You have just purchased MILLPWR by ACU-RITE , a versatile and flexible 2-axis Control/
3-axis Readout system that effectively combines powerful features and functionality with ease of use at an
affordable price.
MILLPWR satisfies the needs of the milling market where manual and automated operation are both useful
and needed. MILLPWR
other non-productive operations thereby increasing your efficiency, producti vity and profitability.
MILLPWR is designed and manufactured in the United States at ACU-RITE’s ISO-9001 registered facility.
MILLPWR is a complete system that includes ground and hardened ball screws, powerful DC servo motors,
a user friendly operator console with a built-in floppy disk drive, a controller cabinet containing an
electronics module (which includes a large hard disk drive) and a motor control module. The system is
closed-looped with positioning feedback provided by the use of ACU-RITE’s precision glass scales
(2µm/.0001” resolution).
MILLPWR utilizes a conversational, menu prompted format that makes it easy for you to learn and quick for
you to program. No prior programming experience or training is necessary. All you have to do is simpl y
enter part dimensions directly from the print. MILLPWR automatically calculates the tool path... with
immediate part view graphic feedback providing program verification. MILLPWR’s intuitiveness allows you
to learn how to operate MILLPWR and begin making parts, and profits, in a matter of hours.
MILLPWR is backed by a comprehensive 1-year warranty, with nationwide support provided by a factory
trained and certified distribution network.
Thank you for choosing ACU-RITE. We’re confident you’ll be more than glad you did.
Sincerely,
ACU-RITE INC.
also maximizes your throughput by significantly reducing set-up time, scrap and
MILLPWR System Setup Access Code
An access code must be entered before the system setup
parameters can be set or changed. This prevents inadvertently
resetting parameters.
IMPORTANT
The access code is 8891
Refer to section 7, “System Setup.”
IMPORTANT
Supervisors may wish to remove this page from the
MILLPWRmanual after initially setting up the system
parameters. Keep it in a safe place for future use.
387900-970 Edition E
TABLE OF CONTENTS
Section 1. Introduction
System Overview...........................................................................1-1
Rear of Operator Console Side of Controller Cabinet
/
X
-
+
Contrast and
brightness
knobs --adjust
them for best
picture
Main power
switch. Use this
to turn MILLPWR
on and off.
Power
Switch for
console only
(just leave it
on)
Page 1-2Operation Manual
INTRODUCTION
MILLPWR
Keypad Layout
These let you set up
the MILLPWR, get
information about
what you are doing,
switch between
program (PGM) and
DRO, and “USE” the
milling functions as
steps in a program.
Main
Function Keys
INFO
SET
UP
VIEW
PGM
Milling Functions
TOOLRECTCIRCLE
POS
LINE
ARCBLEND
Numeric Keypad
and Calculator
ABS
INC
78
9
HOLES
CALC
/
With these keys, you define
the operations you want
MILLPWR to perform.
These operations end up
as “steps” in a program, or
you can run just one of
them at any time.
DRO
CANCEL
USE
Press GO to run your program, and
STOP to stop it. The FEED keys let
you adjust the cutting speed on the
fly.
45
6
123
.
DEL
0
Cursor and Motion Control Keys
FEED
+
FEED
-
+/-
ENTER
X
+
Enter all numerical
values with these
keys. When you’re
entering dimensions,
you can specify
absolute or incremental.
-
The handy 4-function
calculator can be used
at any time. Trig and
geometry assistance
is available with a press
of the CALC key.
GOSTOP
Operation Manual Page 1-3
INTRODUCTION
MILLPWR
The cursor keys help you
navigate around the screen
while you are using
MILLPWR.
Page 1-4Operation Manual
INTRODUCTION
2 3 4
MILLPWR
Screen Layout
The MILLPWR display screen is divided into four sections.
SERVO
FEED 0 100%
OFF
ZERO XZERO YZERO Z
SCALE 1.0000TOOL:
DATUM
MOVE
TABLE
INCH
1
2
3
4
Status bar - displays the servo motor status (on/off), feed rate, current tool, scale, and
inch/mm display view.
Information screen - displays information for the job being performed.
• Used as a readout, the screen will display the current location for each axis.
• When programming, a list of milling operations and part view graphics will
be displayed.
• To calculate data geometrically, lines and arcs can be constructed and
displayed.
Message line - operator prompts and messages will appear here.
Softkeys - variable key functions appear here; functions are selected by pressing
the hard key directly below the softkey message.
Operation Manual Page 1-5
INTRODUCTION
MILLPWR
Saving, Backing Up, and Cr eating Directories for Programs
When you begin to create programs for your MILLPWR to run, you can save your
If you're writing a
long program,
don't wait until
the end to save
your work.
Frequent saving
reduces the risk
of losing work
due to a power
interruption.
programs in any of three places—on MILLPWR’s internal hard disk drive, on a 3
½” floppy disk, or on your PC’s hard disk drive. Saving your work means it will
not be lost if the MILLPWR is turned off or if there is a power failure.
Your MILLPWR is also equipped with a backup feature that enables you to make
duplicate copies of your saved programs. We recommend backing up your work
as an extra precaution against accidental deletions, hard disk drive failures, or other
problems that may prevent you from recovering your original files. Backing up your
programs takes only a few moments—and will save you valuable time if a problem
does occur.
And as you save and back up your programs, you can neatly organize them in any of
the three default directories (“MILLPWR,” “A:,” and “REMTSTOR”) or in
personalized directories you create on your own.
For more details about how to save programs, back up files, and create directories,
refer to the Programming section.
Note: Before you save or back up programs on your PC’s hard disk drive, refer to the
Remote Storage and System Setup sections for setup instructions.
Emergency Table Stop Button
The large red button on the front of the MILLPWR operator console is the emergency
TABLE STOP. In the event of a malfunction or programming error, press the emergency
TABLE STOP button to disengage the servo motors. Disengaging the servos will
cause all table movement to stop.
WARNING
Pressing the emergency TABLE STOP button will NOT
stop the rotation of the cutting tool unless your machine
has been specifically wired to do so. Therefore, in the
event of an emergency, if your machine has not been
wired to stop the rotation of the cutting tool, be prepared
to raise the quill in addition to pressing the emergency
TABLE STOP button.
Page 1-6Operation Manual
INTRODUCTION
MILLPWR
Conventions
Axis Conventions
Cartesian Coordinates
When programming a part using MILLPWR, table movement and tool motion are
determined by the use of positive or negative numbers. MILLPWR has been factory set
with the following positive and negative directions for X, Y, and Z:
X-axis: the table will move to the left, with tool
motion to the right, for positive positions.
Y-axis: the table will move toward you while tool
motion is away from you for positive positions.
Z-axis: quill movements up (away from the table
surface) are for positive positions.
Polar Coordinates
The polar radius (R), is the distance from datum (absolute zero) to a point. The polar
angle (A), is formed by the X-axis and the radius, positive counter- clockwise. The
angle is always measured from the positive X-axis.
6
5
4
3
2
1
R=6.4
A=39°
0
1234560
Operation Manual Page 1-7
INTRODUCTION
MILLPWR
Absolute / Incremental
Dimensions you enter from the print can be either absolute or incremental.
Absolute dimensions are measured from the datum which is the workpiece zero.
Incremental dimensions are measured from one point to another.
+Y
1.5
4
ABC
2
3.625
absolute coordinates of a point.
Both absolute and incremental dimensions can be used on the same workpiece. For
example, Hole C has the dimensions X = 3.625 INC from hole A, Y = 1.5 ABS.
Example: Polar and Incremental
Here is how to enter the angle of a line:
If your drawing provides the angles from one end, you need to use polar and
incremental. The end of the line is measured incrementally from the beginning of the
line.
+X
Holes A and B are dimensioned as absolute, but hole C is
dimensioned incrementally from A.
When entering these dimensions in the MILLPWR, we
would say:
Hole A: X = 2.000 ABS
Hole B: X = 4.000 ABS
Hole C: X = 3.625 INC from hole A
It will often be easier to describe a location in terms of
incremental dimensions than it would be to calculate the
6
5
4
3
2
1
0
P1 (From)
5.0
P2 (To)
0123456
- 53°
Page 1-8Operation Manual
INTRODUCTION
MILLPWR
Notice that if you don’t use incremental coordinates, Point 2 will be incorrect because it
will be measured from the datum instead of from Point 1.
Operation Manual Page 1-9
INTRODUCTION
MILLPWR
BLANK PAGE
Page 1-10Operation Manual
DRO
MILLPWR
DRO FUNCTIONS
Start-Up
Power Up
• Make sure the power switch on the back of the Operator’s Console is on.
• Turn the on/off switch on the side of the controller cabinet ON.
After the program has loaded, the following screen will appear:
SERVO
FEED 0 100%
OFF
SCALE 1.0000TOOL:
INCH
DRO stands
for “digital
readout”.
INC
X
0.0000
INC
Y
0.0000
INC
Z
0.0000
ZERO XZERO YZERO ZDATUM
This is called the “DRO” screen. It shows you the current tool position. Here you
can use several DRO functions to set up your job. In fact, you can use this as a
normal DRO when you use your machine manually.
0.0000
0.0000
0.0000
ABS
ABS
ABS
MOVE
TABLE
Operation Manual Page 2-1
DRO
MILLPWR
Finding Home
The ACU-RITE’s ENC150 precision glass scales included with your MILLPWR
system are different from standard ENC150 glass scales because they have only
one reference mark. The reference mark will be located between five and eight
inches from the centerline of your scale. The reference mark will most likely be
found in the positive count direction for both the X and Y axes; however, it may be
found in the negative count direction depending upon how the scale(s) are mounted.
MILLPWR must find these reference marks after power-up in order to establish the
farthest table travel, so you won’t crash the table. You must find home before you
can run a program.
To find home, press the DATUM softkey, then the FIND HOME softkey. The
Once you are
familiar with where
the reference marks
are, you can use the
“MOVE TABLE”
function to get close
to them before you
press "FIND HOME".
table will move, one axis at a time, to find the reference positions.
If the table moves until it hits the hard stops and the servo motor stops, it
means the table was already positioned past the home position. Use the
handcranks to move the table away from the end and press FIND HOME
again. Should the FIND HOME softkey be pressed immediately after home has
been found, the table will move to the hard stops and the servo motors will
disengage.
DATUM is a term
for “workpiece
zero” or “absolute
zero”.
After home has been found, the DRO display will change. The absolute display
shows the tool position from the most recent datum.
Page 2-2Operation Manual
DRO
MILLPWR
DRO Functions
Reset an Axis
Pressing the ZERO X, ZERO Y, or ZERO Z softkey will zero the incremental position
of that axis.
You can’t change
to metric if you
have an “inch”
program active,
and vice versa.
Note that the
arrow keys will
move the table!
Inch - Metric
To change the measurement system between inches and metric units, press the
SETUP key to get the INCH and MM softkeys. Select the system you want, and
press USE NEW SETTINGS.
Move Table
This function lets you move the table rapidly using the arrow keys. Pressing the
MOVE TABLE softkey will caution you that the arrow keys no longer move around
the screen, but will instead move the table.
SERVO ONFEED 0 100%
X
Y
Z
INC
0.000
INC
0.000
INC
0.000
SCALE 1.0000TOOL:
0.0000
0.0000
0.0000
INCH
ABS
ABS
ABS
!
CAUTION
ARROW KEYS
WILL MOVE TABLE
PRESS CANCEL WHEN FINISHED MOVING TABLE.
MOVE
TABLE
Operation Manual Page 2-3
DRO
MILLPWR
The table moves in the direction of the arrows. You can move in both X and Y at
the same time.
MOVE TABLE AWAY
FROM YOU
While the MOVE TABLE
It’s a REALLY good
idea to fold in the
handcrank handles
before moving the
table!
Establishing a Datum
A datum is a reference point that you establish as the workpiece zero. You need to
set a datum for each job. The location on the workpiece that is to be used as the
datum will be determined by the way the part is dimensioned on the blueprint. In
general, you should select a datum location so that you may enter most dimensions
directly, without calculations.
MOVE
TABLE
LEFT
MOVE
TABLE
RIGHT
MOVE TABLE
TOWARDS YOU
softkey is pressed, the
servo motors are on.
Press it again to turn them
off.
The datum position is not lost at power-down, so you can quit in the middle of a job
at night and easily resume it the next morning.
The simplest datum location to set is where you can position the tool exactly at that
location in all three axes.
• Position the
workpiece so that the
datum point is directly
beneath the tool. This
point might be a
corner, the center of a
bolt hole pattern, etc.
SERVO
X:
Y:
Z:
OFF
FEED 0 100%
SET DATUM
X
Y
Z
INC
0.0000
INC
0.0000
INC
0.0000
SCALE 1.0000TOOL:
0.0000
0.0000
0.0000
• Press the DATUM
softkey and the Set
Datum entry form will
appear.
• Press the X=0, Y=0,
and/or Z=0 softkey(s)
ENTER THE NEW ABSOLUTE POSITION OF THE TOOL CENTER.
X = 0Y = 0Z = 0
FIND
HOME
USE
PROBE
MOVE
TABLE
to establish workpiece zero.
INCH
ABS
ABS
ABS
•Press USE to lock in the workpiece zero.
Page 2-4Operation Manual
DRO
MILLPWR
If you can’t position the tool center right at the datum, you’ll need to enter a value
for each axis. The value to use is the absolute position of the tool center from the
new datum. For one axis at a time, position the tool to a known location, such as
the edge of the workpiece. Without moving the tool, enter the desired location of
the tool center and press ENTER. Then move to position the next axis. When all are
entered, press USE.
DISTANCE TO
The MILLPWR
calculator helps a lot
here---To set the
datum for the X axis,
enter:
0.3875/2+.005. Then,
since the tool center is
left of the datum,
change the sign.
.005 SHIM
0.3875
TOOL
ENTER
+
While you are setting the datum, you can use the MOVE TABLE softkey to help you
with long moves.
Using A Probe
You may use a touch probe or edge finder to get very accurate edge locations.
Make sure the diameter of the probe is correct (it’s found in the SET-UP list).
Install the probe and connect it to the back of the Operator Console. Then, for one
axis at a time, enter the absolute position of the edge to be touched into the datum
form, press the USE PROBE softkey, and move the table slowly until the probe
touches the workpiece. When the probe touches, the USE PROBE softkey will
release. Press the USE key to set the absolute position of each axis.
TIP:
Right after you find
home, you
can move quickly to
your previous datum
using the position
function:
POS
GO
Operation Manual Page 2-5
DRO
MILLPWR
One Time Milling Functions
Any of the milling functions, except BLEND, can be used “one time” without creating
a program. Press the desired milling function key, fill in the information, and press
GO.
The information for each function will be remembered for the next time you use it.
Each function is described in the Program Steps section.
For many of the milling functions, such as a pocket, you will need to set the proper
tool diameter. You can use the TOOL key as a one-time function to do this.
Page 2-6Operation Manual
PROGRAMMING
MILLPWR
PROGRAMMING
Programming Considerations
Depth of Cut
Since the vertical Z-axis is not controlled by a servo motor, you must make changes to
the depth of cut manually.
You don’t have to program the depth, but if you do, MILLPWR will preset the
programmed value into the DRO for you. Then, when it’s time, MILLPWR will show
you the DRO and ask you to set the depth.
If you are not programming depth, leave it set to 0.
Tool Offset
With MILLPWR, you never have to worry about the actual tool path. Because of
MILLPWR ’s tool radius compensation capability, you program only the actual part
dimensions. When you program a line, arc, or frame, use the TOOL OFFSET field to tell
MILLPWR which side of the cut you want the tool to be on.
Picture yourself standing behind the tool as it is moving. If the tool is on the left of the
workpiece, use “left” offset. If the tool is to the right of the workpiece, use “right” offset.
By using left and right offsets,
you can program the
LEFT OFFSET
RIGHT OFFSET
dimensions of the part as
found on the blueprint.
MILLPWR will take care of
all cutter radius
compensation. You do not
have to program the tool
path.
If you use “center” offset, the
programmed dimensions are
for the center of the tool.
For some milling functions, like Frame and Arc, “inside” and “outside” offsets help you
visualize where the tool is.
Operation Manual Page 3-1
PROGRAMMING
MILLPWR
“From” and “To” Points
MILLPWR lines and arcs are defined by both FROM and
TO points. MILLPWR will automatically go to the start
point before it asks you to set the depth.
Datum Selection
The datum is the point where all absolute dimensions are measured from. You must look
at the blueprint of the part and decide what to use as a datum. You should pick a point
which will let you enter most of the dimensions directly, without calculations. However,
any point you select will give the same results.
FROMTO
FROM
X1ABS
Y1ABS
TO
X2ABS
Y2ABS
Absolute and Incremental Dimensions
To help you enter dimensions directly from the blueprint, MILLPWR allows direct entry
of both absolute and incremental dimensions. Any dimension measured from the point
you select as the datum is called absolute.
A dimension measured from any other point is called incremental. This “other point” is
called the incremental reference point.
For the part drawn below, if we put the datum in the center of the hole (point F), all
dimensions are absolute.
Point X Y
A -7.123 ABS -3.936 ABS
B 3.421 ABS -3.936 ABS
C 3.421 ABS 3.603 ABS
D -4.893 ABS 3.603 ABS
E -7.123 ABS 1.011 ABS
1.011
7.123
D
E
2.96 DIA
THRU HOLE
3.4214.893
F
C
3.603
3.936
F 0.00 ABS 0.00 ABS
AB
Page 3-2Operation Manual
PROGRAMMING
MILLPWR
If we use point A as our datum, many of the given dimensions are incremental because
they are measured from the incremental reference point F and not from the datum.
Point X Y
MILLPWR will
display marks to
the right of each
program step
number for
continuous
contours.
7.123
D
A 0.00 ABS 0.00 ABS
B 3.421 INC F 0.00 ABS
C 3.421 INC F 3.603 INC F
D -4.893 INC F 3.603 INC F
E 0.00 ABS 1.011 INC F
F 7.123 ABS 3.936 ABS
1.011
E
2.96 DIA
THRU HOLE
A
Continuous Milling
When you program a continuous contour made up of lines and arcs, MILLPWR
will mill the contour without stopping. MILLPWR will detect a continuous contour
automatically. There are no special keypresses or different functions to learn.
For lines and arcs to be continuous, they must:
FROMTO
•have the same Z depth,
3.4214.893
F
C
3.603
3.936
B
FROM
• be cut with the same tool,
• be cut on the same side,
TO
• and, of course, they must “touch”--the end of one
must be the same as the start of the next.
When you follow one line (or arc) with another, MILLPWR assumes that you want them
to be connected. It automatically fills in the FROM point, Z depth, and tool offset. All you
have to do is fill in the TO point, and press USE.
You can have different feedrates within a continuous contour by entering the feedrates
you want in each step of the contour.
Operation Manual Page 3-3
PROGRAMMING
MILLPWR
Creating a Program
Press the PGMkey, and the following program screen appears.
SERVO
OFF
CURRENT PROGRAM
PROGRAM
FUNCTIONS
FEED 0 100%
END OF 0
CLEAR
PROGRAM
EXPLODE
MORE
STEPS
SCALE 1.0000TOOL:
RUN
OPTIONS
INCH
You create a program by creating a list of milling steps to be performed. As you add to
your list, each step will be drawn immediately on the screen so you can see a picture
of your part in progress.
Program
Step
Listing
• To enter a milling step, press the appropriate milling function key. The function
you select will appear in the program listing, and you can enter the information
SERVO
OFF
CURRENT PROGRAM
001SET TOOL
002MILL ARC
X
FEED 0 100%
2 OF 2
MILL ARC002
FROM
X1ABS
Y1ABS
TO
X2ABS
Y2ABS
DEPTH
ZABS
RADIUS
DIRECTION
CCW
TOOL
0.500 DIAMETER
FL END ML
CENTER OFFSET
10FEEDIPM
TEACH
POSITION
TYPE
SCALE 1.0000TOOL:
INCH
Enter
information
about the arc
into this form.
MOREPOLAR
Page 3-4Operation Manual
PROGRAMMING
MILLPWR
describing the step into the form.
• After entering all the data for a step, press the USE key to accept the data. This
updates the picture and moves down for the next step.
SERVO
OFF
CURRENT PROGRAM
001SET TOOL
002MILL ARC
PROGRAM
FUNCTIONS
FEED 0 100%
END OF 2
CLEAR
PROGRAM
EXPLODE
MORE
STEPS
SCALE 1.0000TOOL:
RUN
OPTIONS
INCH
• To change a step, use the arrow keys to move to the step and press USE or ENTER.
When you have made your changes, press USE to put the changed step back into
the program.
• To delete a step, move to the step and press the DEL key.
• To insert a step, move to where you want the new step to go, and press the new
milling function key.
If you decide not to use a milling function that you have selected, press the CANCEL key.
In addition to the milling functions, the MORE STEPS softkey lets you pick from a
number of other useful steps, such as REPEAT and ROTATE. All steps are described in
the Program Steps section.
Operation Manual Page 3-5
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