ACU-RITE MILLPWR Auxiliary User Manual

REFERENCE MANUAL

UXILIARY MACHINE INTERFACE

Limited Warranty

The ACU-RITE Auxiliary Machine Interface (AMI) has a limited warranty against defects in material and workmanship for a period of one (1) year from the original date of purchase.

ACU-RITE will, at its option and expense, repair or replace any component(s) of the Auxiliary Machine Interface in question which fails to satisfy this warranty provided that ACU-RITE shall have received notice of the claimed defect(s) during the limited warranty period.

The limited warranty covers all components and accessories and applies only to those Auxiliary Machine Interface products which have been installed and operated in accordance with the instructions in the Auxiliary Machine Interface reference manual(s). ACU-RITE shall have no obligation with respect to any defect(s) or other condition(s) caused in whole or in part by the end user’s abuse, incorrect use, improper maintenance, misuse, modification of the product(s), or by the repair or maintenance of such product(s) by any person except persons deemed qualified to do so by ACU-RITE.

Responsibility for loss in operating performance or other conditions beyond ACU-RITE’s control cannot and will not be accepted by ACU-RITE.

The foregoing limited warranty obligations are in lieu of any and all expressed and/or implied warranties of fitness or merchantability or otherwise, and state ACU-RITE’s entire liability and the end user’s exclusive remedy, under any circumstance, for any claim of damage.

AMI Reference Manual

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

AMI System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Connector Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Input Devices (J2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Output Devices (J18) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

AMI Output Device Overview . . . . . . . . . . . . . . . . . . . . . . . 9

Emergency Stop Inputs (J4) . . . . . . . . . . . . . . . . . . . . . . . . . 13

Emergency Stop Output (J17). . . . . . . . . . . . . . . . . . . . . . . . 16

AMI Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Connecting to

MILL

PPWWRR

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

General Wiring Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Connecting to a Power Source . . . . . . . . . . . . . . . . . . . . . . . 21

AMI Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Programming Auxiliary Output Devices Wired to J18

(Aux. 1-4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Motor Assembly Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

AMI Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Table of Contents

2003-704 Ed D

This symbol alerts you to important information

concerning the installation and/or operation of the

Auxiliary Machine Interface (AMI).

Read these instructions carefully and place them in a

safe and convenient location for future reference.

AMI with Spindle Control Reference Manual

Introduction

This manual discusses how the Auxiliary Machine Interface (AMI) system works in conjunction with the ACU-RITE

MILLPWR

system.

Preparation

Read and understand all instructions in this manual before beginning the installation. Each item has an overview section which will explain their capabilities and will help ensure that each system is installed properly.

Before you begin, ensure the location where you are planning installation, can fully support the power supply requirements that are identified in the Electrical Specifications section at the end of this manual.

Tools

A typical AMI installation will require the following tools:

• Small, flat-tipped screwdriver

• Wire stripper

• Size “F” drill (0.257" diameter)

• 5/16"-18 tap

AMI Reference Manual

Components

There are two types of AMI systems currently available from ACU-RITE. One supports 115 volts and the other one supports 230 volts of power. Both AMIs include a cable for connecting the system to MILLPWR. The 115V AMI also includes a cord for connecting the system to a

MILLPWR servo motor.

230V AMI

Interface Cable

(included with both

types of AMI)

115V AMI

(includes power cord)

AMI Reference Manual

AMI System Overview

The following is a quick reference guide with each connectors name, the page where its description appears, and their most common uses. Figure 1 on the next page shows all connector locations.

There are five connectors available. Four of them are to be used for multiple applications, while the J16 is limited to wiring an external 230V/115V AMI to a power source. Always identify the correct connector for your particular application and read its description in its entirety before beginning the wiring procedure.

Device Input J2 (refer to page 5):

• Monitor the position of machine guards

• Monitor the oil level of automatic lubrication systems

• Remote Go Input

Device Output J18 (refer to page 8):

• Control up to four devices (i.e., coolant pumps and rotary indexers)

• Activate external devices during hole patterns and position/drill steps

Emergency Stop Input J4 (refer to page 13):

• Add table limit switches to the emergency stop circuitry

• Add an emergency stop button to the emergency stop circuitry

Emergency Stop Output J17 (refer to page 16):

• Add other controls to the emergency stop circuitry

Power Input J16 (refer to page 21):

• For use with 230V systems or with an alternate 115V power source—connects AMI to a power source

Connector Descriptions

AMI Reference Manual

Fig. 1

AMI Reference Manual

Input Devices (J2)

The J2 input connector is commonly used to:

• Monitor the position of machine guards

• Monitor the oil level of an automatic lubrication system

• Remote Go Input

Do not apply power directly to the AMI input pins.

Connector Definitions

Machine Guards are safety features that will alter the activity of certain program functions when they are open.

When guard switches are open:

1) Find Home feature cannot be initiated.

2) Single Cycle cannot be run.

3) A program cannot be run.

4) The table is still able to be moved.

If the guard switches are opened during

these operations:

1) Find Home feature will be aborted.

2) The program currently operating will pause and the table will stop moving, but the program will not be aborted.

3) Single Cycle will pause.

Table 1 (J2)

Pin #

Description

9 10 11 12 13 14 15 16

Not active Not active Not active Not active Not active Not active Not active Not active

Pin #

Description

1 2 3 4 5 6 7 8

Machine Guard input Machine Guard input Low Oil input Low Oil input Remote Go input Remote Go input Not active Not active

AMI Reference Manual

Figure 2 shows a typical wiring diagram for machine guards. As the diagram illustrates, the machine guard switch should be wired to pins 1 and 2. When the machine guard switches are open, the contacts to those pins will open, and an Operator Intervention Message (OIM) message will appear on the MILLPWR screen.

Note:

If guards are not used then pin 1 and pin 2 of J2 must be jumpered.

Low Oil is a safety feature that will, under certain conditions, stop program

functions when the lubrication pump supply reaches a certain minimum level of oil. The normally closed low oil switch should be wired to pins 3 and 4.

When the low oil switch opens:

1) Find Home, Move Table, Single Cycle and all program functions cannot be initiated.

If the low oil feature activates during

these operations:

1) Find Home and Move Table functions will be aborted.

2) Single Cycle and program functions will complete their current path and then pause.

Note:

If a low oil sensor is not used, then pins 3 and 4 must be jumpered.

Fig. 2

AMI Reference Manual

If you are not using the J2 or J4 connec-

tor on the AMI, you must wire a jumper at this time to close the circuitry. Otherwise, when you power on

MILLPWR

and the AMI, an emergency stop condi-

tion will automatically occur and

neither system will run.

Remote Go provides a switch input that can be used in place of the operator pressing the

GO key. Pins 5 and 6 (J2) are reserved for this function.

Note:

The Remote Go input signal must be held for a minimum of

0.2 seconds in either ON or OFF mode in order for it to be recognized by the AMI.

AMI Reference Manual

Output Devices (J18)

The J18 output connector is commonly used to:

• Control up to five devices (i.e., coolant pumps and rotary indexers) from within a MILLPWR program.

• Activate external devices during hole patterns and position/drill steps.

Common relay contact Normally Open relay contact Normally Closed relay contact Common relay contact Normally Open relay contact Normally Closed relay contact Common relay contact Normally Open relay contact Normally Closed relay contact Common relay contact Normally Open relay contact Normally Closed relay contact Common relay contact Normally Open relay contact Normally Closed relay contact Common relay contact Normally Open relay contact Normally Closed relay contact Common relay contact Normally Open relay contact Normally Closed relay contact Common relay contact Normally Open relay contact Normally Closed relay contact

Table 2 (J18)

Pin #

Description

Output Function (Default State)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

AMI output #1 AMI output #1 AMI output #1 AMI output #2 AMI output #2 AMI output #2 AMI output #3 AMI output #3 AMI output #3 AMI output #4 AMI output #4 AMI output #4 AMI output #5 AMI output #5 AMI output #5 AMI output #6 AMI output #6 AMI output #6 AMI output #7 AMI output #7 AMI output #7 AMI output #8 AMI output #8 AMI output #8

Normally = Relay de-energized

AMI with Spindle Control Reference Manual

AMI Output Device Overview

MILLPWR AMI interface allows it to control four (4) separate functions such as

mist and flood coolant, indexers,etc. There are three (3) programmable options available when programming an AMI step:

• PULSE - Sends a signal to a device for a programmable length of time. (The pulse duration can not exceed 999.9 seconds).

• ON - Sends a signal until program signals off, or at the completion of the program.

• OFF - Sends a signal to turn device off.

Each of the signals listed above can be set to display, or not display an Operator Intervention Message (OIM) at the auxiliary function step.

• NO - Will signal with no OIM. The signal is sent to the device and the program continues to run. No operator intervention is required.

• BEFORE - Will signal after an OIM. An OIM indicates that pressing “GO” will activate the programmed device. Pressing “GO” causes the signal to be sent, and the program continues to run.

• AFTER - Will signal before an OIM. The signal is sent to the device prior to displaying an OIM. After a signal has been sent, an OIM will be displayed prompting the operator to press “GO” and the program continues to run.

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