Basic Operation - PCNC 770

This chapter provides an overview of the basic controls of the PCNC mill.

WARNING! Unattended Operation: Machine is not designed to operate unattended. Do not leave machine unattended during operation. When machine is not in use, turn the main disconnect off. Failure to do so could result in death, serious injury, and/or machine damage.

Control Locations

There are two control locations, the Operator Panel and the (on-screen) PathPilot^® interface. All control functions can be found in one or the other location.

Operator Panel

The Operator Panel is located on the door of the electrical cabinet (see Figure 1). It contains physical buttons that control the following functions:

• Start

• E-stop

• Controller On/Off

• Coolant On/Off/Auto

• Spindle Manual/Auto

• Spindle Start/Stop

• Spindle Forward/Reverse

It also contains the Accessory inlet, the Spindle Speed Dial (RPM x 100), and Spindle Lockout.

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Figure 1

NOTE: The Operator Panel is not compatible with the PCNC 1100 or PCNC 770 full enclosure kit and is therefore removed and discarded during installation of either. In this scenario, these controls are accessed (on mills without an operator panel) via the PathPilot interface.

PathPilot Interface

PathPilot is a sophisticated CNC controller for Tormach products. All aspects of the mill is controlled via the on-screen PathPilot interface. There are four primary ways to interact with PathPilot:

• Keyboard

• Mouse

• Jog shuttle (optional)

• Touch screen (optional)

For further information on the PathPilot interface, see “PathPilot Interface”.

Initializing the Mill

To prepare the mill for motion, the mill must be initialized.

Vital Reference

After powering on, the PCNC mill must be referenced in the X-, Y-, and Z-axes. Execute the referencing procedure as follows:

1. Power on the mill following the “Power Off/On Procedure”.

2. Click the flashing Reset button on the PathPilot interface.

3. Click REF Z, REF X, and REF Y.

Jogging

Manual Control Group

The Manual Control Group’s buttons and slider allow the operator to perform tasks related to manual control of the mill, including jogging the mill axes, changing the current tool number, feed rate, or spindle speed, and starting or stopping the spindle (see Figure 2).

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Figure 2

Jogging Controls

Tormach mills can be jogged with either the Jog Shuttle (PN 30616) shown in Figure 3 or by using the keyboard’s arrow keys (see Figure 4):

• The right arrow jogs X-axis in the positive X direction (table moves left of operator).

• The left arrow jogs X-axis in the negative X direction (table moves right of operator).

• The up arrow jogs Y-axis in the positive Y direction (moves table towards operator).

• The down arrow jogs Y-axis in the negative Y direction (moves table away from operator).

• The Page Up key jogs the Z-axis in the positive Z direction (moves spindle up).

• The Page Down key moves the Z-axis in the negative Z direction (moves spindle down).

NOTE: Jogging is not permitted during G-code program execution or MDI moves.

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Figure 3: Jogging with Keyboard Keys

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Figure 4: Jog Shuttle

Jog Shuttle

The Jog Shuttle (PN 30616), shown in Figure 4, is an optional accessory that many operators find increases productivity, especially on short-run jobs requiring extensive setting up of the workpiece and tooling.

The X, Y, Z, and A buttons are used to jog the X-, Y-, Z-, and A-axis respectively. An illuminated LED light beside an axis DRO on the PathPilot interface indicates which axis is selected for jogging. The the Step button on the Jog Shuttle cycles through the available jog step sizes. The active size is indicated by an illuminated LED light on the Step Size buttons on the PathPilot interface.

For more information on jogging methods, see “PathPilot Interface”.

Spindle Controls

Manual Spindle Control Via Operator Panel

The operator panel-based spindle controls are outlined below:

• To control the spindle via the Operator Panel switch the spindle to Manual (see Figure 1).

• Use the Spindle Speed Dial to select the desired spindle RPM. The numbers correspond to spindle speeds when the belt is in the high position.

• Use the spindle direction switches to select Forward for clockwise and Reverse for counterclockwise.

• Press Start to activate the spindle. Press Stop to stop the spindle.

Automated Spindle Control Via PathPilot Interface

To control the spindle via the PathPilot interface, switch the spindle to Auto on the Operator Panel

(see Figure 1).

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Figure 5

Ensure the Spindle Range button’s LED light (see Figure 5) correctly corresponds to the spindle belt position, either Hi or Lo; click to toggle between the two positions. For more information on the procedure to change belt position, refer to “Changing Spindle Speed Range” section later in this chapter.

NOTE: A mismatch between the Spindle Range button and actual spindle belt position will result in the commanded speed being different from the indicated RPMs. See table below for available speed ranges for each spindle option.

To specify spindle RPMs, click the DRO. Using the keyboard, type the desired RPM and press Enter.

• Click FWD to run the spindle clockwise

• Click REV to run the spindle counterclockwise

• Click Stop to stop the spindle

Changing Spindle Speed Range

Each PCNC mill has two speed ranges as outlined in the table below.

The range change is performed by moving the spindle belt from the top pair of pulleys (high speed range) to the lower pair of pulleys (low speed range).

To change belt position:

WARNING! Electrical Shock Hazard: Be sure to power off machine before making any electrical modifications. Failure to do so may result in serious injury or death.

1. Power off mill according to power off/on procedure detailed in chapter 3, Installation.

2. Open spindle door.

3. Unlock motor mounting plate:

   1. On a PCNC 1100: Use the rear handle (see Figure 6)

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Figure 6

4. Pull spindle motor forward. The spindle belt slackens.

5. Move the spindle belt from one pulley to another. (see Figure 6)

6. Re-tighten the spindle belt so that there is approximately 1/8”-1/4” of belt deflection midway between the pulleys with a firm finger press.

7. Lock the motor mounting plate and stow handles (if equipped) in the vertical position.

Tool Holders

This section describes using tooling compatible with the standard R8 spindle. For more information on other spindle options, refer to the product-specific documentation.

The Tormach Tooling System (TTS^®) is the recommended tool holding method for PCNC mills. The advantages of TTS over other tooling options include:

• Exact tool offset repeatability

• Easily adaptable to tool presetting techniques

• Quickest manual tool change time

• Shortest tool change clearance distance

• Compatibility with Tormach power drawbar and Tormach automatic tool changer (ATC)

TTS uses a precision 3/4” collet in combination with a drawbar and interchangeable TTS tool holders. Many different TTS tool holders are available.

Prior to using TTS for the first time, the TTS collet must be installed. To install the collet:

1. Using a clean rag, apply a degreasing agent to the inside taper of the spindle and also the entire surface of TTS collet. Wipe clean and dry.

2. Apply a small amount of Anti-seize (PN 31273) grease to the following surfaces: drawbar threads, outside taper of TTS collet, inside taper of R8 spindle. Do not apply grease to the inside surface of the TTS collet.

3. Open the spindle door.

4. Swing the spindle locking fork so it engages with the flats on the top of the spindle. If necessary turn the spindle by hand until the flats line up.

5. Using one hand, insert the TTS collet into the bottom of the spindle. Twist the collet while applying light upward pressure until the collet groove aligns with the spindle alignment pin and the collet is pushed completely inside the spindle taper. With the other hand, insert the drawbar into the top of the spindle and rotate the drawbar several turns to engage several threads in the TTS collet.

6. To finish tightening the drawbar, place and hold a TTS tool holder inside the TTS collet and against the spindle nose. Use a 13 mm wrench to rotate the drawbar and tighten the collet against the TTS tool holder.

To change a TTS tool holder, loosen the drawbar by one turn with a 13 mm wrench. Then, grasp the tool holder in one hand and use a mallet to gently strike the top of the drawbar. Remove the tool holder and repeat steps 5 and 6 (above) to install a new tool holder.

Tips on Using Tormach Tooling System (TTS)

• Never tighten the TTS collet without a tool holder inserted

• Never change tools while a tool holder is in the spindle as this may damage the spindle alignment pin

• To minimize tool pull-out, periodically wipe tool holder shanks clean/dry with a degreasing agent

• When not in use, apply a protective spray (WD-40^® or similar) to prevent surface rust on bare metal surfaces of tool holders

• The drawbar and TTS collet are wear items. Inspect threads and mating surfaces regularly and replace if damage or wear is apparent as it reduces the ability to tighten tools properly

R8 collets and R8 taper tool holders are also compatible. These are installed in a similar manner to the TTS collet as described above, but must be removed completely during each tool change.

NOTE: The PCNC 1100 ships with a drawbar with 7/16”-20 UNF thread.

Part Setup/Workholding

Work must be secured to the table prior to machining. Each PCNC mill has three 5/8” T-slots that run parallel to the X-axis. The slots are precision ground to:

A 5” vise is recommended. Tormach offers the following vises:

For more information on proper setup and use of the 5” vises, refer to documentation that ships with product.

A number of other ways can be employed for workholding. These include toe clamps, fixture plates, chucks, and vacuum tables.

Looking for more information?

This is a section of the PCNC 770 operator's manual. To view the whole manual, go to Tormach document UM10350.

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.