tormach P 1100 User Manual
PCNC 1100 Manual
Part Number 30625
– Rev C
4
-1
Questions or comments?
Please email us at:
with Mach 3 Control
tech@tormach.com
©2006/07/08 Tormach® LLC. All rights reserved.
iiContents
Using Tormach PCNC 1100 ii 30625 Rev C4-1
Contents
1. Preface.............................................................................................1-1
1.1 Safety...............................................................................................................................1-1
1.1.1 Electrical Safety................................................................................................................1-1
1.1.2 General Operating Safety..................................................................................................1-1
1.1.3 Safety Publications...........................................................................................................1-2
1.1.4 Safety Precautions.............................................................................................................1-2
1.2 Personal CNC Concept...................................................................................................1-3
1.3 Performance Expectations..............................................................................................1-3
1.3.1 Cutting Ability..................................................................................................................1-3
1.3.2 Understanding Accuracy...................................................................................................1-4
1.3.3 Resolution, Accuracy and Repeatability of the PCNC........................................................1-4
1.4 Scope and Intellectual Property......................................................................................1-4
1.5 Nomenclature..................................................................................................................1-5
2. Preparation......................................................................................2-1
2.1 Planning for Your PCNC................................................................................................2-1
2.1.1 Electrical Connection........................................................................................................2-1
2.1.2 Location and Mounting.....................................................................................................2-1
2.1.3 Computer Mounting Arrangement.....................................................................................2-3
2.1.4 Learning and Training.......................................................................................................2-3
2.2 Receiving, Unpacking and Checking Shipment..............................................................2-4
2.2.1 Moving the Crate..............................................................................................................2-4
2.2.2 Uncrating and Inspection...................................................................................................2-4
2.3 Assembling Y-axis Drive.................................................................................................2-4
2.4 Mounting the PCNC.......................................................................................................2-5
2.4.1 Lifting onto Stand.............................................................................................................2-5
2.4.1.1 Lifting from Below................................................................................................2-5
2.4.1.2 Lifting from Above................................................................................................2-5
2.4.2 Fixing to Stand.................................................................................................................2-6
2.4.3 Accessories.......................................................................................................................2-7
2.5 Power to the PCNC.........................................................................................................2-7
2.6 Power for Machine Accessories......................................................................................2-7
2.7 Control Computer and Software Installation.................................................................2-7
2.7.1 Computer Specification.....................................................................................................2-7
2.7.2 Optimizing the Windows Installation.................................................................................2-8
2.7.3 Installing the Control Software..........................................................................................2-9
2.7.3.1 Installing................................................................................................................2-9
2.7.3.2 Vital Re-boot.........................................................................................................2-9
2.7.3.3 Testing the Installation.........................................................................................2-10
2.7.3.4 DriverTest After a Software Crash........................................................................2-11
2.7.3.5 Manual Driver Installation and Un-installation......................................................2-11
2.8 Running the PCNC.......................................................................................................2-11
2.8.1 Main Switch and Control Panel.......................................................................................2-12
2.8.2 Changing the Spindle Speed Range.................................................................................2-14
2.8.3 Computer Control of the Spindle and Coolant..................................................................2-14
2.8.4 MDI for Entering G- and M-code Commands..................................................................2-15
iiContents
2.8.5 Jogging the Axes.............................................................................................................2-16
2.9 Summary.......................................................................................................................2-16
3. Making Your First Part....................................................................3-1
3.1 Coordinates.....................................................................................................................3-1
3.1.1 Referencing the Machine...................................................................................................3-1
3.2 Loading a Demonstration Program................................................................................3-2
3.3 Running the Demonstration Part-program....................................................................3-3
3.3.1 Part Material.....................................................................................................................3-3
3.3.2 Setting Work Offsets.........................................................................................................3-3
3.3.3 Cutting in Air....................................................................................................................3-4
3.3.4 Cutting the Actual Part......................................................................................................3-4
3.3.5 Summary..........................................................................................................................3-6
4. Routes from an Idea to a Part........................................................4-1
4.1 Controlling the PCNC.....................................................................................................4-1
4.2 Choosing the Appropriate Design Software...................................................................4-2
4.3 Software for CAD/CAM.................................................................................................4-2
4.3.1 3D CAD...........................................................................................................................4-3
4.3.2 2D CAD...........................................................................................................................4-3
4.3.3 CAM................................................................................................................................4-4
4.3.4 Running the G-code..........................................................................................................4-6
4.3.5 CAD/CAM Systems..........................................................................................................4-6
4.4 Programming with Wizards...........................................................................................4-9
4.4.1 Machining Wizard Concept...............................................................................................4-9
4.4.1.1 Selecting and Running a Wizard.............................................................................4-9
4.4.1.2 Standard Wizard Features.......................................................................................4-9
4.4.1.3 G-code from a Wizard..........................................................................................4-10
4.4.1.4 Commercial Wizards............................................................................................4-10
5. Machine Controls............................................................................5-1
5.1 Machine Operation.........................................................................................................5-1
5.1.1 Operator’s Panel...............................................................................................................5-1
5.1.2 Tool Changing..................................................................................................................5-3
5.1.2.1 Tooling Strategy....................................................................................................5-3
5.1.2.2 Changing R8 Tools................................................................................................5-3
5.1.2.3 Changing TTS Tools..............................................................................................5-4
5.1.3 Spindle Speed Ranges.......................................................................................................5-5
5.2 Screen Control Panels.....................................................................................................5-5
5.2.1 Using the Screens.............................................................................................................5-5
5.2.2 Families of Related Controls.............................................................................................5-5
5.2.2.1 Screen Switching Controls.....................................................................................5-5
5.2.2.2 Axis Control Family...............................................................................................5-6
5.2.2.3 Jogging Control Family..........................................................................................5-7
5.2.2.4 Spindle Speed Control Family................................................................................5-8
5.2.2.5 Feed Control Family..............................................................................................5-9
5.2.2.6 Program Running Control Family.........................................................................5-10
5.2.2.7 Toolpath Control Family......................................................................................5-11
5.2.2.8 File Control Family..............................................................................................5-12
5.2.2.9 Work Offset and Tool Table Control Family.........................................................5-13
5.2.2.10 MDI and Teach Control Family............................................................................5-13
5.2.2.11 Loop Control Family............................................................................................5-13
5.2.2.12 Modes and Mode Alarm Control Family...............................................................5-14
Using Tormach PCNC 1100 ii 30625 Rev C4-1
Contents
5.2.2.13 Rotational Diameter Control Family.....................................................................5-14
5.2.2.14 Toolchange Position Control Family.....................................................................5-14
5.2.2.15 Inhibits and Overrides Control Family..................................................................5-15
5.2.2.16 Feeds and Speeds Calculator................................................................................5-15
5.2.2.17 Tapping Configuration Family..............................................................................5-15
5.2.2.18 Misc. Settings Control Family..............................................................................5-16
5.3 USB Jogging Pendants..................................................................................................5-16
5.3.1 Jog/Shuttle Controller.....................................................................................................5-17
5.3.2 Keypad Pendant..............................................................................................................5-17
6. Using Multiple Tools.......................................................................6-1
6.1 Offsets and Coordinate Systems.....................................................................................6-1
6.2 Measuring Techniques....................................................................................................6-2
6.2.1 “Roll-Your-Own” Gauge Method......................................................................................6-2
6.2.2 Roller Gauge Method........................................................................................................6-3
6.2.3 Adjustable Parallel Method...............................................................................................6-4
6.2.4 Comments on Accuracy....................................................................................................6-4
6.3 Setting Work Offsets.......................................................................................................6-5
6.3.1 Direct Entry to Axis DRO.................................................................................................6-5
6.3.2 Using the Touch Buttons...................................................................................................6-5
6.3.3 Setting X and Y Offsets....................................................................................................6-5
6.3.3.1 With a Probe..........................................................................................................6-6
6.3.3.2 Measuring Off an Edge..........................................................................................6-6
6.3.3.3 Laser Centering Techniques...................................................................................6-6
6.4 Tool Offsets.....................................................................................................................6-7
6.4.1 Tormach Tooling System..................................................................................................6-7
6.4.2 How Tool Offsets Work....................................................................................................6-7
6.4.3 Master Tool and Numbering Tools....................................................................................6-9
6.4.4 Using the Probe and Tool Setter......................................................................................6-10
6.4.5 Tool Length Offsets with TTS.........................................................................................6-10
6.4.6 Tool Length Offsets with General Tooling.......................................................................6-11
6.4.7 Comments on Tool Offsets..............................................................................................6-11
6.5 Multiple Work Origins.................................................................................................6-12
6.5.1 G54 Work Offset............................................................................................................6-12
6.5.2 Other Work Offsets.........................................................................................................6-12
6.6 Cutter Diameter Compensation....................................................................................6-12
6.6.1 CAD/CAM and Wizards.................................................................................................6-12
6.6.2 Control Software Compensation......................................................................................6-12
6.6.3 Two Kinds of Contour....................................................................................................6-13
6.6.3.1 Material Edge Contour.........................................................................................6-13
6.6.3.2 Toolpath Contour.................................................................................................6-14
7. Part-programming Language Reference.......................................7-1
7.1 Definitions.......................................................................................................................7-1
7.1.1 Control Software...............................................................................................................7-1
7.1.2 Linear Axes......................................................................................................................7-1
7.1.3 Rotational Axes................................................................................................................7-1
7.1.4 Scaling Input.....................................................................................................................7-1
7.1.5 Controlled Point................................................................................................................7-1
7.1.6 Coordinated Linear Motion...............................................................................................7-2
7.1.7 Feed Rate..........................................................................................................................7-2
7.1.8 Arc Motion.......................................................................................................................7-2
7.1.9 Coolant.............................................................................................................................7-3
7.1.10 Dwell................................................................................................................................7-3
7.1.11 Units.................................................................................................................................7-3
30635 Rev C4-1 iii Using Tormach PCNC 1100
ivContents
7.1.12 Current Position................................................................................................................7-3
7.1.13 Selected Plane...................................................................................................................7-3
7.1.14 Tool Table........................................................................................................................7-3
7.1.15 Path Control Modes..........................................................................................................7-3
7.2 Interpreter Interaction with Controls............................................................................7-4
7.2.1 Feed and Speed Override controls.....................................................................................7-4
7.2.2 Block Delete Control........................................................................................................7-4
7.2.3 Optional Program Stop Control.........................................................................................7-4
7.3 Tool File..........................................................................................................................7-4
7.4 Part-programs Language................................................................................................7-4
7.4.1 Overview..........................................................................................................................7-4
7.4.2 Parameters........................................................................................................................7-5
7.4.3 Coordinate Systems..........................................................................................................7-5
7.5 Formatting Code Lines (Block)......................................................................................7-5
7.5.1 Line Number.....................................................................................................................7-5
7.5.2 Subroutine Labels.............................................................................................................7-6
7.5.3 Word................................................................................................................................7-7
7.5.3.1 Number..................................................................................................................7-7
7.5.3.2 Parameter Value.....................................................................................................7-7
7.5.3.3 Expressions and Binary Operations........................................................................7-7
7.5.3.4 Unary Operation Value..........................................................................................7-8
7.5.4 Parameter Setting..............................................................................................................7-8
7.5.5 Comments and Messages..................................................................................................7-8
7.5.6 Item Repeats.....................................................................................................................7-9
7.5.7 Item Order........................................................................................................................7-9
7.5.8 Commands and Machine Modes........................................................................................7-9
7.6 Modal Groups...............................................................................................................7-10
7.7 G-codes..........................................................................................................................7-11
7.7.1 Rapid Linear Motion – G00.............................................................................................7-11
7.7.2 Linear Motion at Feed Rate – G01...................................................................................7-13
7.7.3 Arc at Feed Rate – G02 and G03.....................................................................................7-13
7.7.3.1 Radius Format Arc...............................................................................................7-13
7.7.3.2 Center Format Arc...............................................................................................7-14
7.7.4 Dwell – G04...................................................................................................................7-15
7.7.5 Coordinate System Data Tool and Work Offset Tables – G10..........................................7-15
7.7.6 Clockwise/Counterclockwise Circular Pocket – G12 and G13..........................................7-16
7.7.7 Exit and Enter Polar Mode – G15 and G16......................................................................7-16
7.7.8 Plane Selection – G17, G18 and G19...............................................................................7-16
7.7.9 Length Units – G20 and G21...........................................................................................7-17
7.7.10 Return to Home – G28 and G30......................................................................................7-17
7.7.11 Reference Axes – G28.1..................................................................................................7-17
7.7.12 Straight Probe – G31.......................................................................................................7-17
7.7.12.1 Straight Probe Command.....................................................................................7-17
7.7.12.2 Using the Straight Probe Command......................................................................7-18
7.7.12.3 Example Code......................................................................................................7-18
7.7.13 Cutter Radius Compensation – G40, G41 and G42..........................................................7-19
7.7.14 Tool Length Offsets – G43, G44 and G49.......................................................................7-19
7.7.15 Scale Factors – G50 and G51..........................................................................................7-20
7.7.16 Temporary Coordinate System Offset – G52...................................................................7-20
7.7.17 Move in Absolute Coordinates – G53..............................................................................7-20
7.7.18 Select Work Offset Coordinate System – G54 to G59 & G59 P~......................................7-21
7.7.19 Set Path Control Mode – G61 and G64............................................................................7-21
7.7.20 Coordinate system rotation – G68 and G69......................................................................7-21
7.7.21 Canned Cycle – High Speed Peck Drill – G73.................................................................7-21
7.7.22 Cancel Modal Motion – G80...........................................................................................7-22
7.7.23 Canned Cycles – G81 to G89..........................................................................................7-22
7.7.23.1 Preliminary and In-Between Motion.....................................................................7-23
Using Tormach PCNC 1100 iv 30625 Rev C4-1
Contents
7.7.23.2 G81 Cycle............................................................................................................7-23
7.7.23.3 G82 Cycle............................................................................................................7-24
7.7.23.4 G83 Cycle............................................................................................................7-24
7.7.23.5 G85 Cycle............................................................................................................7-25
7.7.23.6 G86 Cycle............................................................................................................7-25
7.7.23.7 G88 Cycle............................................................................................................7-25
7.7.23.8 G89 Cycle............................................................................................................7-25
7.7.24 Distance Mode – G90 and G91........................................................................................7-26
7.7.25 G92 Offsets – G92, G92.1, G92.2 and G92.3...................................................................7-26
7.7.26 Feed Rate Mode – G93, G94 and G95.............................................................................7-27
7.7.27 Canned Cycle Return Level – G98 and G99....................................................................7-27
7.8 Built-in M-codes...........................................................................................................7-27
7.8.1 Program Stopping and Ending – M0, M1, M2 and M30...................................................7-27
7.8.2 Spindle Control – M3, M4 and M5..................................................................................7-28
7.8.3 Tool change – M6...........................................................................................................7-29
7.8.4 Coolant Control – M7, M8 and M9.................................................................................7-29
7.8.5 Re-run from First Line – M47.........................................................................................7-29
7.8.6 Override Control – M48 and M49...................................................................................7-29
7.8.7 Call Subroutine – M98....................................................................................................7-29
7.8.8 Return from Subroutine – M99........................................................................................7-30
7.9 Application Defined M-codes........................................................................................7-30
7.9.1 Self-reversing Tapping Cycles.........................................................................................7-30
7.9.2 Goto Toolchange Position – M998..................................................................................7-30
7.9.3 User Defined M-codes....................................................................................................7-30
7.10 Other Input Codes........................................................................................................7-31
7.10.1 Feed Rate – F..................................................................................................................7-31
7.10.2 Spindle Speed – S...........................................................................................................7-31
7.10.3 Select Tool – T...............................................................................................................7-31
7.11 Order of Execution.......................................................................................................7-31
7.12 Error Handling.............................................................................................................7-31
8. Machine Upgrades and Configuration...........................................8-1
8.1 Fourth Axis – Rotary Table............................................................................................8-1
8.1.1 Installing the Electronics...................................................................................................8-1
8.1.2 Utilizing the Fourth Axis...................................................................................................8-1
8.1.2.1 Referencing and Zeroing the Fourth Axis...............................................................8-1
8.1.2.2 Diameter Compensation Feature.............................................................................8-1
8.1.3 Fourth Axis Applications..................................................................................................8-1
8.1.3.1 Engraving on a Periphery of a Cylinder..................................................................8-2
8.1.3.2 Gear Cutting..........................................................................................................8-2
8.2 Digitizer Probes...............................................................................................................8-3
8.2.1 Introduction to Uses of Probes and Tool Setters.................................................................8-3
8.2.2 Probing for Work/Tool Setting..........................................................................................8-4
8.2.2.1 Simple X/Y Probing...............................................................................................8-5
8.2.2.2 Z Probing...............................................................................................................8-7
8.2.2.3 Comprehensive X/Y Probing..................................................................................8-8
8.2.2.4 Probe Calibration.................................................................................................8-11
8.2.3 Digitizing parts from a model or for reverse engineering..................................................8-12
8.2.4 The Probe Electrical Interface.........................................................................................8-12
8.3 Auto-reverse tapping....................................................................................................8-13
9. Warranty, Specifications, Customization and Troubleshooting.9-1
9.1 Intended Use Statement..................................................................................................9-1
30635 Rev C4-1 v Using Tormach PCNC 1100
viContents
9.2 Support............................................................................................................................9-1
• This manual – ALWAYS the first place to check!! .................................................9-1
• Related documents found at: http://www.tormach.com/documents.htm...................9-1
• Our website at: www.tormach.com.........................................................................9-1
• Email to: info@tormach.com..................................................................................9-1
• Telephone Tormach at: 608-849-8381....................................................................9-1
• Fax Tormach at: 209-885-4534...............................................................................9-1
9.3 Outside of the Scope of Intended Use.............................................................................9-1
9.4 Specifications...................................................................................................................9-2
9.4.1 Mechanical.......................................................................................................................9-2
9.4.2 Electrical..........................................................................................................................9-2
9.4.3 System..............................................................................................................................9-3
9.4.4 Options.............................................................................................................................9-3
9.5 Maintenance....................................................................................................................9-3
9.5.1 Foreword – Understanding Machine Design......................................................................9-3
9.5.1.1 Machine Stiffness...................................................................................................9-3
9.5.1.2 Backlash, Friction, and Lost Motion.......................................................................9-4
9.5.1.3 Factors Combine....................................................................................................9-4
9.5.1.4 Adjusting Geometry...............................................................................................9-4
9.5.1.5 Achieving Accuracy in Machining..........................................................................9-5
9.5.2 Protecting from Rust.........................................................................................................9-5
9.5.3 Gibs and Dovetail Slideways.............................................................................................9-5
9.5.4 Way Covers......................................................................................................................9-6
9.5.5 Axis Adjustment...............................................................................................................9-6
9.5.6 Adjusting Ballscrew Preload.............................................................................................9-7
9.5.6.1 Understanding Preloaded Angular Contact Bearings...............................................9-8
9.5.6.2 Making the Adjustment..........................................................................................9-8
9.5.7 Adjusting Mating Surfaces..............................................................................................9-10
9.5.8 Speed Calibration............................................................................................................9-10
9.5.9 Using a Non-standard Printer Port...................................................................................9-12
9.5.10 Defining Your Own Sizes for Step-mode Jogging............................................................9-14
9.5.11 Configuring to start in Metric units..................................................................................9-14
9.6 Troubleshooting............................................................................................................9-14
9.6.1 Overview........................................................................................................................9-14
9.6.2 Philosophy of Troubleshooting........................................................................................9-15
9.6.3 Tips and Tools for Troubleshooting (Equipment and Procedures).....................................9-17
9.6.3.1 Safety..................................................................................................................9-17
9.6.3.2 Tip on Computer Diagnostics...............................................................................9-17
9.6.3.3 Tools...................................................................................................................9-18
9.6.3.4 Using the digital multi meter for electrical tests....................................................9-18
9.6.3.5 Contacting Technical Support...............................................................................9-19
9.6.4 Frequently Found Problems (Repeat Offenders)..............................................................9-19
9.6.4.1 Loose Wires.........................................................................................................9-19
9.6.4.2 Wire Hairs...........................................................................................................9-20
9.6.4.3 Poor Cable Connections.......................................................................................9-20
9.6.4.4 Software Restart...................................................................................................9-20
9.6.4.5 Sensors (on the PCNC1100 the End of Travel Sensors).........................................9-20
9.6.4.6 Flaky Computer...................................................................................................9-20
9.6.4.7 Control Software license not installed...................................................................9-20
9.6.4.8 Unexplained stop or limit switch error while running............................................9-20
9.6.5 Which sub-system should I troubleshoot..........................................................................9-21
9.6.5.1 Power Distribution Sub-system............................................................................9-22
9.6.5.2 Control Power Sub-system...................................................................................9-25
9.6.5.3 Computer Control Communication Sub-Section....................................................9-28
9.6.5.4 Axes Drive Sub-system........................................................................................9-30
9.6.5.5 Spindle Drive Sub-system....................................................................................9-42
9.7 Mechanical maintenance...............................................................................................9-48
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9.8 Electrical maintenance..................................................................................................9-49
9.9 Preparation for Transport............................................................................................9-50
9.10 Disassembly for Transport...........................................................................................9-50
10. Appendices....................................................................................10-1
10.1 Appendix 1 – Not Used..................................................................................................10-1
10.2 Appendix 2 – Exploded Parts Views.............................................................................10-1
10.3 Appendix 3 – Optimization of Windows XP...............................................................10-11
10.3.1 Remove Unnecessary Services and Startup Programs....................................................10-11
10.3.2 Disable Power Management..........................................................................................10-12
10.3.3 Disable Automatic Updates...........................................................................................10-12
10.3.4 Set Computer to Standard PC not ACPI PC...................................................................10-12
10.4 Revision history...........................................................................................................10-13
11. Index..................................................................................................15
30635 Rev C4-1 vii Using Tormach PCNC 1100
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.
Preface
The PCNC 1100 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 supply 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 (i.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
dangerous 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.
30635 Rev C4-1 1-1 Using Tormach PCNC 1100
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
1.1.4
Safety Publications
Tormach recommends the following publications for assistance in enhancing the safe use of
this machine.
• Safety Requirements for The Construction, Care and Use of Drilling, Milling and
Boring Machines (ANSI B11.8-1983). Available from The American National
Standards Institute, 1430 Broadway, New York, New York 10018.
• 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.
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. Avoid moving parts. Before operating this machine remove all jewellery including watches
and rings, neckties and any loose-fitting clothing.
4. Keep your hair away from moving parts.
5. Take off gloves before you operate the machine. Gloves are easily caught in moving parts
or cutting tools.
6. Never operate with unbalanced tooling or spindle fixtures.
7. Remove all tools (wrenches, chuck keys, etc.) from the spindle and machine surface before
you begin. Loose items can become dangerous flying projectiles.
8. Use adequate work clamping. Do not allow your work piece to become a projectile.
9. Never operate a milling machine after consuming alcoholic beverages or taking strong
medication.
10. Protect your hands. Stop the machine spindle and ensure that the computer control is
stopped before you:
• Change tools;
• Change parts or adjust the work piece;
• Change the belt/pulley position;
• Clear away chips, oil or coolant – always use a chip scraper or brush;
• Make an adjustment to the part, fixture, coolant nozzle or take measurements;
• Remove protective shields or safeguards – do not reach for the part, tool or fixture
around a guard.
11. Keep work area well lit. Ask for additional light if needed.
12. 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 1-2 30625 Rev C4-1
13. Avoid getting pinched in places where the table, saddle or spindle head create “pinch
points” while in motion.
14. 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.
15. Always use proper feeds and speeds, as well as depth and width of cut, to prevent tool
breakage.
16. Use proper cutting tools for the job.
17. Do not use dull or damaged cutting tools. They break easily and become dangerous
projectiles. Never use longer or larger tools than necessary.
18. 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.
19. 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.
20. 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 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.
Preface
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 & 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 creation.
The PCNC 1100 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 1/2" diameter 2
flute cutter at around 18 IPM (inches per minute) and 3000 RPM, using a full 1/2" 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 3/8". The example above, using a 1/2" cutter, results in a
surface speed of 390 SFM (surface feed per minute), a 3/8" 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
1100 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
1
/2" end mill, the surface speed calculation indicates 230 RPM, but that is below the minimum
spindle speed of the PCNC 1100. By switching to a 1/4" end mill the recommended spindle
speed becomes 460 RPM, well within the capability of the PCNC 1100. By keeping close to
general machining recommendations your tools will last longer and you will have a better cut.
30635 Rev C4-1 1-3 Using Tormach PCNC 1100
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 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 give enough details about how to install, setup and use your
PCNC 1100. 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 assumes familiarity with using 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. 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 1100. 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 made to make this manual as complete and as accurate as possible but no
warranty or fitness is implied. The information provided is on an “as is” basis. The authors and
publisher shall have neither liability nor responsibility to any person or entity with respect to
any loss or damages arising from the information contained in this manual.
Windows XP and Windows Vista 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.
Using Tormach PCNC 1100 1-4 30625 Rev C4-1
1.5 Nomenclature
This manual uses the following typographical nomenclature:
Software control
Refers to a Control Software “soft” control. (i.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 (e.g., G01X34.8)
Used to show G-code programs.
Key name (e.g., Enter)
Tells you to press the indicated key.
Preface
30635 Rev C4-1 1-5 Using Tormach PCNC 1100
2. Preparation
This chapter 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
2.1 Planning for Your PCNC
2.1.1 Electrical Connection
The PCNC 1100 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.
Preparation
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.
2.1.2 Location and Mounting
People experienced with CNC machining will undoubtedly have ideas as to how they want to
setup their PCNC 1100 (figure 2.1). While the machine can be configured in many different
ways, there are a few limitations. Many fully 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
Figure 2.1 – An example mounting on stand
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Preparation
a dimensional outline. With manual milling many people are accustom to dry cutting, clearing
chips with a small brush as they go.
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 tools 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 aspects of safety: setup,
location, operation, security and all other factors that involve safety.
The PCNC 1100 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 82" 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
5
4
USB jogging
pendant
3
LCD
Screen
Keyboard
6
2
1
Personal
computer
Personal
computer
Figure 2.2 – Computer and display
Using Tormach PCNC 1100 2-2 30625 Rev C4-1
Preparation
to avoid errors when doing tool changes during a job.
2.1.3 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 (10FT USB 2.0 A to A Male/Female Extension Cable).
3. USB multimedia mini-keyboard with integral 2-port USB hub. 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. It also has two USB ports. These can
be used for a USB mouse, USB flash drive or one of the PCNC jogging pendants. The
keyboard is not sealed against coolant or chips. This is Tormach PN 30284 (Mini Media
USB Keyboard w/hub).
4. A Tormach USB jogging pendent is a very useful accessory for jogging, manual operations
and machine setup. Two options are available: 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 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 (10FT 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.
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 you local voltage.
2.1.4 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.
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 for
areas of CAD/CAM/CNC which are new to you. Tormach sales can help point you in
appropriate directions.
30635 Rev C4-1 2-3 Using Tormach PCNC 1100
Preparation
2.2 Receiving, Unpacking and Checking Shipment
2.2.1 Moving the Crate
The PCNC 1100 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 lbs (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.
Figure 2.3 – Crated machine as delivered
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 to
remove the machine from its pallet.
• Un-strap the stepper motor from its
transit position (figure 2.5).
• Remove the sheet steel cover from the
Y-axis drive coupling box (at base of
column behind the machine).
• 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).
Figure 2.4 – Un-crated machine on pallet
Figure 2.5 – Y-axis motor as shipped and
mounting flange
• 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 ¼ turn so the motor is
free to self align.
Using Tormach PCNC 1100 2-4 30625 Rev C4-1
Preparation
• 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 (i.e., outside face) of
an old auto engine timing belt or polyvee 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 the
alignment of the coupling.
• A final check of alignment should be
made when the machine is under
computer control. This involves
Figure 2.6 – coupling the Y drive motor
loosening the motor retaining screws ¼
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.
2.4 Mounting the PCNC
2.4.1 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 to1000
lbs 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.
2.4.1.1 Lifting from Below
The base of the machine has four 7/8" 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 lift the machine. These should be solid
steel bars, not pipes and be ¾" or
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).
7
/
" in diameter.
8
Figure 2.7 – Hoist bar for slinging the
mill
30635 Rev C4-1 2-5 Using Tormach PCNC 1100
Preparation
toothed belt
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 1100.
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 and 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 ½"
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
machine accuracy. Despite the
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
needed, such that the left/right tram is within your desired tolerance. Something like 0.002” is
usually all that is 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 lb machine is placed on it. Be aware that welded steel stands are neither stress
relieved 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”.
Figure 2.8 – Slinging geometry
Figure 2.9 – Manual moving table by back of old
Using Tormach PCNC 1100 2-6 30625 Rev C4-1
Preparation
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.
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 Accessories
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
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.
Figure 2.11 – Power and interface connectors
2.7 Control Computer and Software Installation
2.7.1 Computer Specification
You need to provide a computer running Microsoft Windows XP (Home or Professional
edition). Consult Tormach LLC for information on use of the PCNC with Windows Vista.
The system does not require a particularly powerful computer but there are certain requirements
for optimal operation. You should have:
• A CPU 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.
• Most laptop computers are unsuitable and any which can 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
30635 Rev C4-1 2-7 Using Tormach PCNC 1100
Preparation
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 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” 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 and
run them 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. This will make it easy to plug in the pointing
device (mouse/track-ball), a pendant and a USB flash drive.
• If you choose to use a mouse or trackball then, you should get the “optical” kind. Mouse
balls and workshop conditions do not mix well.
2.7.2 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 subsystem. This can sometimes interfere with timing of movement of PCNC and lead to spoiled
work.
The simplest advice is:
• 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.
• 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.
• Do not install other software packages on the computer. If you wish the control
computer to be dual purpose then we advise 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.
Using Tormach PCNC 1100 2-8 30625 Rev C4-1
Appendix 3 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).
2.7.3 Installing the Control Software
2.7.3.1 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>Details from the menu. Double-click on the file Install.BAT to run it. You will 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.
Preparation
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.
2.7.3.2 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.
Figure 2.12 – The DriverTest program display
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 able 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
30635 Rev C4-1 2-9 Using Tormach PCNC 1100
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 is first installed. Windows XP
boots reasonably quickly that it is not much hardship to do it every time.
2.7.3.3 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 (qtask.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.
Preparation
Because of these factors, it is 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 click the file
DriverTest or if you display file extensions DriverTest.exe (figure 2.12).
You can ignore all the boxes with the exception of the Pulse Frequency. It should be fairly
steady around 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 pulse 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 2.12, 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 3/8" 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.
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 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
Using Tormach PCNC 1100 2-10 30625 Rev C4-1
Preparation
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 i8529 interrupt controller. To display the DOS window enter
CMD as the program after Start Button>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.
2.7.3.4 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 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.
2.7.3.5 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.
• Open the Windows Control Panel and double-click on the icon or line for System.
• 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).
• Tell the wizard you have already installed it and then proceed to the next screen.
• 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.
• 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).
• The list you are shown will include an entry for Mach x pulsing engine. Select this and
go to the next screen.
• 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. Windows will install the driver.
The driver can be uninstalled rather more simply.
• Open the Control panel and double-click on the icon or line for System.
• Select Hardware and click Device Manager.
• 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.
2.8 Running the PCNC
You have now completed the installation and merely need to connect the PCNC to the
computer.
Now close down Windows and switch off the PC. Connect the parallel port of the computer 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
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immunity to electrical noise, which is important to reliable operation. Do not use inferior
cables. Power the computer 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).
2.8.1 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
Switch the main switch ON and switch the computer power on at the PCNC control panel
(figure 2.13).
Preparation
Figure 2.13 – Control panel layout
If your computer does not power up when power is applied to the cord you will have to press
the computer’s power-on button. Restart the computer and use the desktop shortcut (PCNCM3) to run the Control
Program (figure 2.14).
This will allow you to
perform all the important
functions on the standard
machine. If you have the 4th
axis or want to use G-code
features like Optional Stop
then you may wish to use the
Comprehensive Run screen
(figure 2.15). In this case
click the Comp Run button to
change the display.
The screen “Light Emitting
Diodes” (LEDs in this
manual) by the Reset button
will be flashing as will the
Using Tormach PCNC 1100 2-12 30625 Rev C4-1
Figure 2.14 – Simple main screen
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 button has been pressed the
start button is inoperative until the stop button is
released.
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 the correct indication but you will have to find the fault
before you can move the PCNC axes under computer control.
Preparation
Figure 2.15 – Comprehensive Run screen
Spindle
Coolant
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.
Switch to Manual 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 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.
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Preparation
Accessory Socket
The Accessory socket is for connection of accessories such as a touch probe. See Chapter 8 for
details of the interface.
2.8.2 Changing the Spindle Speed Range
The PCNC has two speed ranges.
The low range, 350 to 1750 RPM, is
suitable for most machining
operations with ferrous and other
tough materials. The high range, 900
to 4500 RPM is suitable for small
diameter cutters, plastics and nonferrous 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 the 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 of pulleys to the other (figure 2.16).
Figure 2.16 – Changing spindle pulleys
For the following tests, select the low speed range by placing
the belt on the lower pair of pulleys). Retighten the belt so
there is between 1/8" and ¼" movement between the pulleys,
lock the motor mounting and stow the handles in the vertical
position.
2.8.3 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 2.14. The portion shown in figure
2.17 shows the controls for the spindle.
Use the mouse to click the Hi/Lo button. You will see that the
screen LEDs depicting the pulleys will change and the
appropriate maximum speed will be displayed below them.
Choose the Low setting to correspond to the PCNC pulleys.
Note: Just after starting the system the screen LEDs may not
correspond to the indicated maximum speed. The speed value
is always correct and a click on the Hi/Lo button will bring the
LEDs into step.
Next to the label S, is a digital read-out (DRO) of the
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 2.18 shows the
Figure 2.17 – Spindle controls
Figure 2.18 – Setting S word
Using Tormach PCNC 1100 2-14 30625 Rev C4-1
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