ACU-RITE MILLPWR 3 Axes User Manual

MILLPWR Setup Access Code

An access code must be entered before the installation setup parameters can be accessed or changed.

Refer to Section 7, Setup.

The access code is 8891.

Supervisors may wish to remove this page from the MILLPWR

Operation Manual after initially setting up the installation setup

parameters. Keep it in a safe place for future use.

IMPORTANT

TABLE OF CONTENTS

MILLPWR

Operation Manual

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

Operator Console Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

Keypad Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

Screen Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

Table Stop Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6

Axis Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6

Count Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6

Cartesian Coordinates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7

Polar Coordinates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7

Absolute and Incremental Dimensions . . . . . . . . . . . . . . . . . . . . . .1-8

Z-axis Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9

Z-axis Retract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9

Begin and End Depths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9

Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9

Disengaging the Z-axis Drive System . . . . . . . . . . . . . . . . . . . . . .1-10

Setting Z-axis Datum when Changing Tools . . . . . . . . . . . . . . . . . . . .1-12

Drilling Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12

Peck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12

Tool Retract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12

Dwell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12

Saving, Backing Up, and Creating Directories . . . . . . . . . . . . . . . . . .1-13

DRO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

Power Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

Screen Saver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

Finding Home . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

DRO Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

Move Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

Zeroing an Axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

Inch/millimeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

Teach Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

Using an Electronic Edge Finder . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

Skewing a Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7

Establishing Datum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9

Hard Key Milling Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12

TABLE OF CONTENTS

MILLPWR

Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

Programming Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

“From” and “To” Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

Depth of Cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

Tool Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

Datum Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

Absolute and Incremental Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

Continuous Milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

Creating a Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

The View Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7

Follow Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7

Show Tool Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7

Zoom In, Zoom Out and Restore . . . . . . . . . . . . . . . . . . . . . . . . . .3-7

Running a Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8

Skewing a Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8

Establishing Datum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10

Testing Your

MILLPWR Program . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13

Single Step . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13

Dry Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13

Graphics Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13

Manual Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14

Disable Look Ahead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14

Machining Your Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15

Feed + and Feed - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16

Manually Positioning the Quill . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16

Program Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17

Directories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18

Creating a Sub-directory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19

Selecting a Directory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21

Deleting a Directory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23

Saving a Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24

Naming a Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25

Loading a

MILLPWR (MPT) Program . . . . . . . . . . . . . . . . . . . . . . . .3-26

From

MILLPWR's internal memory . . . . . . . . . . . . . . . . . . . . . . . . .3-26

From a 3

2" floppy disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27

From your PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28

Translating a DXF file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28

Operation Manual

TABLE OF CONTENTS

MILLPWR

Operation Manual

Loading a G-code file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-29

Running a G-code Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31

MILLPWR - G-code Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-33

Merging Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-37

Backing Up a Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-38

Deleting a Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-39

Demonstration Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

Selecting Datum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

Beginning the Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

Selecting a Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

Programming the Contour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

Programming the Bolthole Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12

Programming the Rectangular Pocket . . . . . . . . . . . . . . . . . . . . . . . . .4-15

Saving Your Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-17

Testing Your Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18

Running the Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-19

Tool Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-20

Clearing the Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-20

Program Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

Simple Milling and Drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

Programming a Tool Step w/Repeatable Tool Length Offsets . . . . . . .5-2

Entering the First Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

Changing to a Tool of Unknown Length in the DRO . . . . . . . . . . . . . .5-4

Changing to a Tool Of Unknown Length in PGM . . . . . . . . . . . . . . . .5-4

Position/Drill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6

Centerline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7

Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8

Arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9

Blend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11

Rectangular Milling Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13

Pocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13

Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16

Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18

Slot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-20

iii

TABLE OF CONTENTS

MILLPWR

Operation Manual

Circular Milling Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-22

Pocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-22

Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-24

Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-26

Helix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-28

Hole Patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-30

Row of Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-30

Hole Frame and Hole Array . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-32

Bolthole Circle Patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-35

Additional Milling Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-37

Custom Pocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-37

Repeat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-39

Rotate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-40

Mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-41

Contour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-42

Engrave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-44

Engrave Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-44

Engrave Arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-47

Ellipse Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-49

Chamfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-51

Reference Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-53

Island . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-54

Spiral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-55

Comment Step . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-57

Auxiliary Function (AMI Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-58

Step Functions Softkey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-60

Explode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-60

Reverse Step . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-62

Reverse Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-62

Change Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-63

Delete Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-64

Copy/Move Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-65

Calculator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

Math Functions (+, -, ÷, x) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2

Trig Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2

Geometry Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4

TABLE OF CONTENTS

MILLPWR

Operation Manual

Working with the Geometry Calculator . . . . . . . . . . . . . . . . . . . . . . .6-4

GeoCalc

™

Quick Reference Table . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5

Using GeoCalc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6

Calculator Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7

Saving Results Calculated in GeoCalc . . . . . . . . . . . . . . . . . . . . . .6-7

Loading GeoCalc Results That You Previously Saved . . . . . . . . .6-8

Loading Programs into GeoCalc . . . . . . . . . . . . . . . . . . . . . . . . . .6-9

Clearing GeoCalc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9

Example Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10

Strategy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10

Starting the Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11

Entering the Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11

Finding the Arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14

Finding the Points of Tangency . . . . . . . . . . . . . . . . . . . . . . . .6-15

Returning Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-16

RPM Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-18

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1

Job Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2

Tool Library . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2

Using the Tool Library with Tool length offsets . . . . . . . . . . . . . . . . .7-4

Entering the First Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5

Using the Tool Library . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7

Scale Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-11

Display Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12

Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12

INC Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12

Display Resolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12

Point Entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12

“From” Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-13

Stepover Entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-13

Pass/Peck/Retract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-13

Electronic Edge Finder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-14

Job Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-14

Feed Rate Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-16

Step Override % . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-16

Max % . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-16

TABLE OF CONTENTS

MILLPWR

Min % . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-16

Dry Run Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-16

Default Feed Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-16

Unit/(Min) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-16

Full Cut Feed Rate % . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-16

Installation Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-17

Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-17

Error Compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-18

Encoder Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-19

Travel Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-21

Error Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-22

Serial Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-23

Z-axis Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-23

Spindle Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-24

Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-24

Servo Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-25

Automatically Tuning the Servo in Console Mode . . . . . . . . . . . . .7-26

AMI Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-28

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-29

Motor Assembly Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-30

Signal Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-31

Table Stop Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-32

Circle Interpolation Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-33

Examples of Circle Interpolation Test Results . . . . . . . . . . .7-34

Keypad Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-35

Display Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-36

Disk Utilization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-37

Set Time and Date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-38

System Statistics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-38

Max Servo Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-39

Remote Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-1

Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-1

Choosing a Serial Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-1

Operation Manual

TABLE OF CONTENTS

MILLPWR

Operation Manual

Connecting MILLPWR to Your PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

Installing the Remote Storage Program onto Your PC . . . . . . . . . . . . . 8-3

For Windows

95 and 98 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-3

For MS DOS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

Setting Up Your COM Port and BAUD Rates . . . . . . . . . . . . . . . . . . . . . .8-4

Activating the Remote Storage Feature in

MILLPWR . . . . . . . . . . . . . . . . .8-5

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-5

Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-1

Using the Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-1

Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-2

Re-aligning (Tramming) the Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-15

vii

2013-178 Ed. A

This symbol alerts you to important information

concerning the operation of your MILLPWR system.

Characteristic Specification

Operating conditions 0° to 40° C (32° to 104° F)

25% to 85% relative humidity (non-condensing)

Storage conditions

-20° to 60° C (-4° to 140° F)

25% to 95% relative humidty (non-condensing)

115V~ (±20%), single phase

47 - 63 Hz

8.5A rms nom., 18A rms peak—inrush

Input requirements:

Voltage

Frequency

Current

Fuse

15A/250V resettable circuit breaker

Position signals, channels A & B

TTL square wave signal in quadrature (90° nominal phase relationship) Maximum input rate: 50 kHz

Reference signal: TTL square wave

Encoder input

Edge finder input

Compatible with ACU-RITE®Electronic Edge Finder

Class A

FCC compliance

MILLPWR System Specifications

INTRODUCTION

MILLPWR

Operation Manual

INTRODUCTION

System Overview

1-1

Licensed under U. S. Patent No. 5,941,663 (applies to Linear Encoder systems with Z-axis only)

Operator Console

ACU-RITE

™

Scales

Motor Drive Assemblies

INTRODUCTION

MILLPWR

Operation Manual

1-2

Front View of Operator Console

Rear View of Operator Console

INTRODUCTION

MILLPWR

Operation Manual

1-3

Main Function Keys

Switch from absolute to incremental (or vice versa) in the DRO display and milling function numeric fields.

Manipulate your part graphic.

Display the digital readout.

Exit from a milling function.

Add a step to your program once you’ve completed an entry form.

Display the program screen.

Keypad Layout

Milling Functions

Use these keys to create a program. All but

BLEND may also be used as one-time milling

functions from the DRO display.

Special Function Keys

INFO

SETUP

CALC

Access information about any

MILLPWR function.

Switch from inches to millimeters or vice versa.

Add to your tool library, set your feed rates, change your display options and define other system parameters.

Perform standard (+, -, x, ÷), trigonometry, geometry and RPM calculations.

Cursor and Motion Control

STOP

FEED+ FEED-

ARROWS

Start your program.

Press this key once to pause your program, twice to exit.

Increase or decrease your feed rate.

These keys enable you to position your table or move your cursor.

Numeric Keypad and Calculator

Enter program data and perform math calculations. Press the

CLEAR

key to delete information from a data field. Press the

ENTER key

to accept the information you’ve entered.

INTRODUCTION

MILLPWR

Screen Layout

The MILLPWR display screen is divided into four sections.

Status bar - displays the servo motor status (ON/OFF), feed rate, current tool, scale, job clock, and

the current display setting (inches or millimeters).

Information area - displays information about the job being performed.

• Readout (DRO) - used as a digital readout, the display will show the current

position for each axis.

• Program (PGM) - when programming, a list of program steps (milling functions)

and part-view graphics will be displayed.

• Calculator (CALC) - the geometry calculator enables you to calculate missing

information and then insert it into your program.

Message line - operator prompts and messages will appear here.

Softkeys - various milling functions appear here; functions are selected by pressing the

softkey directly below each category. When a key appears pressed in it is selected. When it appears “up” it is not selected.

Operation Manual

1-4

INTRODUCTION

MILLPWR

Operation Manual

Table Stop Button

The large red button located in the lower left corner on the front of your

MILLPWR operator

console is the

TABLE STOP. In the event of a malfunction or programming error, press the

TABLE STOP button to turn off the servo motors. This will immediately stop all positioning for

each axis.

1-5

Pressing the TABLE STOP button will NOT stop the rotation of

the cutting tool unless your machine has been configured to do

so. If your machine has not been wired to stop the rotation of the

cutting tool, be prepared to raise the tool and power down the

spindle in addition to pressing the

TABLE STOP button.

WARNING!

INTRODUCTION

MILLPWR

Axis Conventions

Count Direction

When programming a part using

MILLPWR, table movement and tool movement are

determined by the use of positive or negative numbers.

MILLPWR has been factory

set with the following positive and negative count directions for the X, Y and Z-axes:

X-axis: The table will move to the left and the

tool will move to the right for a positive count direction.

Y-axis: The table will move toward you while

the tool moves away from you for a positive count direction.

Z-axis: The quill will move up (away from

the table surface) for a positive count direction.

Operation Manual

1-6

Conventions

INTRODUCTION

MILLPWR

Operation Manual

1-7

Cartesian Coordinates

A cartesian coordinate is a position that can be measured from the X- and Y-axes.

Polar Coordinates

A polar coordinate is a position that is defined by an angle and a radius.

INTRODUCTION

MILLPWR

Operation Manual

1-8

Absolute and Incremental Dimensions

Dimensions that you enter from a print are either absolute or incremental.

Absolute dimensions are measured from datum (also known as workpiece zero). Incremental dimensions are measured from one point to another.

Holes A and B are dimensioned using absolute values. Hole C is dimensioned incrementally from Hole A.

When entering these dimensions, we would say:

Hole A: 002 Position/Drill

X 2.0000 ABS

Y 1.5000 ABS

Hole B: 003 Position/Drill

X 4.0000 ABS

Y 1.5000 ABS

Hole C: 004 Position/Drill

X 3.6250 INC

Y 1.5000 ABS

Note:

Both absolute and incremental dimensions may be used to define a position, as shown with Hole C.

It’s often easier to describe a location in terms of incremental dimensions rather than calculate its absolute coordinates.

002 - This indicates that the X position will

increment from the X value in Step 2.

INTRODUCTION

MILLPWR

Operation Manual

1-9

Z-axis Retract

The Z-axis retract is the position the quill returns to between program steps. By setting a retract position, you can ensure that the tool you are using does not make contact with your workpiece when the quill moves from one position to the next. It’s a good idea to establish a retract position for the Z-axis each time you power up your system; otherwise,

MILLPWR

will use the quill’s upper travel limit as the Z-axis retract position.

Note:

Loading a PGM will reset the Z-axis retract to the Z upper limit.

Note:

If your tool is above the Z-axis retract position when you run a program, the table will rapidly move to position, and then the quill will rapidly move down to the retract position. If the tool is below the retract position, the quill will rapidly move up to the retract position first, and then the table will rapidly move into position.

Begin and End Depths

The “Begin” and “End” depths determine where the tool will begin and end its cutting motion. They may be specified as absolute (ABS) or incremental (INC) distances. If the “Begin” field is left blank, you will be prompted to manually position the quill to the desired depth.

Once the quill has reached its retract position, it will rapidly move to the “Begin” depth then move at the programmed feed rate to the “End” depth.

If the travel limit for the Z-axis is set below the established retract position, a travel limit fault will occur and the program will stop.

Pass

“Pass” refers to the number of cuts that are used to machine an area to its “End” depth. You can control how frequently a pass occurs by entering a value in the “Pass” field whenever it appears. (If you don’t want to program more than one pass, leave the field blank.)

Z-axis Conventions

INTRODUCTION

MILLPWR

Disengaging the Z-axis Drive System (Rotary Encoder)

MILLPWR provides you with the flexibility to switch between two-

axes and three-axes operation.

To disengage the Z-axis drive system from your

MILLPWR

system:

• Leave the “Begin” field blank when you program a step or a one-time milling function.

• Raise the quill, then loosen the quick release knob located on the front of the Z-axis drive system.

• When you run the program step or one-time milling function, you will be prompted to manually position the quill.

To re-engage the Z-axis drive system, lift the quill handle until you feel the drive assembly become seated, then tighten the quick release knob.

The following Operator Intervention Messages (OIMs) apply to Rotary Encoders:

Operation Manual

1-10

INTRODUCTION

MILLPWR

Operation Manual

1-11

Disengaging the Z-axis Drive System (Linear Encoder Option)

MILLPWR provides you with the flexibility to switch between two-axes and three-axes operation.

To disengage the Z-axis drive system from your

MILLPWR

system:

• Leave the “Begin” field blank when you program a step or a one-time milling function.

• Raise the quill, then loosen the quick release knob located on the front of the Z-axis drive system.

• When you run the program step or one-time milling function, you will be prompted to manually position the quill.

To re-engage the Z-axis drive system, lift the quill handle until you feel the drive assembly become seated, then tighten the quick release knob.

The following OIM apply to the optional Z-axis Linear Encoder (only):

INTRODUCTION

MILLPWR

Operation Manual

1-12

Setting Z-axis Datum when Changing Tools

Whenever you encounter a

SET TOOL step, MILLPWR will display the DRO screen and let you know

which tool to load. If no tool diameter was programmed in the “Tool Step,” you will be prompted to provide one.

• Use the

MOVE TABLE softkey and arrow keys to

move the tool away from your workpiece.

• Press the move table softkey again to turn off the motors.

• Insert the required tool into the spindle.

• Using the MOVE TABLE feature, position the tool over

the surface of a known depth on your workpiece.

• Press the

DATUM softkey.

• Position your tool so that it touches a known surface, then enter that position into the Z-axis datum.

• Press the USE key.

• Raise the tool and press the GO key to continue the program.

Drilling Conventions

Peck

“Hole” and “Position/Drill” steps give you the option of programming the quill to “peck” or pause briefly. Peck cycles are used to break chips and reduce chip buildup during drilling operations.

You can control how frequently a peck occurs by entering a value in the “Peck” field.

Tool Retract

Using the “Tool Retract” feature, you can program

MILLPWR to raise the quill at a speci-

fied distance or frequency. This will allow the tool you’re drilling with to cool.

Dwell

“Dwell” is the length of time (in seconds) that the quill will pause during a tool retract.

If the surface is at datum 0, use the Z = 0 softkey.

INTRODUCTION

MILLPWR

Operation Manual

1-13

Saving, Backing Up, and Creating Directories for Programs

When you create programs with

MILLPWR, you can save them in any of

three places—within

MILLPWR's internal memory, on a 3

/2" floppy disk, or on your PC using Remote Storage. Saving your work means it will not be lost if

MILLPWR is powered down or if there is a power interrup-

tion.

MILLPWR is also equipped with a back up feature that enables you to

make duplicate copies of your saved programs to floppy disc or Remote Storage. We recommend that you back up your programs regularly to avoid accidental loss or other problems that may prevent you from recovering your original programs. Backing up your programs takes only a few moments—and will save you valuable time if a problem does occur.

As you save and back up your programs, you can neatly organize them in any of the following three main directories ("

MILLPWR," "A:

" and "REMTSTOR") or in personalized subdirec-

tories that you can create.

Note:

Before you save or back up programs onto your PC, refer to Remote Storage and Setup for instructions.

For more details about how to save programs, back up files and create directories, refer to Programming.

If you’re creating a long program, don’t wait until the end to save your work.

Frequent saving reduces the risk of losing your work due to a power interruption.

DRO

MILLPWR

Operation Manual

2-1

DRO

Start Up

Power Up

Press the power switch (located on the rear of the operator console) to “I.” The Power Indicator (located in the upper left corner of the operator console) will light up green.

Once

MILLPWR has been powered up, the following screen will appear:

Anytime your system is inactive for approximately 90 minutes, the LCD display will shut off, and a blank screen will appear. This screen saver function is designed to prolong the life of your operator console display. If your screen is blank, check that the Power Indicator light is illuminated. Press any key on the operator console or move the table and the display will reappear. If the Power Indicator light is not illuminated yellow, then power to your

MILLPWR system has been interrupted.

Screen Saver

DRO

MILLPWR

Operation Manual

2-2

Finding Home (Rotary Encoder)

You must find home before you run a program. To find home immediately after startup, locate the Z-axis at the top of the fixed mark then press the

FIND HOME softkey.

Otherwise, press the

DATUM softkey, then the FIND HOME softkey. The table will auto-

matically move a short distance along the Z-, Y- and then X-axes to find home. Z-axis finds home first. You will have to locate the Z-axis at the top of the location mark before finding home.

When finding home,

MILLPWR will use ACU-RITE’s advanced Position-Trac

™

technology. Position-Trac works by using a very precise distance-encrypted reference mark line pattern that's been placed onto each ACU-RITE precision glass scale included with your

MILLPWR system. Proprietary software decodes the line pattern which then allows you to

accurately find home and reestablish workpiece zero from any position.

With Position-Trac, there is no need to leave the system powered up when it is not being used. You’ll be able to easily, quickly and accurately reestablish workpiece zero after power loss.

After home has been found, the tool’s position (relative to your most recent datum) will be displayed.

If you don't find home before moving the table, you will risk exceeding the table's travel limits and damaging the milling machine,

MILLPWR or both.

DRO

MILLPWR

Operation Manual

2-3

Finding Home (Linear Encoder Option)

You must find home before you run a program. To find home immediately after startup, press the

FIND HOME softkey. Otherwise, press the DATUM softkey, then the FIND HOME

softkey. The table will automatically move a few inches along the Z-, Y- and then X-axes to find home.

When finding home,

MILLPWR will use ACU-RITE’s advanced Position-Trac

™

technology. Position-Trac works by using a very precise distance-encrypted reference mark line pattern that's been placed onto each ACU-RITE precision glass scale included with your

MILLPWR system. Proprietary software decodes the line pattern which then allows you to

accurately find home and reestablish workpiece zero from any position.

With Position-Trac, there is no need to leave the system powered up when it is not being used. You’ll be able to easily, quickly and accurately reestablish workpiece zero after power loss.

After home has been found, the tool’s position (relative to your most recent datum) will be displayed.

If you don't find home before moving the table, you will risk exceeding the table's travel limits and damaging the milling machine,

MILLPWR or both.

Datum is a term used to describe "workpiece zero" or "absolute zero."

After you power up and find home, you can quickly move to datum by pressing the POS key, followed by the GO key!

DRO

MILLPWR

Operation Manual

2-4

DRO Functions

The digital readout (DRO) display shows you the current tool position. While operating in the DRO mode, you can use several functions, such as skew and datum, to set up your job. You can also use this as a standard DRO when you use your machine manually.

Move Table

The move table feature lets you move the table rapidly (or at an established feed rate) using the arrow keys.

• Press the

MOVE TABLE softkey to turn the servo motors on. Press

it again to turn them off.

• Enter the desired feed rate or skip this step to move at a rapid feed rate.

• If you want the arrow keys to move the table in increments, press the

0.001, 0.01 or 0.1 softkey. (A different set of softkeys will

appear if you are measuring in millimeters.)

• Move the table. You can move the X-, Y- and Z-axes simultaneously by pressing two arrow keys and

Z UP or Z DOWN softkeys at the same time.

• Press the

FEED+ and FEED- keys to adjust your feed rate.

It’s a good idea to fold in the handles before moving the table.

DRO

MILLPWR

Operation Manual

2-5

Zeroing an Axis

Pressing the ZERO X, ZERO Y or ZERO Z softkeys will zero the incremental position for those axes.

You need to set datum to establish the point from which all absolute dimensions are based.

Inch/millimeter

You can display inch or millimeter positions. Press the

MM key to switch from one

to the other.

Teach Position

Whenever X, Y or Z coordinates are being entered, the

TEACH POSITION softkey will

appear, enabling you to “teach”

MILLPWR the coordinate(s) you want to use. MILLPWR

will base each coordinate on the current absolute position and enter that position into the field that you’ve highlighted.

o “teach” MILLPWR a coordinate (while programming a milling function, such as a

line):

• Using the arrow keys, highlight the X-, Y- or Z-axis field.

• Move your tool, indicator, or electronic edge finder to the position

you want to teach.

• Press the

TEACH POSITION softkey to enter that location then press

ENTER. (If you use an electronic edge finder, the positions will

automatically be entered on contact—even if you over-travel.)

• Use the numeric keypad and calculator functions to adjust the number.

· Repeat the steps above for each axis and each location you want to teach.

· Press USE to accept the information or press CANCEL to return to the previous screen

without saving teach position(s).

As you’re programming, you can switch between the DRO and PGM screens without losing your program.

DRO

MILLPWR

Operation Manual

2-6

Using an Electronic Edge Finder

An ACU-RITE

Electronic Edge Finder enables you to “teach” positions, find the center point of a circle, skew a part or locate datum (also known as workpiece zero) by simply “touching off” on the part. The greatest advantage of an electronic edge finder is that it instantly senses when you’ve made contact with the point —even when you over-travel.

MILLPWR lets you define the “Diameter” and “Unit” of measure (either inches or millimeters)

for an electronic edge finder. Once this information has been entered,

MILLPWR will automati-

cally compensate for the radius of the tip of the electronic edge finder when performing any of the operations mentioned above.

o define the diameter and unit of measure:

• Press the SETUP key and highlight “Electronic Edge Finder.”

• Press the

ENTER key.

• Enter a value for the edge finder’s diameter, select a unit of measure (inches or mil-

limeters) then press the

USE key.

• Press the

USE NEW SETTINGS softkey.

Defining the diameter and unit of measure is necessary before using the edge finder because these steps give

MILLPWR the required data it needs to properly place the centerline of the spin-

dle over the indicated edge.

Now the electronic edge finder can be used.

To teach a coordinate with the edge finder, highlight the appropriate field then slowly move the table until the electronic edge finder touches the workpiece. When the electronic edge finder touches the part’s surface, the coordinate will appear in the data field. The electronic edge finder is active whenever an entry field is highlighted.

DRO

MILLPWR

Operation Manual

2-7

Skewing a Part

With

MILLPWR, you can save time setting up a job by skewing your part. The skew function

automatically compensates for the offset angle of your part—so if your part is not perfectly parallel with either the X- or Y-axis, you won’t have to spend time indicating it in.

To skew a part, simply “touch off” on two or more points along one axis (either X or Y). You can use the electronic edge finder to skew your part or you can use a mechanical indicator and teach position—either way, it’s fast and easy.

Note:

Choose a line that you want to make parallel with the table’s X- or Y-axis—do not enter coordinates along a curve, along two different lines or along a line that’s positioned at a true 45 degree angle.

MILLPWR will calculate the skew angle based

upon a straight line between the points you’ve entered.

If you’re working with a part that has a rough edge, it’s best to enter multiple points along the straightest edge so that

MILLPWR can more accurately calculate the skew angle.

Note:

The skew feature does not work with G-code programs. Remove any skew angle prior to running a G-code program.

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