Install the 1100M/770M Automatic Tool Changer

Please read this section before you begin installing your Automatic Tool Changer (ATC).

  • Power Drawbar Install the Power Drawbar on your machine before installing the ATC. If you have a Power Drawbar button, don't install it: the button's functionality is replaced by the ATC.
  • PathPilot You must update your controller to the latest version of PathPilot before installing and operating the ATC. If you don't, there's a risk that the ATC could become inoperable. Follow the instructions detailed in Before You Begin.

Before You Begin

Required Tools

  • 1-1/2 in. adjustable wrench
  • Marker
  • Metric hex wrench set
  • Phillips screwdriver
  • Small, flat-head screwdriver
  • Snips
  • Socket wrench and a 13 mm socket

Air Requirements

  • Air Pressure Between 90 psi and 120 psi (620 kPa to 825 kPa).

    If the air supply is more than 120 psi (825 kPa), you must use a regulator.

  • Dry Air We recommend using a compressed air dryer, desiccator, or filter between the air compressor and the machine.

  • Lubricated Air You must lubricate the air with air tool oil.

    Use the FRL Filter-Regulator-Lubricator (PN 32457) or similar for this purpose.

Disassemble the Power Drawbar Button

  1. Depending on your machine's setup, do one of the following:
    • If you're installing an Automatic Tool Changer (ATC) on a new machine, skip this procedure and go to Install the Air Cylinder.
    • If you previously installed the Power Drawbar button assembly, you must first disassemble it. Go to Step 2.
  2. Disconnect the shop air supply from the machine.
  3. Disconnect all air lines from the Power Drawbar button.
  4. Remove four M5 × 0.8 - 10 mm button head cap screws that secure the Power Drawbar button cover.
  5. Remove two M4 × 0.7 - 50 mm socket head cap screws that secure the Power Drawbar button to the spindle head.
  6. Remove the Power Drawbar button from the spindle head.

Install the Air Cylinder

  1. Attach the air cylinder on to the ATC main assembly.

    Putting the air cylinder into the ATC main assembly.

  2. Secure the air cylinder to the ATC main assembly with a 12 mm hex wrench (provided) and two M14 × 20 mm socket head cap screws.

    Putting the air cylinder hardware into the air cylinder.

  3. Connect the air lines from the ATC main assembly to the air cylinder as follows:
    • Connect the short air line to the front of the cylinder.
    • Connect the long air line to the back of the cylinder.

Mount the Automatic Tool Changer Bracket

  1. Identify the four provided standoffs that are used to mount the ATC to the Z-column:
    • Three fixed standoffs
    • One tilt standoff
  2. Remove the flange nuts and the washers from the standoffs, and then set them aside.
  3. Identify and remove the four set screws on the Z-column with a flat-blade screwdriver.

  4. Install the four standoffs on the Z-column as shown in the following image.

    Four standoffs installed on the Z-column.

  5. Securely tighten the standoffs on the Z-column with a 1-1/2 in. adjustable wrench.

  6. Put the ATC mounting bracket on the standoff's threaded studs as shown in the following image.

    ATC mounting bracket moving on to the four standoffs.

    Verify that the tilt standoff's eccentric cam fits into the large slot on the ATC mounting bracket.

  7. Secure the bracket by reinstalling the washers and flange nuts that you removed in Step 2 with a 13 mm socket.

  8. Pull the bracket toward the front of the machine. You'll make adjustments to the location of the bracket later in this procedure, but we recommend starting with it moved forward.

Install the Main Assembly

  1. Remove the four preinstalled M8 × 1.25 - 16 mm socket head cap screws and washers from the bottom of the ATC electrical cabinet. Then, set all aside for later use.

    Team Lift Required: You must have the aid of more than one person to lift and move the object. The object is heavy, and lifting it by yourself can cause serious injury.

  2. Lift the ATC main assembly on to the mounting bracket.

    ATC main assembly positioned above the mounting bracket.

  3. Align the locating pin on the ATC main assembly with the matching hole in the mounting bracket.
  4. Secure the ATC main assembly to the mounting bracket with the four M8 × 1.25 - 16 mm socket head cap screws and washers that you set aside in Step 1.

Level the ATC

Prepare the Machine

  1. Push the tool tray toward the spindle.

    Tool tray moved in toward the spindle.

  2. Verify that the linear bearing on the ATC is flush with the ATC main assembly.

    Linear bearing flush with the ATC main assembly.

  3. Find a straight rod between 8 in. and 12 in. (203 mm and 305 mm) long. Verify that it's straight: roll it on a known flat surface (like a granite surface plate).

    You'll use the rod to verify that the ATC is correctly installed on the mill, so it must be straight.

  4. Put the alignment rod into a tool holder.

  5. Put the tool holder into the fork so that the groove in the tool holder slides into the fork. Don't rest the tool holder on top of the fork.

    Groove on a Tormach Tooling System (TTS) aligned with the shoulder of an ATC fork.

  6. Put a machinist's square on the machine table.

Examine Perpendicularity in the Y Direction

  1. Verify that the rod is perpendicular to the machine table in the Y direction: compare the rod's position to the vertical edge of the machinist's square.
  2. Loosen the flange nuts on the standoffs.

  3. Turn the tilt standoff with an adjustable wrench, and slowly pivot the ATC until the rod is perpendicular to the vertical edge of the machinist's square.

    Tilt standoff.

  4. Tighten the flange nuts with a 13 mm socket.
  5. Reexamine the alignment of the ATC in the Y direction. If the rod isn't perpendicular to the vertical edge of the machinist's square, repeat Steps 2 through 5.

Examine Perpendicularity in the X Direction

  1. Verify that the rod is perpendicular to the machine table in the X direction: compare the rod's position to the vertical edge of the machinist's square.

  2. Loosen the two socket head cap screws on the linear rails.

    Socket head cap screws on the linear rails.

  3. Slowly pivot the linear rails up or down until the rod is perpendicular to the vertical edge of the machinist's square.
  4. Tighten the socket head cap screws.
  5. Reexamine the alignment of the ATC in the X direction. If the rod isn't perpendicular to the vertical edge of the machinist's square, repeat Steps 2 through 5.

Examine the Alignment of the Carousel Door Opening

  1. Remove the tool holder from the fork, and set it aside.

    You'll need this tool later in the installation procedure to make further alignments.

  2. Power on the machine and the PathPilot controller.

    1. Insert the power plug(s) into the wall outlet. If your system is hardwired, restore power to the circuit breaker(s).
    2. Turn the PathPilot controller strip to ON.
    3. Turn the Main Disconnect switch to ON on the side of the electrical cabinet.
    4. Twist out the machine's red Emergency Stop button, which enables movement to the machine axes and the spindle.
    5. Press the StartReset button.
    6. Bring the machine out of reset and reference it.
  3. Verify that the ATC is all the way forward (toward the spindle), and then slowly move the Z-axis down (-Z) to examine the clearance of the carousel door opening.
  4. Verify that the carousel door opening is approximately equal to the front back and left of the spindle mounting flange:

    • If the carousel door opening is approximately equal, go to Step 8.

      Distance between the carousel door opening and the spindle mounting flange.

    • If the carousel door opening must be adjusted, go to Step 5.

  5. Loosen the four socket head cap screws that secure the ATC main assembly to the mounting bracket with a 6 mm hex wrench.

    Socket head cap screws securing the ATC main assembly to the mounting bracket.

  6. Adjust the carousel door opening as required:
    • If the Carousel Door Opening is Contacting the Front Pivot the ATC around the locating pin on the bottom of the mounting bracket toward the front of the machine (closer to you).
    • If the Carousel Door Opening is Contacting the Back Pivot the ATC around the locating pin on the bottom of the mounting bracket toward the back of the machine (closer to the machine column).

    • If the Carousel Door Opening is Contacting the Left Loosen the four flange nuts that attach the mounting bracket to the column to move the bracket forward or backward.

      Moving the ATC mounting bracket could change the position of the tilt standoff (on the Z-column). If you move it, you must verify that the ATC is still correctly installed; go to Install the 1100M/770M Automatic Tool Changer.

      Repeat this step as needed.

  7. Tighten the socket head cap screws and the flange nuts (if you loosened them in Step 5).
  8. Move the tool tray to its retracted position.
  9. Center the machine table: from the PathPilot interface, in the MDI Line DRO field, type G20 G53 G1 X9 Y-5.5 Z0 F20G20 G53 G1 X7 Y-3.75 Z0 F20G20 G53 G1 X5 Y-3.125 Z0 F20G20 G53 G1 X9 Y-4.75 Z0 F20. Then select the Enter key.

  10. Power off the machine and the PathPilot controller.

    1. Push in the machine's red Emergency Stop button, which removes power to motion control.
    2. From the PathPilot interface, select Exit.
    3. Turn the Main Disconnect switch to OFF on the side of the electrical cabinet.
    4. Remove the power plug(s) from the wall outlet. If your system is hardwired, isolate the machine by opening its circuit breaker(s).
    5. Follow correct lockout/tagout procedures.

Make Air Connections

  1. Cut the cable tie that secures the ATC cables and plastic tubes together with snips.

  2. Route the loose ends of the two 1/4 in. plastic tubes connected to the ATC main assembly through the enclosure knockout, up the energy chain, and toward the Power Drawbar.

    Crush Hazard: If the ATC isn't completely retracted, it could move once the air is reconnected. When you reconnect the air, you must keep your hands away from the ATC.

  3. Connect the loose ends of the 1/4 in. plastic tubes in the following order:
    1. Connect the Retract (PDB Bottom) airline to the bottom push-to-connect elbow on the Power Drawbar.
    2. Connect the Advance (PDB Top) airline to the top push-to-connect elbow on the Power Drawbar

    3. Connect the air supply line from the FRL to the air in port in the ATC main assembly, as shown in the following image.

      Air in port in the ATC main assembly.

    4. If you haven't already done so, connect your shop's air supply to the FRL.

Make Electrical Connections

  1. Route the ATC power cable and the USB cable toward the rear of the machine and out of one of the enclosure knockouts.
  2. Put the USB cable in the access hole in the rear of the stand toward the controller.
  3. Put the USB cable into any open USB port on the PathPilot controller.
  4. Connect the ATC power cable to the ATC Power connector on the side of the electrical cabinet (below the Enclosure Lights Power connectors).

Verify the Installation

  1. Power on the machine and the PathPilot controller.

    1. Insert the power plug(s) into the wall outlet. If your system is hardwired, restore power to the circuit breaker(s).
    2. Turn the PathPilot controller strip to ON.
    3. Turn the Main Disconnect switch to ON on the side of the electrical cabinet.
    4. Twist out the machine's red Emergency Stop button, which enables movement to the machine axes and the spindle.
    5. Press the StartReset button.
    6. Bring the machine out of reset and reference it.

    You must update your controller to the latest version of PathPilot before operating the Automatic Tool Changer. If you don't, there's a risk that the ATC could become inoperable.

  2. If you have not yet done so, you must make sure that the PathPilot controller is updated to the latest version of PathPilot: From the Status tab, select Update. Then, follow the on-screen instructions.

  3. From the PathPilot interface, on the Settings tab, select the ATC radio button.

    ATC radio button on the Settings tab.

    The ATC tab appears in the PathPilot interface.

    If prompted, you may need to update the firmware for the ATC. Follow the on-screen instructions.

  4. Load a tool into the spindle:

    1. Push and hold the colletdrawbar open button on the side of the ATC.

      Collet Drawbar open button on the side of the ATC.

      The colletdrawbar opens.

    2. Load a tool into the spindle.

    3. Release the button.

      The colletdrawbar closes.

  5. From the PathPilot interface, on the Main tab, in the RPM DRO field, type 1000. Then select the Enter key.

  6. Select FWD.

    The spindle starts.

  7. From the Status tab, make sure that the VFD Running green light comes on.

    VFD Running light on the Status tab.

    If the VFD Running light did not come on in the previous step, we can help. Email support@tormach.com to contact Tormach Technical Support for guidance on how to proceed.

  8. Select Stop.

    The spindle stops.

Adjust the Power Drawbar

After the initial installation, you must complete a final drawbar tension adjustment. For more information, see Adjust the Drawbar Tension. If you don't complete a drawbar tension adjustment, there's a risk of tool pull-out.

Adjust the Drawbar Tension

This adjustment sets the highest possible drawbar tension while still allowing the Power Drawbar cylinder to release the tool. For information, seeAbout Drawbar Tension.

After the initial installation, you must examine the drawbar tension weekly. During periods of heavy use, examine the drawbar tension more frequently. If you don't, there's a risk of tool pull-out.

To adjust the drawbar tension:

  1. Put an empty Tormach Tooling System (TTS) tool holder into the collet.
  2. While using one hand to support the tool holder, use the other to push the Release Tool button.
  3. Depending on whether the tool holder releases or not, do one of the following:
    • If the Tool Holder Releases Tighten the Power Drawbar in quarter-turn increments with two adjustable wrenches. After each turn, push the Release Tool button. Stop when the tool holder does not release. Then, loosen the Power Drawbar one quarter-turn with two adjustable wrenches.
    • If the Tool Holder Doesn't Release Loosen the Power Drawbar in quarter-turn increments with two adjustable wrenches while pushing the Release Tool button. Stop when the tool holder releases.
  4. Make a visual reference to help you set or adjust the drawbar tension in the future: use a paint pen to make a witness mark on both the head of the drawbar and the end of the spindle.

About Drawbar Tension

While machining, the Tormach Tooling System (TTS) collet holds a Tormach Tooling System (TTS) tool holder in the spindle by applying a clamping force to both the shank and the shoulder of the tool. The tension force that is applied to the drawbar pulls the Tormach Tooling System (TTS) collet into the spindle taper, which then applies the clamping force to the Tormach Tooling System (TTS) tool.

The force on the drawbar — known as drawbar tension — is applied differently depending on the tool changing method:

  • Automatic (using the Power Drawbar) Tension is applied by the compressed spring washers.
  • Manual Tension is applied when you tighten the drawbar into the collet using a wrench.

Adjust the Initial Setup

In this adjustment, you'll verify that there's enough clearance between the end of the drawbar and the Power Drawbar cylinder.

If you don't do this adjustment, there's a risk that the drawbar can loosen, or that operations can be louder than normal.

  1. Examine the space between the hex head screw on the Power Drawbar cylinder's rod and the top of the drawbar.

    Correctly spaced drawbar and Power Drawbar cylinder.

  2. Verify that the gap is between 3/64 in. and 1/8 in. (1 mm and 3 mm). Depending on the size of the gap, do one of the following:
    • Between 3/64 in. and 1/8 in. (1 mm and 3 mm) You have completed adjusting the initial setup. Go to Operation.
    • Less Than 3/64 in. (1 mm) Go to Step 3.
  3. Disconnect the shop's air supply from the Power Drawbar button.
  4. Pull out the quick-release pin.

  5. Pivot the Power Drawbar cylinder assembly to the left so that you can access the Power Drawbar cylinder's rod.

    Power Drawbar cylinder pivoted to the left.

  6. Remove the hex head screw on the Power Drawbar cylinder’s rod with an adjustable wrench, and set it aside.

    Hex head screw on the Power Drawbar cylinder's rod.

  7. Remove the M16 washer from the Power Drawbar cylinder’s rod, and set it aside.

    M16 washer removed from the Power Drawbar cylinder's rod.

  8. Put the hex head screw back in, and then tighten it completely with an adjustable wrench.
  9. Pivot the Power Drawbar cylinder to the original location.
  10. Push in the quick-release pin.
  11. Reconnect the shop's air supply to the Power Drawbar button.
  12. Examine the space between the hex head screw on the Power Drawbar cylinder’s rod and the top of the drawbar.
  13. Verify that the gap is between 3/64 in. and 1/8 in. (1 mm and 3 mm). Depending on the size of the gap, do one of the following:
    • Between 3/64 in. and 1/8 in. (1 mm and 3 mm) You have completed adjusting the initial setup.
    • Less Than 1/8 in. (1 mm) Go to Step 14.
  14. Find the three provided M14 flat washers.
  15. Put one M14 flat washer under each mounting post on the Power Drawbar cylinder.

Make Final Alignments

Adjust the Tool Tray Load Position

  1. Verify that there's no tool in the spindle.

  2. From the PathPilot interface, on the ATC tab, select Ref Tool Tray.

    Ref Tool Tray button on the ATC tab.

    The tool tray spins.

    You're only required to reference the tool tray once, unlike the mill axes’ referencing procedure.

  3. Select Go to Tray Load Position.

    Go to Tray Load Position button on the ATC tab.

  4. When prompted, select OK.

    The tool tray moves forward.

  5. Put the tool holder with the rod into the fork.
  6. From the PathPilot interface, slowly jog the Z-axis down (-Z) to bring the spindle nose toward the tool in the tool tray.
  7. Make sure that the tool’s shank is aligned concentrically with the collet in the spindle.
  8. If the tool's shank isn't aligned, do the following:

    • Adjust the Alignment of the Tool in the Y Direction (toward or away from the Z column) Determine if the tray must move clockwise or counterclockwise. From the PathPilot interface, in the ATC tab, either select -- to step the tool tray counterclockwise or ++ to step the tool tray clockwise.

      Moving the tool tray clockwise or counterclockwise.

    • Adjust the Alignment of the Tool in the X Direction (left or right) Determine if the tray must move left or right. Use two wrenches to loosen the jam nut on the end of the cylinder rod, making sure that you don't spin the rod end when adjusting the jam nut. Then, either turn the rod end one-half turn further on to the cylinder rod to move the tool tray to the left, or turn it one-half turn off of the cylinder rod to move the tool tray to the right. Once finished, tighten the jam nut.

      Moving the tool tray left or right.

    Repeat adjustments until the tool's shank is concentric with the collet in the spindle.

  9. From the PathPilot interface, on the ATC tab, select Retract.

Verify the Alignment

  1. From the PathPilot interface, select Go to Tray Load Position.

  2. Slowly jog the Z-axis down (-Z) over the tool’s shank.
  3. Verify that the tool’s shank moves freely into the collet.
  4. Depending on the tool's shank movement, do one of the following:

Set the Tool Change Height

  1. From the PathPilot interface, slowly jog the Z-axis down (-Z) over the tool. Stop jogging when the spindle nose just makes contact with the shoulder of the tool holder.

  2. On the ATC tab, select Set TC POS.

    Set TC POS button on the ATC tab.

    The tool change position is set.

Adjust for Rotational Play

There's a small amount of rotational play built into the Automatic Tool Changer (ATC) carousel. This play allows for some misalignment during tool changes, and you must adjust for it in both directions. The taper on the tool shank also helps align the tool during a tool change.

To adjust for rotational play:

  1. From the PathPilot interface, on the ATC tab, select Tray Fwd to rotate the tray clockwise (forward) one full tool slot.

    Tray FWD and Tray REV buttons on the ATC tab.

  2. Select Tray Rev to rotate the tray counterclockwise (backward) one full tool slot.
  3. Verify that the tool’s shank is aligned with the collet in the spindle.
  4. Depending on the alignment, do one of the following:
    • Aligned You have completed aligning the ATC. Remove the tool from the fork. Go to Step 5.
    • Not Aligned You must readjust the tool tray rotation. Go to Adjust the Tool Tray Load Position.

  5. From the PathPilot interface, on the Main tab, drag the Maxvel Override slider to the left. This reduces the maximum velocity by the percentage shown.

    Maxvel Override slider on the Main tab.

  6. Do a test tool change. Because the maximum velocity is reduced, it's easier to verify the alignment of the ATC and stop the machine if further adjustment is required.

    Use the Spacebar key to pause the tool change, if needed.