Final Note We should re iterate that it is much better for a CAM program to generate the path of the tool allowing for its diameter because it can see the implications of cutting complex corners in a way which the control software cannot Using Tormach PCNC 1100 Series II 6 22 31138 Rev B1 4 T 7 1 7 1 1 7 1 2 7 1 3 7 1 4 Programming language reference Part programming Language Reference This section defines the language G codes etc that are understood and interpreted by the Control Software This chapter is intended for reference purposes Sample programs using these commands are included in the folder C PCNC3 GCode If you want to learn about the principles of the control language so you can write programs by hand from first principles then you should consult an introductory textbook on G code programming Definitions Control Software This is the term used for the program running under Microsoft Windows in the PC connected to your PCNC In this chapter the Control Software is shor
346. to know that a machine is functioning improperly if one does not know how the machine is supposed to behave The third key principle in troubleshooting is noting what has changed in the environment since the machine worked properly This principle becomes a larger factor after the machine has been in service for some time because the start up learning process 1s complete and any kinks with the hardware have been worked out The following are some events which could cause difficulties e The machine was moved e There was a thunderstorm and lots of lightning since the machine was last used and now the electronics don t work e There was water in my basement where the machine is located Using Tormach PCNC 1100 Series II 9 16 31138 Rev B1 4 Warranty Specifications Customization and Troubleshooting e It froze hard last night and the machine is in my unheated outbuilding e My son was home on spring break and he may have run the machine while I was away or even did something with the computer e There were problems when I tried to cut steel I had only cut aluminum and plastic prior to this A fourth key principle is to work smart One should always make a list of tests which can be done make sure to save room for recording your results After making up the list rank the tests in order of difficulty in performing the test Then do the simple tests first and then do the tests that seem to address the most likely cause of the pro
347. to startup the system in metric each time you need to edit the file Cry PCNC3 macros PCNC M3 m990 m1s The start of this file looks similar to this This macro implements PCNC INIT actions Add G21 G20 change if needed Uses UserLabel 2 UserDRO 1209 Using a simple text editor e g Notepad add the following line after this code Code G21 make PCNC to start in metric i e G21 mode Save the edit The machine will then start in G21 metric mode 31138 Rev B1 4 9 15 Using Tormach PCNC 1100 Series II 9 6 9 6 1 9 6 2 Warranty Specifications Customization and Troubleshooting Troubleshooting Overview Tormach is taking a different approach to troubleshooting documentation than is typically encountered We feel that a discussion of general troubleshooting methods is quite important yet we have not seen this information presented by others We have therefore begun this document with a section on the Philosophy of Troubleshooting We feel that if you spend a few minutes on this section you will be in a better position to effectively trouble shoot problems The Philosophy of Troubleshooting is followed by a section containing Tips and Tools for Troubleshooting Next comes a list of Frequently Found Problems FFP s which comes from our experience in working with customers We urge you to review this section every time you are having a problem There is a reason the items made it to this list The remainder of this
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349. ts of unexplainable problems have been cured by swapping out computers whose history was unknown It is far better to put an old computer you have confidence in on your machine than take a chance on an unknown used computer Used computers have been found to be more susceptible to electrical noise Laptop computers will almost never work on a PCNC and should not be considered Control Software license not installed The control software can be installed without the license It will run small programs without the license being activated Once a program exceeds approximately 500 lines the program will fail to execute the following line and the program will halt without warning No other diagnostic information will be displayed Machine Controllers purchased through Tormach will have the control software loaded but WILL NOT have the license loaded It is up to the user to load the license CD that came with the machine Unexplained stop or limit switch error while running Electrical noise can cause strange and un repeatable problems Tormach has found that by adding a Ferrite suppressor to the Parallel Port Cable going from the computer to the machine Using Tormach PCNC 1100 Series II 9 22 31138 Rev B1 4 Warranty Specifications Customization and Troubleshooting will eliminate many of these problems We have also found that simply adding a second Parallel Port Cable in series with the existing cable reduces the problems with electrical n
350. ulkhead Cable PN 30278 which positions a USB port to the outside of the machine stand Keyboard and Mouse The controller supports with USB figure 2 13 sockets at 5 or PS 2 style mouse and keyboard connections sockets 1 amp 2 Wireless keyboards and mice are not recommended Both powered Figure 2 13 Rear of and passive USB hubs have a history of problems when used in TMC combination with Mach3 software We recommend that all USB devices plug directly into the USB ports on the controller sockets 5 Display Connect the display to socket 4 figure 2 13 l Refer to http www tormach com document_library DS30278 USBBulkheadCable pdf Using Tormach PCNC 1100 Series II 2 8 31138 Rev B1 4 2 7 2 4 2 7 2 9 2 7 3 2 7 3 1 2 7 3 2 2 7 3 3 2 7 3 4 2 7 4 2 7 4 1 Preparation Speaker and Microphone Connections Speaker and microphone connections are possible but not recommended Power Connections Check the voltage setting before connecting power figure 2 13 location 13 The controller can be set to run on either 115 VAC or 230 VAC and will operate equally well on 50 or 60 Hz power Operating the Controller About the Operating System The MachOS operating system is built with Microsoft Embedded Standard but it looks and acts much like Windows XP Pro If you are familiar with Windows XP then you know how to use MachOS The Tormach Machine Controller has s been designed and configured to work w
351. ulse count is based on one second of Windows time variations in Windows time will make the pulse count look like it is swinging around a lot even when it is rock solid Basically if you see a similar screen to figure A3 1 everything is working well so close the DriverTest program and skip to the section Running the PCNC below Windows experts might be interested to see a few other things The white rectangular window is a type of timing analyzer When it is running it displays a line with small variations indicated These variations are the changes in timing from one interrupt cycle to another There should be no lines longer than 14 or so on an 17 screen on most systems Even if there are variations its possible they are below the threshold necessary to create timing jitters so when your machine tool is connected you should perform a movement test to see if jogging and G00 G01 moves are smooth A line with big spikes or other patterns will limit the high speed performance of your mill You may have one of three things happen to you when running the test which may indicate a problem 1 Screen shows wide variation or clearly periodic variation of timing In this case you need to complete a computer optimization detailed in Appendix 3 section 10 3 of this manual 2 Driver not found or installed contact Art This means that the driver is not loaded into Windows for some reason This can occur on XP systems which have a corruption of
352. umber of seconds e Retract the Z axis at traverse rate to clear Z 7 7 23 4 G83 Cycle The G83 cycle often called peck drilling is intended for deep drilling or milling with chip breaking See also G73 The retracts in this cycle clear the hole of chips and cut off any long stringers which are common when drilling in aluminum This cycle takes a Q number which represents a delta increment along the Z axis Program GOS XY Yen AY Re Le Oe e Preliminary motion as described above e Move the Z axis only at the current feed rate downward by delta or to the Z position whichever is less deep Rapid back out to the clear Z e Rapid back down to the current hole bottom backed off a bit e Repeat steps 1 2 and 3 until the Z position is reached at step 1 e Retract the Z axis at traverse rate to clear Z It is an error if e The Q number is negative or zero 31138 Rev B1 4 7 29 Using Tormach PCNC 1100 Series II Programming language reference 7 7 23 5 G85 Cycle The G85 cycle is intended for boring or reaming but could be used for drilling or milling Program G85 X Y Z A R L e Preliminary motion as described above e Move the Z axis only at the current feed rate to the Z position e Retract the Z axis at the current feed rate to clear Z 7 7 23 6 G86 Cycle The G86 cycle is intended for boring This cycle uses a P number for the number of seconds to dwell Program G86 X Y Z A R L P e Prelim
353. unctioning drive Y Axis in figure 9 27 NOTE Do not swap any wires on a live system Power down first or damage may result Jog the Y axis in both directions Jog the X axis in both directions 9 35 If not tightened down parallel cables will come loose also look for any bent pins at the connection point Turn on power after completion and check for operation Remove the cover plate over the coupling and observe if the motor is turning but the screw is not Since there are at least 3 identical electronic driver modules in the Axis Drive Sub system swapping control signals between modules is very helpful during troubleshooting One must recognize that if control signals are switched from the electronic driver modules on the non functioning axis to a module on a functioning axis the end of travel limit switch on the non functioning axis will not work Take care to avoid reaching the end of travel when moving an axis If the X axis moves properly the control signals are good then it is likely the Y axis driver is bad If the Y axis does not move or moves in only one direction a bad Y axis driver is confirmed If commanding the X Axis moves the Y Axis it s likely there was a poor connection in the ribbon cable connector to the axis driver module Swap the ribbon cables back and repeat the test Inspect the ribbon cable connectors Wiggling them may be worthwhile to try It is also possible that ther
354. understanding will be invaluable whether you make production parts yourself or your designs are manufactured by others Using Tormach PCNC 1100 Series II 3 6 31138 Rev B1 4 From an idea to a part 4 Routes from an Idea to a Part This chapter describes the different ways in which you can define parts to be made with the PCNC It explains in detail how to use those features which are supplied built in to or bundled with the PCNC Control Software 4 1 Controlling the PCNC If you have run the sample program used in the previous chapter then you will have seen the control language of the PCNC scrolling through the G code window as it is executed Although this may look complex it is actually very simple It was originally designed for machines whose computer was comparable in power to the one in a microwave oven or multifunction TV remote control F Keyboard _ os ontrols Te E Keyboard Direct Code GO X2 1 Y3 4 Entry on MDI PCNC 1100 Software C134 Run Code Program File G90G80G49 i gt giog ae GO Z20 GO Sok 6521 V3 0343 M3 239 000 G1 Z0 0000 239 000 G2 X2 5087 Y3 6823 13 2919 G1 X2 5087 Y6 6988 G2 X2 852 1 Y7 3468 13 2919 J6 6988 G1 X3 8022 Y7 3468 G2 X4 1456 Y6 6988 13 3623 J6 6988 ae G1 X4 1456 Y5 7764 G3 X4 4890 Y5 ae 14 9288 J5 7764 G
355. units per rev G95 0 0 cecceeeeeeeeeeeees 7 31 PUNE COMMON TANI Vie ogi certo ce vsstainscccnntroacads stenadonntatess 5 12 First part AS stil E E AE E T 3 1 Fixture coordinate select CSAS dened enea a 7 24 Fixture coordinate systems setting G10 7 17 Fourth axis diameter compensation of feedrate 8 1 engraving on a cylinder sseesseesseessseessees 8 2 gear CUMING Soni rast e bebauadeeteel ood 8 3 referencing and ZerOiNg cecceceeeceeeeeeeeeeenes 8 1 Fourthaxis on PENG insna 8 1 Frequently Found Problems 0cccseeeee 9 20 Fromidea 10 apan Gopacestdanh dutch bans 4 G G amp M codes OV CEVICW ireann E ETA 4 1 31138 Rev B1 4 Appendices G00 rapid linear MOTION ccecseeeceeeeeeeeees 7 11 G01 linear feedrate MOVE xcs c2ss22crssehcesesesntereveres 7 13 GOD CIOE WISE AT Caere 7 14 G03 counterclockwise ALC cceececseeeceeeeeeeeees 7 14 GORA OWE Merrin A EAA 7 17 G10 set coordinate systems cccceeeeeeeeeees 7 17 G12 circular pOCkel rs 7 18 G13 circular POCkKEE ernus 7 18 G15 exit Polar mode ec eccccseeeceeeeeeeeees 7 18 G16 enter Polar mode ce eccccseeeceeeeeeeeees 7 18 GIT Select AY PANC 7 19 GIS Sele AZ PINE ii ea oatetbonksien 7 19 GIIS SCIECESY Z planea 7 19 G20 inch units setting eeseesseesseesseeeseeess 7 19 G21 millimetre units setting eeeeeee 7 19 G28 STE
356. upply is 230 VAC and is used for all axis and spindle motion The secondary supply is 115 VAC The secondary supply is used to provide power to the accessory outlets only and is not used for machine control Either power supply can provide lethal electrical shocks Both power inputs should be unplugged before working in the electrical cabinet Grounding Both primary and secondary power inputs must be grounded During installation it is not enough to assume that the ground line of a wall outlet is properly grounded Check continuity between the machine frame and true earth ground water pipe or similar to ensure a good ground connection A Ground Fault Interrupt or GFI 1 e Residual Current Circuit Breaker or RCCB in Europe outlet must be used to supply the power to the 115 VAC power input Your computer monitor and coolant system are not bolted to the machine frame so proper grounding cannot be assumed The combination of electrical power and water based coolant systems makes the GFI protection very important Electrical Panel NEVER operate the machine tool with the cabinet door open NEVER allow a coolant pump to operate with the cabinet door open DO NOT allow the coolant system to flow coolant directly at the cabinet door seal or on the operator console controls Neither the cabinet door seal nor the electrical controls are sealed against liquids Retained Electrical Power Electronic devices within the electrical cabinet may retain dan
357. urrent system This is rather misleadingly called Absolute IJ mode The IJ mode is set using the button and LED on the Settings screen The choice of modes is to provide compatibility with commercial controllers You will probably find Incremental to be best In Absolute it will of course usually be necessary to use both I and J words unless by chance the arc s center is at the origin When the X Y plane is selected program G2 X Y Z A I J or use G3 instead of G2 The axis words are all optional except that at least one of X and Y must be used I and J are the offsets from the current location or coordinates depending on IJ mode X and Y directions respectively of the center of the circle I and J are optional except that at least one of the two must be used It is an error if e X and Y are both omitted e IandJ are both omitted When the XZ plane is selected program G02 X Y Z A I K or use G03 instead of G02 The axis words are all optional except that at least one of X and Z must be used I and K are the offsets from the current location or coordinates depending on IJ mode X and Z directions respectively of the center of the circle I and K are optional except that at least one of the two must be used It is an error if e X and Z are both omitted e and K are both omitted When the YZ plane is selected program G02 X Y Z A J K or use G03 instead of G02 The axis words are all optional except that
358. utton has been pressed the start button is inoperative until the stop button is released n RESET No File Loaded _Hesteny Chaa r codes Sinple Ram CUAN Comp Rus A MOI Ale Tootwat any Oftsets AN5 l Settings Alte Diagnostics ANT PONG M3 R23 SRev66 Program Run Figure 2 15 Simple main screen VIGIS G0 GIT Gen G27 GW GHC ar G29 G99 GE L E A iC eoa A OLpRLyaemeppeoeve Ns planes pee 0 0000 sat n Z _2 0000 2 T A 0 0000 f mal a TAn 3200 me een teen ene Ret te ms a _tactina cote ROE remy 9 00 F E 6 00 ET Hunima se T _9 awe Erraty aak Sep MS _ ae Sts io _ 0 0000 Fusaviaat Cori 11 40 0005 Ce 15 aan Gute Toot _ 218 Cone tahia Mane War Rani nou Soeh OU EE or Corset COA Momed Oziss __ 0 Mer Ekosed Tine Step _ 00 Locp Actre W _ L Zhhbt 10 00 ish owi Spindle OMFS EE TATE Som or ma lai Initiateasion Macro Called on reset FCRCHE REENE Skai Gani DLIIL Stes Mcse at tome item at wii aaz Toph Abi intear nan Setiego zma mergante nna Figure 2 16 Comprehensive Run screen The Machine LED indicates that the Start button has been pressed When it is lit then the Machine OK LED on the computer screen should be solid green If this does not happen then you should check that the cable between the PCNC and computer is fully plugged in at both ends You will be able to test some controls on the PCNC even if the LED does not give th
359. v B1 4 Warranty Specifications Customization and Troubleshooting e Frequency output proportional to speed Range is 7 HZ to 142 HZ e Load in percent Load is proportional to the torque the motor is outputting e Status rd for ready ih for inhibit which will occur when there is no jumper between terminals B2 and B4 on the drive ri ttl e Fault information letters tr for trip and a code for the fault There are several trips that are worthy of note shown in the table below Table 5 3 Spindle VFD Trips Trip Code Likely Cause DC Bus Under voltage This happens every time the VFD is powered down OU DC Bus Overvoltage Braking Resistor failed open or wiring connection open between the VFD and the resistor VED output instantaneous over Phase to phase or phase to ground short on output of current VFD to motor e e Braking resistor instantaneous Braking resistor shorted or partially shorted out or over current short in wiring between the VFD and the resistor I t power on braking resistor Excessive braking resistor energy caused by too frequent and too severe deceleration cycles or AC supply voltage too high I t power on VFD output You are working the spindle motor too hard current used to protect motor Consider running the spindle motor at half speed for 10 minutes with no load to cool the motor down VED has calculated it is working You are working the spindle motor too hard Stop too hard and needs to
360. ving power from the drive for 30 seconds by use of the Spindle Lockout Key Switch The letters tr on the left side of the display indicate a drive trip and the letters on the right define the type of trip See Table 5 3 Spindle Drive Trips in the Details section for a list of drive trips Symptoms are spindle takes a long time to slow down Using Tormach PCNC 1100 Series II Warranty Specifications Customization and Troubleshooting Spindle Drive Sub System Checklist Table 5 1 continued Spindle will not turn in Manual or Auto Discussion Possible Cause Prob Action to SEERE Cause of Problem py OSS aeon Belt is Loose or Broken or sheaves are not fixed to motor or spindle Defective Drive Un Mis programmed Drive Defective Tormach Machine Control Board Defective cables between the Control Board and the Spindle drive Using Tormach PCNC 1100 Series II Check the mechanical system If the display is not on and there is nominal 230 VAC between wires L16 and L26 the drive is defective Push the M button on the front panel of the drive momentarily The display will change to 01___0 0 with the 01 blinking Momentarily push the up arrow key to the right of the M key the 01 changes to 02 Take note of the number to the right of the 02 Your VFD should read 170 X where X designates the VFD program version If it does not display this value than your drive
361. w 1 and the others number clockwise when looking from the top Screw 2 faces the operator s left Screw 3 faces the mill column Like the active probe a positive number is tightening the screw and a negative number loosening it You must loosen the screw s first then tighten the other s e You will not be able to estimate say 0 11 turns so get as near as you can and repeat the procedure getting nearer and nearer to the ideal point where all screw movements are zero For most purposes 0 03 of a turn which is about 0 001 will be good enough e Make sure all the screws are tight and re check the calibration 8 2 3 Digitizing parts from a model or for reverse engineering Details of the software for this will be published in a later revision on this document 8 2 4 The Probe Electrical Interface _ ae Solder side of Panel Mount 12VDC _ ____4 Pind 12 VDC DIN Connector on Mill cabinet 5V0C Pint 6 VDC y Pin Input sinking Fol chid 45 ophokoletcr OVDC a Pin 4 common Common Figure 8 22 PCNC1100 Interface to probe Probes are connected to the auxiliary socket is provided on the operators control panel This can be used for interfacing any device that needs an input that can be read by the Control Software It can be used for user supplied devices The exact interfacing will depend on the device to be used but the following description of the available signals will allow liaison with the device supplier d
362. was simply not available and despite all the pitfalls and complications application of G41 G42 cutter compensation in a CNC machine tool was more common There was simply no other solution Now that high quality CAM software is widely available most people do tool offsets in CAM and don t bother with using G41 G42 for offsets in the machine controller Nevertheless there remain instances where controller based offsets are useful If you decide to use the G41 G42 codes be prepared for considerable debugging Some apparent roadblocks may be avoided through experimentation and minor modifications to your G code program Others may be inherent to Mach3 or the desired geometry you are trying to achieve As a matter of practical experience we recommend path planning in CAM and avoiding the use of G41 G42 where possible When it becomes necessary to us the G41 G42 functions we suggest you apply the codes to simple geometry parts applying small compensations i e wear compensation not cutter radius compensation using 2 segment lead in and be prepared for some experimentation debugging 6 8 8 Resources for Debugging Cutter Compensation As noted earlier Tormach cannot provide program debugging support nor resolve application specific questions regarding the use of cutter compensation Basic solutions for debugging code files can usually be resolved through a systematic approach of divide and conquer where you section codes and single step
363. ween the balls and races which results in backlash Preloading bearings is the technique of putting opposing pairs of bearings in compression This technique will eliminate the open space but apparent backlash more correctly called lost motion will still exist There will always be some force required for motion Since the bearings are compressible remember steel is a spring there will be some motion required for compression before enough force is delivered and motion is obtained This is lost motion and has the same effect as conventional backlash When you re working to tune a machine you should be aware that if there is backlash of more than 0 003 there is some conventional backlash and something needs to be adjusted or replaced Backlash of 0 0015 or less is probably lost motion and not conventional backlash There are compromises and tradeoffs made when you tune a machine Tightening the gibs on the X axis will reduce backlash in Y but it also increases the force required for motion in X thus increasing lost motion in X Increasing the preload on a bearing pair will reduce lost motion but it will shorten the life of the bearing Factors Combine Machine setup and tuning is done under no load conditions The accuracy of machined work is going to be worse because tool flex work piece flex fixture flex and other factors combine with the basic machine accuracy Even thermal expansion adds to the mix A 30 ball screw will change
364. with working with multiple coordinate systems Referenced Scale The LED is green if the axis has been referenced 1 e is in a known actual position Many users prefer to always run the PCNC in the referenced state Each axis can be referenced using its Ref button or the linear axes can be referenced together using the Ref XYZ button The De Ref All button does not move the axes but stops them being in the referenced state Scale factors for any axes can be set by G51 and can be cleared by G50 If a scale factor other than 1 0 is set then it is applied to coordinates when they appear in G code e g as X words Y words etc The Scale LED will flash as a reminder that a scale is set for an axis The value defined by G51 will appear and can be set in the Scale DRO Negative values mirror the coordinates about the relevant axis The G50 button executes a G50 command to set all scales to 1 0 Correction Radius Rotary axes can have the approximate size of the work piece defined using the Rotational Diameter control family This size is used when making blended feed rate calculations for coordinated motion including the 4th Axis The LED indicates that a non zero value is defined Jog Shuttle Axis The axis that is selected for jogging by the Tormach Jog Shuttle Controller is indicated by a LED by the top left corner of the corresponding DRO Jog ON OFF Ctri Alt Jog Step Num 5 2 2 3 Jogging Control Famil TETS es
365. wn in figure 7 5 if they occur on the same line If you wish to impose a different order e g to turn coolant off before the spindle is stopped just code the commands on separate blocks Using Tormach PCNC 1100 Series II 7 36 31138 Rev B1 4 Programming language reference 7 12 Error Handling This section describes error handling in the Control Software The Control Software sometimes ignores things that it does not understand If a command does not work as expected or does not do anything check that you have typed it correctly The Control Software does not check for axis over travel or excessively high feeds or speeds Nor does it does not detect situations where a legal command does something unfortunate such as machining a fixture 31138 Rev B1 4 7 37 Using Tormach PCNC 1100 Series Il 8 Machine upgrades and configuration Machine Upgrades and Configuration 8 1 8 1 2 1 8 1 2 2 Fourth Axis Rotary Table The fourth axis can be used as a rotary table 1 e with its axis of rotation parallel to the Z axis or more commonly as a dividing indexing head with its axis of rotation parallel to the X axis Installing the Electronics Full details for installing the electronics and setting up the rotary table can be found in the Tormach 4th Axis and Rotary Products Manual RotaryProducts_UM pdf This comes with every Tormach 4th axis Kit and is also available to download from our website www tormach com Utilizin
366. xplained later in this chapter Although we Referenced the machine so machine coordinates are zero at the home switch position this is not essential Clicking the Zero button on axis DROs will set a work offset value whatever the value of the machine coordinates So to summarize any move made in a part program or by typing in the MDI line which gives a new set of program coordinate values will cause the Control Software to add on the appropriate offsets and then move the machine position to the newly calculated value of the machine coordinates value The sum it does is shown on the Offsets screen You may find it helpful to move the tool around on your machine above some scrap stock and use a tape measure to reconcile the DRO readings with the machine position relative to the switches and the stock When you have a clear picture in your mind of what is happening you have mastered the idea of offsets and should have no problems with this chapter 6 7 Multiple Work Origins 6 7 1 G54 Work Offset The previous explanations of offsets have only referred to a single set X Y Z A of work offsets These are always in effect when the Control Software is loaded It is sometimes useful to have another set of offsets and for them to be persistent when the system is closed down and reloaded Suppose you have a machine vice permanently fixed to the table It would be useful to remember the top left corner of its fixed jaw as this is a simple datum to lo
367. y L11 and L21 and the Filter passes power on wires L23 and L24 to contacts on the contactors C1 and C2 Should main power be lost to the machine when the Control Power circuit is on the Control Power circuit turns off and stays off until power is restored and the start Button is pressed This prevents the machine from re starting without operator action after any removal of power which could occur with a brownout or momentary loss of power to a storm or power distribution problem Transformer XFM1 reduces the incoming voltage from a nominal 230 or 220 VAC toa nominal 115 or 110 VAC 115V control circuits are industry standard in North America this allows the use of readily available Pushbuttons Contactors and other control circuit components If your wall breaker consistently trips whenever you power up the Spindle see section 9 6 5 5 than you should verify that the main machine power is not coming through a Ground Fault Circuit Interrupt devise GFI or known as RCCB in Europe as the filters in the spindle drive can allow minor leakage current to ground that while considered safe may also be sufficient to trip a normal GFI beaker RIGHT SIDE INSIDE BOX INSIDE DOOR OUTSIDE DOOR Figure 9 24 Machine Cabinet Component Locations for Control Power 31138 Rev B1 4 9 29 Using Tormach PCNC 1100 Series Il Warranty Specifications Customization and Troubleshooting 9 6 5 3 Computer Control Communication Sub Section Overview
368. y bad Other size arcs in the range tiny to 165 degrees or 195 to 345 degrees are OK Here is an example of a radius format command to mill an arc Gly GO X Ok oY ee OR ZO Zo Oe That means to make a clockwise as viewed from the positive Z axis circular or helical arc whose axis is parallel to the Z axis ending where X 1 0 Y 1 5 and Z 0 5 with a radius of 2 0 If the starting value of Z is 0 5 this is an arc of a circle parallel to the X Y plane otherwise it is a helical arc 31138 Rev B1 4 7 15 Using Tormach PCNC 1100 Series II Programming language reference 7 7 3 2 Center Format Arc In the center format the coordinates of the end point of the arc in the selected plane are specified along with the offsets of the center of the arc from the current location In this format it is OK if the end point of the arc is the same as the current point It is an error if when the arc is projected on the selected plane the distance from the current point to the center differs from the distance from the end point to the center by more than 0 0002 inch if inches are being used or 0 002 millimeter Gf millimeters are being used The center is specified using the I and J words There are two ways of interpreting them The usual way is that I and J are the center relative to the current point at the start of the arc This is sometimes called Incremental IJ mode The second way is that I and J specify the center as actual coordinates in the c
369. ype a value and click in the next DRO This discards the typed value Mach2 CNC Control Program ArtSoft Corporation 2000 2004 6 x File Config View Wizards Operator Help Pocket Dia cw Climb Mill _ccw Conv Mill X Center Pos Stepover i Feedrate Y Center Pos TE Tool Dia Spindle RPM Rapid height Tool Number CW M3 Feed Plunge AN a Spindle Direction Pimm Minch 7 fj Coolant Post Code Save Settings _Clear_ File Rewound Ready SS Figure 4 19 Circular Pocket Wizard G code from a Wizard You should carefully check the code generated by a Wizard particularly if it is one which you have not used before Things to look out for are e Whether the Wizard sets a speed for the spindle S word and starts it and how it controls the coolant e ff any motion will conflict with clamps for your work e Which position on the work piece the Wizard considers to be X 0 Y 0 A good check is to define Z 0 to be a plane a few inches above your work piece and do a test run of the Wizard s code Commercial Wizards While many Wizards are bundled free of charge with the PCNC a set from New Fangled Solutions is a trial version of a product which requires a separate license You can use all its features to evaluate what the Wizards can cut but without the license you cannot actually produce the G code part program
370. ys open after a command has been executed Jog Mode Num It can be closed by Enter when it is blank O C Note All keystrokes go to the MDI when it is open so it 3 i Jog ee is not possible to execute shortcuts or jog the axes If the 10 o af keyboard does not do what you expect then you Shift Joq to Override Joq Mode probably still have the MDI line open Figure 2 21 Simple jog controls Jogging the Axes The final thing to try before actually making your first part is to move jog the PCNC axes using the keyboard There are several options for jogging which will be explained in detail below The jogging controls are at the top right hand side of the screen figure 2 21 Click the Jog ON OFF button or use its shortcut Ctrl Alt J to turn on the screen LEDs beside it if they are not already on Click Jog Mode or use its shortcut to turn on the larger of the LEDs above the word Cont for Continuous jogging Type the value 10 into the Slow Jog Rate DRO do not forget the Enter to accept the value In the next steps you may find the directions of movement are unexpected Therefore when you use the arrow keys you should be prepared to quickly release the key if the axes moves in an unexpected direction or is near its limit of travel Now press the Left Right Up and Down arrows on the keyboard The table will move while you hold the key down If you crash into the limit switches then the LED beside the red Reset button will flash a
371. zed as occurs in a finishing cut Maximum repeatability is achieved when the forces are repeatable both in magnitude and direction Machining is a mix of science skill and art The caveat in stating accuracy and repeatability is that these factors depend on the techniques used by the machinist A skilled machinist can often deliver accuracy that exceeds the accuracy specified by the machine builder while an inexperienced machinist may have difficulty delivering the expected accuracy With this understanding we cannot tell you what accuracy you will be able to achieve in your own work Protecting from Rust Exposed iron and steel surfaces should always be protected from rust and corrosive environments If your machine will be unused for more than a couple days you should mist the machine with light water repellant oil such as WD 40 The rust preventative characteristics of coolant may not be effective in trapped areas It is desirable to apply way oil or machine oil directly to the table surface under the trapped area when you mount a vise or fixture on the machine Neglect this and you may be welcomed by a rusty machine surface when you remove the fixture some days later Gibs Dovetail Slideways and Lubrication The X Y and Z slideways have a bonded layer of skived plastic compound a composition of acetyl and PTFE The material is commonly known under the trade names of Turcite or Rulon This is state of the art technology for oil lu

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