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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)

Quantity

Description

1

1100M+ Enclosure Decal (PN 39393)

1

1100M+ Electrical Cabinet Decal (PN 39392)

3

8-Position Terminal Block (PN 32877)

4 ft1

Butyl Tape Sikaflex (PN 34133PN 51481)

1

Cord Grip (PN 38758)

1

Cord Grip Nut (PN 30806)

4

Cable Gland (PN 35974)

1

Dielectric Grease (PN 38268)

3

Flex Conduit Fitting (PN 30628)

4

M5 × 0.8 - 20 mm Socket Cap Screw (PN 30357)

4

M5 Flat Washer (39305)

4

M5 Lock Washer (PN 30534)

1

M5 Tap (PN 33420)

1

M5 Tap Drill (PN 33641)

1

X-Axis Servo Control Cable (PN 39398)

1

Y-Axis Servo Control Cable (PN 39399)

1

Z-Axis Servo Control Cable (PN 39400)

1

X-Axis Servo Power Cable (PN 39402)

1

Y-Axis Servo Power Cable (PN 39403)

1

Z-Axis Servo Power Cable (PN 39404)

7

Spade Electrical Connector (PN 30610)

1

X-Axis Flex Conduit (PN 30627)

1

X-Axis Motor Cover Assembly (PN 39283)

1

X-Axis Servo Motor (PN 38404)

1

Y-Axis Servo Motor (PN 38701)

1

Z-Axis Brake (PN 38399)

1

Z-Axis Servo Motor (PN 38405)

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.

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  • 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".

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

  2. Downloading and installing an update file requires an Internet connection. From the Status tab, confirm that the Internet button LED light is on. (To configure the network, select the LED light.) Then, select Update.

...

  1. From the Software Update dialog box, select Check Online.

...

  1. The update file is downloaded, and a notification dialog box displays.

  2. From the dialog box, select OK.
    The update file is installed on the PathPilot controller.

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

Install an Update File from a USB Drive

Anchor
usb
usb

  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.

...

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

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

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Remove the Stepper Motors
Anchor
remove
remove

Remove the X-Axis Stepper Motor

  1. On the motor coupler, loosen the two set screws that are closest to the motor with a 3 mm hex wrench.

...

NOTE: Separate the X-axis flex conduit from the other motors' flex conduits. It's easy to confuse them, and you only need the X-axis' flex conduit for the installation of the servo motors.

Remove the Z-Axis Stepper Motor

WARNING! Crash Hazard: You must support the spindle head as described in this document before you make any mechanical or electrical adjustments to the spindle head. (For example, loosening the set screws on the Z-axis motor coupler.) If you make adjustments without first supporting the spindle head, it could result in the spindle head crashing on the machine table.

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  1. Pull the wires from the motor out of the machine column.

  2. Remove the flex conduit fittings from the machine column with Channellock pliers. Discard the fittings.

  3. Remove the motor from the machine with a 4 mm hex wrench.

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

Remove the Y-Axis Stepper Motor

  1. On the motor coupler, loosen the two set screws that are closest to the motor with a 3 mm hex wrench.

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  1. To prevent coolant from entering the X-axis motor cover, you must first apply a layer of butyl tape Sikaflex before putting back the tool tray. Clean the surfaces of the X-axis motor cover and the tool tray with a mild degreaser (like Simple Green®) to make sure that the butyl tape Sikaflex bonds.

  2. Find the roll tube of butyl tape Sikaflex provided with this kit, and the tool tray that you set aside in "Prepare the Machine".

  3. Remove the cover paper, and then put strips of butyl tape Put a bead of Sikaflex along the top edges of the X-axis motor cover as shown in the following image.

...

Remove the remaining cover paper from the butyl tape strips.

...

  1. Put a bead of Sikaflex around the screw holes on the bottom of the tool tray.

...

Remove the remaining cover paper from all butyl tape strips.

  1. Attach the tool tray to the X-axis motor mount with the screws that you set aside in "Prepare the Machine".

  2. Verify that the tool tray is flush with the machine table: move a 1-2-3 block (or similar) across the two surfaces. Depending on the result, do one of the following:

    1. Tool Tray is Flush with the Machine Table Go to Step

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    1. 23.

    2. Tool Tray isn't Flush with the Machine Table Squeeze the tool tray down with a bar clamp until it's flush with the machine table, as shown in the following image. Then, tighten the screws.

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  1. 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

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NOTE: You recorded the locations of the original Z-axis brake wires in "Remove the Stepper Motor Drivers".

  1. Find the three servo power cables that you put into the electrical cabinet in "Install the Servo Motors".

  2. Find the six spade electrical connectors provided with this kit.

  3. Remove 1/4 in. of insulation from each of the wires on the power cables. Then, crimp one spade electrical connector to each of the wires with a wire crimper.

  4. Route the power cables through the wire troughs and toward the DC-BUS board.

  5. Connect the spade connectors on the power wires to the DC-BUS board as detailed in the following table.

Wire Number

Connection

X-Axis

210

X-

211

X+

Y-Axis

220

Y-

221

Y+

Z-Axis

230

Z-

231

Z+

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

  2. Put back the wire trough covers.

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

  4. 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.
      The PathPilot interface displays.

  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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To view a PDF version of your manual, go to Tormach document TD10580.

If you have additional questions, 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.