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Purpose

This document gives instructions on installing the 1100M+ Servo Upgrade Kit on a mill.

Product Information

Product: 1100M+ Servo Upgrade Kit (PN 39274)

NOTE: If any items are missing, we can help. Create a support ticket with Tormach Technical Support at tormach.com/how-to-submit-a-support-ticket for guidance on how to proceed.

Required Tools

This procedure requires the following tools. Collect them before you begin.

• 1-2-3 block (or similar)

• Adhesive tape

• Ammonia-free window cleaner (or similar)

• Bar clamp

• Center punch

• Channellock pliers

• Electric drill

• Electrical tape (or similar)

• Flat-blade screwdriver

• Flat-blade screwdriver, small

• Ladder (about 3 ft)

• Marker

• Metric hex wrench set

• Mild degreaser (like Simple Green®)

• Needle-nose pliers

• Paper towels

• Phillips screwdriver

• Plastic squeegee (or similar)

• Tap handle

• Two-by-four, two (or similar 3-in. block of wood)

• Wire crimper

• Wire stripper

Before You Begin

• Automatic Oiler Required You must confirm that the mill is regularly oiled. If you don't, there's a risk of motor faults. Use an Automatic Oiler Kit: 230 Vac (PN 38255).

• Clean Machine Clean all chips and swarf from the machine with a bench brush and a dustpan.

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• ECMv1.5 Update Kit Required If you don't have an ECMv1.5 or later control board, you must first install the ECM1v1.5 Update Kit (PN 39257). For information, see the product's documentation.

• Keep All Hardware To install the servo motors, you'll reuse many items currently used on the machine. Keep all hardware unless you're specifically instructed to discard it. If you don't, there's a risk that you won't have the hardware you need to complete the installation.

• PathPilot v2.2.X or Later Required Only PathPilot v2.2.X and later has settings required to use a servo motor mill configuration. For information, go to "Update PathPilot".

Update PathPilot

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Update Update

Before you begin to install this kit, you must verify that the PathPilot controller is updated to the latest version of PathPilot. This is because only PathPilot v2.2.X and later has settings required to use a servo motor mill configuration.

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Install an Update File from a USB Drive

1. From the PathPilot support center, download the most recent PathPilot update file.

2. Transfer the PathPilot update file to a USB drive.

3. Put the USB drive into the PathPilot controller.

4. Confirm that the PathPilot controller is powered on and out of Reset mode.

5. From the Status tab, select Update.

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8. Select the desired update file, and then select Update.
   The update file is installed on the PathPilot controller.

9. Follow the on-screen instructions to restart the PathPilot controller.

Removal

Complete the following steps in the order listed:

Prepare the Machine

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1. If you have any tooling in the spindle, remove it.

2. Remove any workholding from the machine table.

3. Loosen the four screws securing the drip guard to the front of the machine table with a 4 mm hex wrench. Then, remove the drip guard and set it aside.

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16. Power off the machine and the PathPilot controller.

    1. Push in the machine's red Emergency Stop button, which removes power to motion control.

    2. From the PathPilot interface, select Exit.

    3. Turn the Main Disconnect switch to OFF on the side of the electrical cabinet.

    4. Remove the power plug(s) from the wall outlet. If your system is hardwired, isolate the machine by opening its circuit breaker(s).

    5. Follow correct lockout/tagout procedures.

Remove the Stepper Motor Drivers

NOTICE! Only remove wires as instructed in this procedure. If you don't, there's a risk that you could remove wires required for future accessories (like a 4th axis).

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10. Remove all of the stepper motors’ wires from the wire troughs. There are 15 in total:

    1. 210 through 214

    2. 220 through 224

    3. 230 through 234

11. Wires 210, 211, 220, 221, 230, and 231 are now completely disconnected from the electrical cabinet; discard them.

12. Identify the Z-axis brake wires: follow wire 400 and wire 435 (both black) from the Z-axis brake into the electrical cabinet.

13. When you install the new Z-axis brake that's provided with this kit, you must make its wire connections in place of the original Z-axis brake wires. Record the current location for both wire 400 and wire 435 in the electrical cabinet.

14. Remove wire 400 and wire 435 from the electrical cabinet with a small, flat-blade screwdriver. Then, remove both wires from the wire troughs.

15. Remove the Z column panel with a 3 mm hex wrench. Set aside the screws and the column panel.

16. Carefully move the following wires out of the electrical cabinet, through the Z column opening, and then discard them:

    1. 212 through 214

    2. 222 through 224

    3. 232 through 234

    4. 400

    5. 435

17. Remove the sleeves from each of the three groups of wires, and set them aside.

Remove the Stepper Motors

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remove remove

Remove the X-Axis Stepper Motor

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c. Set aside the mounting screws and washers for the installation of the servo motors. Then, discard the motor and its wiring.

Installation

Complete the following steps in the order listed:

Prepare the Machine for the X-Axis Motor Cover

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prepare prepare

On the X-axis motor mount, you must drill and tap four holes that you'll use to secure the X-axis motor cover. Use the template (provided in this document) to drill and tap the holes in the correct location.

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10. Remove the templates from the motor mount.

11. Drill each hole that you marked in Step 9 with the drill bit provided with this kit. Each hole should be approximately 3/4-in. deep.

12. Tap each hole that you drilled in Step 11 with the tap provided with this kit.

Install the Servo Motors

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Install the X-Axis Servo Motor

1. Find one of the flex conduit fittings provided with this kit.

2. Install the flex conduit fitting in place of the plug that you removed in "Remove the Stepper Motors", as shown in the following image.

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25. Find the two wires that you put into the machine column in the rear access compartment of the machine. Then, put the sleeves that you set aside in "Remove the Stepper Motor Drivers" (page 13) over them, and put the wires into the electrical cabinet.

Install the Z-Axis Servo Motor

1. Find two cable glands provided with this kit.

2. Install the two cable glands as shown in the following image.

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12. Tighten the cable glands around the wires with Channellock pliers.

13. Find the dielectric grease provided with this kit. Then, put it on the Molex connectors of the servo power and control wires.

14. Make the servo wire connections at the motor.

15. Find the servo power wires, servo control wires, and Z-axis brake wires that you put into the machine column in the rear access compartment of the machine. Then, put the sleeves that you set aside in "Remove the Stepper Motor Drivers" over them, and put the wires into the electrical cabinet.

Install the Y-Axis Servo Motor

1. Find the Y-Axis Servo Motor, 1100 (PN 38701). Then, install it in place of the motor that you removed in "Remove the Stepper Motors" with the screws and washers that you set aside.

2. Tighten the two set screws on the coupler closest to the motor with a 4 mm hex wrench.

3. Put back the Y-axis motor mount cover with the screws that you set aside in "Prepare the Machine".

4. Early 1100M mills require different routing for the Y-axis motor. Depending on your machine's serial number, do one of the following:

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i. Find the dielectric grease provided with this kit. Then, put it on the Molex connectors of the servo power and control wires. Make the servo wire connections at the motor. Find the servo power wire that you put into the machine column in the rear access compartment of the machine. Then, put the sleeve that you set aside in "Remove the Stepper Motor Drivers" over it, and put the wire into the electrical cabinet.

Make Electrical Connections

1. Remove the four Phillips head screws securing the protective cover to the machine control board with a Phillips screwdriver. Then, set aside the screws and the cover.

2. Find the three green connectors provided with this kit.

3. Identify the pin connection locations on the green connectors. Pin 1 is closest to the small triangle on the outside edge of the connector, as shown in the following image. Pins 2 through 8 follow in sequential order.

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6. Organize the wires into the wire troughs, and then put any excess wire into the machine column.

7. Put back the wire trough covers.

8. Put the protective cover back on the machine control board using the screws that you set aside earlier.

9. Close the electrical cabinet door.

Verify the Installation

1. Put back the Z column cover that you set aside in "Prepare the Machine".

2. Power on the machine and the PathPilot controller.

   1. Insert the power plug(s) into the wall outlet. If your system is hardwired, restore power to the circuit breaker(s).

   2. Turn the Main Disconnect switch to ON on the side of the electrical cabinet.

   3. Twist out the machine's red Emergency Stop button, which enables movement to the machine axes and the spindle.

   4. Press the Reset button.

3. If you haven't yet done so, configure the PathPilot operating system for an servo motor mill configuration:

   1. From the Main tab, in the MDI Line DRO field, type ADMIN CONFIG. Then select the Enter key.

   2. From the Tormach Machine Controller Configuration screen, select the new machine configuration. Then select Save and Exit.

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4. From the PathPilot interface, select Reset.

5. Confirm that the machine can freely move to the reference position:

   1. Reference the Z-axis before referencing the other axes so that the spindle is clear of any possible obstructions: from the PathPilot interface, select Ref Z.

   2. Once the spindle is clear of any possible obstructions, select Ref X and Ref Y.

6. Depending on the result of Step 5, do one of the following:

   1. Correct Movement Remove the set of two-by-fours on the machine table, and put back the drip tray that you set aside in "Prepare the Machine".

   2. Incorrect Movement We can help. Create a support ticket with Tormach Technical Support at tormach.com/how-to-submit-a-support-ticket for guidance on how to proceed.

Apply the 1100M+ Decals

We recommend using a wet application procedure to put the decals on your machine. It's easier to do (you can adjust as you work) and it creates a more professional appearance (you can easily push out air bubbles) – but it takes time to dry. Wait to use the machine until the decals dry completely so that you don't risk swarf (or other debris) moving the decals out of position.

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