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1. ee ee 5 20 Operation Manual ii TABLE OF CONTENTS MILLPWR Circular Milling Functions 0 0 0 eee eee eens 5 22 lues PCc 5 22 gon m hh ho wee oR ee Ree eek ene oe Gea we Oe eee ae 5 24 RUS A PC K rr 5 26 HICK cues ne eee eee eG abe es oe che aey eee oe eek ee woes 5 28 Hole Patterns MERE 5 30 Row OL HOleS oue uy es 22399 Edu ernan 5 30 Hole Frame and Hole Array 0 0 0 cee ee 5 32 Dolthole Circle Pavers 2 so ocucaces d geben RC dede E PES wr qo Ye UR 5 35 Additional Milling Functions 0 0 cece ee ee teens 5 37 Custom Pocket 5 37 R A Lv rm 5 39 lion A bonehead eee Se bane eo ee 5 40 DWHMOP aeugeredeacevagee yew Goa E wee eee aeeuuwees suey oeas 5 41 Gun V oue eh teresa cena tees eek ube eee ee ae he oo ee 5 42 pur goveveasn deve w bode tte eee eet eet eed ee eben gous eee 5 44 POA db pe cee eaere seeks Re mouse enn eon eae ne one eae 5 44 lur E v nm 5 47 lale EWANIC RETE RET TREES ECT TL TITO TT TUTTI TT 5 40 De d C 5 51 Reference POLIUE a uuu auod hak oe oe ee ee he we ee 5 53 ien c C TT TTTITE 5 54 BDIrdl 21292299227 99 0253 97 039 999 9 99 9 eee ee eas Be eee ees 5 55 Comment SICD ada kk doscy 9rd 1d dos oV Sor Oboe eee es ro d 5 57 Auxiliary Function AMI Option
2. 0 0 00 eee eee 5 58 Step Functions Softkey 2 0 0 0 cc ee eens 5 60 PXDIOGS ou sep Y GEEREAUGURSUREERE ER MSS AEN EUR n WEE E 5 60 INOVCISG DICD ao edo 2e sm dece bee Goa Phu sau d EU Ea 5 dE 5 62 Reverse Pal chant heu 40998 9 v EH Re E VE ERU E ben dE Sa de Mods 5 62 Chano SIPS bi c4 5444 tear Ge eadaaeeenheretnatad tees dn sake 5 63 Delete CDS bine ebro eho Os Gee hed eed 5 eh ons 5 64 CODY MOVE SEPS ted daanve eeu ce HbR Chee eh S EA UP ER YER soe ee 5 65 Calculator s eR RR 6 1 Math Functions X asco gruse docs cae chee chew gn ec eae Re Re 6 2 Rar MCI oere a a E RE EEEE 6 2 Geometry Functions auae ewer bene eee BOR doe oe eS ed wee hd 6 4 IV ACU RITE Operation Manual TABLE OF CONTENTS MILLPWHR ACU RITE Working with the Geometry Calculator clle 6 4 GeoCalc Quick Reference Table 0 00 0 00000 6 5 Usima iCOCAIC Pm 6 6 Calculator Functions s eoe vrac tree m badd ere hwRPePssL eR LS PR 6 7 Saving Results Calculated in GeoCalc llus 6 7 Loading GeoCalc Results That You Previously Saved 6 8 Loading Programs into GeoCalc 0 0 0 eee eee 6 9 Cleaning GeoCale rn 6 9 Example Problemi scs seu eura 99 nisu ER PR RUPRUR SUPE Ra dre E UE PRU d 6 10 una wa ewe one deen Bae ee ee wee oe ee ee 6 10 Starting the Program ww ke ene 6 11 Enternno the LINES kasd ooh he dear de EE ERU CS hea eee 6 11 Finding the ArC vi aeew
3. key The ae and keys are BEGIN ABS for performing END 0 0000 ABS math operations FEED 10 00 IPM within a numeric gt ANGLE field TOOL 0 2500 INCH FL END ML TYPE CENTER OFFSET FEED 10 00 IPM TEACH POSITION e Using the keypad enter the following information FROM X1 3 ABS A a f oe afgee nz m LEE Z BEGIN DEPTH 02 ABS m D 2 BBO g 4 4 Operation Manual TO X2 0 ABS Z END DEPTH 25 ABS MILLPWR 001 O02 DEMONSTRATION ACU RITE Now highlight the Offset field The tool specifications will be filled in automatically from the information we entered in step 001 To cut around the outside of the contour in a clockwise direction use a left offset Press the LEFT softkey LEFT MILLPWR has been factory set with a feed rate of 10 inches per minute which is fine for this operation n Press the USE key Notice that the line is immediately displayed on the Program PGM screen This is called immediate part view graphics OFF FEED 0 0 100 TOOL 0 1250 INCH FL END ML SCALE 1 0000 0 00 00 INCH CURRENT PROGRAM SET TOOL MILL LINE PROGRAM CLEAR STEP MORE RUN FUNCTIONS PROGRAM FUNCTIONS STEPS OPTIONS Operation Manual 4 5 DEMONSTRATION MILLPWHR ACU RITE Next program the arc ARC e Press the ARC key MILLPWR assumes that you are continuing from where you left off so it automatica
4. the given lines formed where the given lines intersect line perpendicular to the bisector Points where given Lines perpendicular to the given line and tangent to the Given a radius all arcs tangent to the line intersects given given line and the given arc arc given arc shortest line to the given arc which is perpen dicular to the given line Given an angle all lines tangent to and through the center point of the arc lines from the end points to the center point Center point end points Intersection points Lines tangent to arcs short Given a radius all arcs tangent to both est line between arcs Operation Manual 6 5 CALCULATOR MILL PWR ACU RITE 6 6 Using GeoCalc e Press the POS LINE or ARC key and enter the information that s on your print Refer to Program Steps for assistance e To find a line point or arc highlight the feature s you wish to use and then press the SELECT FEATURE softkey An arrow will appear beside the feature s you ve selected Only two features can be selected at one time e Press the FIND POINT FIND LINE or FIND ARC softkey GeoCalc will automatically find SELECT FIND FIND FIND RETURN CALC FEATURE POINT LINE ARC FEATURE FUNCTIONS all the possible points lines or arcs for the features you ve selected e Either highlight the feature you wish to keep and press the KEEP ONE softkey OR press the KEEP ALL softkey
5. 12 Make sure the axis you are tuning 1s roughly in the middle of its travel Press the GAIN TEST soft key 7 26 Operation Manual SETUP MILLPWH ACU RITE 13 The control will cause the axis to begin moving back and forth approxi mately two 2 inches in each direction 14 While the axis is moving the control automatically adjusts the Gain value until the Following Error is at its lowest value 15 Once the control has reach the optimal Gain value it will automatically stop axis motion and indicate it 1s done by displaying Test Completed 16 The correct values for the Gain and Balance tests have now been established Now you will need to exit and save the new values in to the console 17 Press the STOP TEST soft key then press the USE NEW SETTINGS soft key 18 Power down the console and restart to begin normal operation and have the updated values implemented Operation Manual 7 27 SETUP MILL PWH ACU RITE AMI Outputs In Position Relay The Auxiliary Machine Interface AMI has the ability to send a signal to external devices This signal is sent when MILLPWR is in position for Position Drill steps and Hole pattern steps This 1s when the table has moved to either the X Y coordinates of the position drill step or to each hole of a hole pat tern Choose the appropriate signal for your application from the three options explained below ON When the X Y coordinates for the position drill step
6. CHARACTERS In the Character section highlight a letter number symbol or space Press the ENTER key to make a selection The alphabet block on the left side represents capital letters the block on the right side represents low er case letters To add a space move your cursor to a blank spot anywhere within the Characters box and press the ENTER key You can edit text by pressing the TEXT BLOCK softkey Highlight the character you want to edit and then press one of the following The CLEAR key will delete a character The DELETE LINE softkey will erase the entire line of text that the cursor is in and move all following text lines up The INSERT LINE softkey will insert a blank text line moving exist ing text lines down The CLEAR ALL softkey will erase all of the text within the text block 5 45 PROGRAM STEPS MILL PWR ACU RITE When you ve finished creating editing your text press the EDIT TEXT softkey or press the USE key to return to the Engrave screen MILLPWR will display the text that you ve created on the right e Press the EDIT TEXT softkey if you want to make changes or press the USE key to add the engraving step to your program e Press the EDIT TEXT softkey when you ve finished entering your characters e Press the USE key 5 46 Operation Manual MILLPWR Engrave Arc To engrave along an arc Use mirrored if you re making a mold Operation Manual
7. DRO ACU RITE Finding Home Linear Encoder Option 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 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 technolo gy 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 OFF FEED 0 0 100 SCALE 1 0000 0 00 00 INCH SET DATUM ABS KERAN h aA 0 0 D 0 D 0 D term used to xo a 0 0000 describe work Y After you power up and find home you can quickly move to datum by pressing the POS key fol lowed by the GO key
8. System Statistics The system statistics keep track of the machine s usage The time that the MILLPWR system the display and the servo motors have been running is displayed in hours The distance values for X Y Z and W reflect how far the scales have traveled for each axis To view the system statistics e From the Diagnostics screen highlight System Statistics and press ENTER e Press the EXIT TEST softkey to close the System Statistics screen e Continue with Diagnostics or press the USE NEW SETTINGS softkey SET TiME AND DATE CURRENT TIME 13 32 47 CURRENT DATE 01 30 2000 SYSTEM STATISTICS SYSTEM ON 158 3 HRS DISPLAY ON 147 7 HRS X Y SERVO ON 132 5 HRS Z SERVO ON 96 5 HRS X DISTANCE SMI 3124FT MN TT Y DISTANCE 2M 227FT Z DISTANCE 5279FT W DISTANCE Operation Manual SETUP MILLPWR ACU RITE Max Servo Speed 00 MILLPWR can move each axis a maximum of 100 inches per minute IPM This parameter allows you to establish a lower maximum speed for the X Y axes and or the Z axis To lower the maximum servo speed e Using the arrow keys highlight the X Y SPEED IPM field e Using the keypad enter the new speed for the X and Y axes in inches per minute e Using the arrow keys highlight the Z SPEED IPM field e Using the keypad enter the new speed for the Z axis in inches per minute e Continue with
9. Line 1 Lines Lines 1 and 3 5 1 and 3 c Overlap w Do Not Touch 5 Close Contour Blend Pa It s also possible to close a contour e g a triangle using the blend feature by inserting a blend step immediately after the last step 1n the contour After you enter the blend s radius press the CLOSE CONTOUR softkey and MILLPWR will blend the last step with the first step feu Second Blend Line Blend To program a blend e Highlight a step within your program where you want to place a blend BLEND e Press the BLEND key 4 e Check that the steps listed in the From and To fields are the steps you want to blend If they re incorrect press the CANCEL key and highlight the appropriate step Operation Manual 9 11 PROGRAM STEPS MILL PWR ACU RITE e Enter the blend s radius Press the CLOSE CONTOUR softkey if you want to blend the end of a contour with the beginning STEPS The step numbers in the To and From fields will automat EROM 2 ically change TO 4 R Press either the NORMAL ARC or INVERTED ARC softkey A UE poem normal arc curves outward an inverted arc curves inward FEED RATE 10 00 IPM Line 1 Line 1 Blend Blend Normal Inverted 5 D D ww e e Enter the table s feed rate e Press the USE key 5 12 Operation Manual PROGRAM STEPS MILLPWR Rectangular Milling Functions ACU RITE MILLPWR offers several rectangular milling functions t
10. gt Y J N etc use the Tool Offset field to tell MILLPWR which side of the line you want the tool to be on To determine which offset to use picture yourself following the tool as it is moving If the tool needs to be on the left side of the line use a left offset If the tool needs to be on the right side of the line use a right offset If you use a center offset the programmed dimensions are for the center of the tool For some milling functions like frame and arc inside and outside offsets are available to make it easier for you to define your tool offset Datum Selection SET DATUM Datum is where workpiece absolute zero is located If X mum datum isn t defined on your print then determine datum Y based upon where most of your dimensions originate You z should pick a point which will let you enter most of the lc 00000 dimensions directly with few 1f any calculations refer to Establishing Datum located in Section 2 As you establish datum you ll be prompted to provide a Z retract position 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 its default retract
11. 0 2 PP tert tb tr t g d og 6 13 CALCULATOR MILL PWR ACU RITE Finding the Arc Now that the lines are complete it s time to find the arc Do this by selecting the lines that have been drawn and then using GeoCalc to find the arc Highlight 001 GEOLINE and press the SELECT FEATURE softkey The arrow indicates that the 001 CEOLINE feature has been selected 002 CEOLINE e Now highlight 002 GEOLINE and press the SELECT FEATURE softkey e Press the FIND ARC softkey The message bar will display a field for the arc radius e The print shows that the arc s radius is 0 625 Using the keypad enter 0 625 and then press the USE key GeoCalc will display all of the arcs that have a 0 625 radius and are tangent with the two lines that have been selected A D and B C e Using the arrow keys scroll through the list of found GeoArcs until the arc desired is highlighted e Press the KEEP ONE softkey and GeoCalc will save the arc as item 003 e Arrow down and then press the CLEAR RESULTS softkey to erase the remaining arcs OFF FEED 0 0 100 SCALE 1 0000 0 00 00 INCH OFF FEED 0 0 100 STALE 1 0000 GEOMETRY CALCULATOR DEPUETHUEYISEEUNUENAE 001 gt GEOLINE 002 GEOLINE 001 GEOLINE 002 GEOLINE 003 GEDARC GEOARC GEOARC GEOARC GEOARC GEOARC GEOARC GEURRC 10 or 10 CLERR CALC RESULTS FUNCTIONS END OF 3 CURRENT SELECTIONS O01 GEOLINE AND O02 GEOLINE SELECT FI
12. Arrow down and highlight the Offset field Using the softkeys select the tool offset LEFT CENTER RIGHT INSIDE or OUTSIDE Enter the table s feed rate TOOL If you need to enter a center coordinate 3 point and or sweep 0 1250 INcH FLEND MILL TYPE CENTER OFFSET angle FEED 10 00 IPM CENTER Center nee Enter the center coordinate s position for the X and eet Y axes X3 ABS NS ABS RD SWEEP ANGLE ccZL 3 Point Enter your 3 coordinate s position for the X axis X3 and Y axis Y3 Sweep Angle Enter the sweep angle Information that appears in blue has been calculated If any of these values are already displayed in blue then MILLPWR has enough data for the arc and has calculated the rest Press the USE key Note If the tool size and type listed in the Tool field are incorrect change the tool 9 10 settings before running your program refer to Programming a Tool Step Operation Manual PROGRAM STEPS MILLPWR ACU HITE Blend A blend 1s an arc that connects two lines two arcs or a line and an arc All you have to do is provide the radius for the blend and indicate whether it is normal or inverted MILLPWR will calculate the tangent points for you The two steps you want to blend can but don t have to intersect or touch If they don t come into contact with each other check that your radius 1s large enough to connect them Line 1 i Line 1
13. Power down the system Wait for approximately one minute then power the system up Remember to reestablish machine tool zero using the Find Home routine Run the Keypad Test refer to Diagnostics Section 7 Should the above recommenda tion not correct the problem you are experiencing contact your ACU RITE distributor for repair and or replacement pro cedures Check the message bar for the following message Table Stop Button is Pressed Release the table stop button and press the CLEAR key Review selections in Run Options Review selections in Run Options Check the message bar for the following message DSP fault X Y or Z axis position error check failed Operation Manual MILLPWR Symptom System powers up but motor s will not move cont d Operation Manual TROUBLESHOOTING GUIDE Probable Cause Improper scale connection cont d For Z axis Optional Linear encoder X Y and or Z axes precision glass scales stopped counting ACU RITE Recommended Corrective Action Check the scale connections at the motor assemblies For Z axis Optional Linear encoder While in the DRO display move each axis manually to verify that the precision glass scales count If the precision glass scales do not count perform the follow ing Press the table stop button Swap the X and Y axes servo connections In the DRO display move each axis manually to
14. Press the SET BOTTOM LIMIT softkey Press the USE key Continue with Setup or press the USE NEW SETTINGS softkey Error Checking With the error checking feature enabled MILLPWR can detect scale miscounts and record them in the Error Log MILLPWR will stop the program if a scale miscount 1s detected To enable disable the error checking feature 1 22 From Installation Setup highlight Error Checking and press ENTER Press either the ENABLE or DISABLE softkey Press the USE key Continue with Setup or press the USE NEW SETTINGS softkey ERROR CHECKING W rn d DISABLED Operation Manual MILLPWR SETUP ACU RITE Serial Port You can connect MILLPWR to your PC via the serial port located on the rear of the operator console The serial port allows you to store part programs on your PC To activate the serial port From Installation Setup highlight Serial Port and press ENTER SERIAL PORT FUNCTION i Press the REMOTE STORAGE softkey to change the BAUD RATE Function setting from Off to Remote Storage 56000 2c T HANDSHAKE STATUS Highlight Baud Rate ENABLED Define the Baud rate by pressing the LOWER or HIGHER softkeys The Baud rate you select must match your PC s Baud rate Highlight Handshaking The handshaking feature verifies that MILLPWR and your PC are communicating pro
15. Program Enter information steps are about a milling added function such here as an arc into forms like this CURRENT PROGRAM UNITS ARE INCHES Operation Manual 3 5 PROGRAMMING MILLPWR ACU RITE e After entering all the data for a step press the USE key to add the step to your program This immediately updates the part graphic and positions the cursor for the next step If you decide not to finish a milling function that you have begun simply press the CANCEL key OFF FEED 0 0 100 SCALE 1 0000 0 00 00 INCH CURRENT PROGRAM a he Get x L Rate Nt 001 MILL ARC PROGRAM CLEAR STEP MORE RUN FUNCTIONS PROGRAM FUNCTIONS STEPS OPTIONS To edit a step use the arrow keys to highlight the step you want to change and press USE or ENTER When you have made your changes press USE to accept your changes and place the step back into your program To delete a step highlight the step you want to delete then press CLEAR e To insert a step between the two existing steps position the cursor to where you want the new step to go and press the desired milling function key In addition to the hard key milling functions the MORE STEPS softkey lets you pick from a number of other useful steps such as CUSTOM POCKET ISLAND ELLIPSE MIRROR REPEAT and ROTATE each of which are described in the Program Steps section of this manual 3 6 Operation Manual PROGRAMMING MILLPWR ACU RITE The View Key If you nee
16. Y ABS Z BEGIN END PECK FEED RADIUS DIRECTION ABS 0 0000 ABS DRILL 10 00 IPM CCW HOLES Drill The quill Will feed down then rapidly move up Bore The quill Will feed down then feed up Position You will be prompted to move the quill manually 5 35 PROGRAM STEPS MILLPWR ACU RITE e If you need to program a tool retract start angle and or end angle press TOOL RETRACT PE ul DISTANCE the MORE softkey DWELL SEC START ANGLE o Tool Retract B ENDANGLE Enter the number of tool retracts or the distance between each retract Enter the length of time in seconds that you want the tool ME I3 0 2500 INCH to dwell pause DRILL TYPE Start Angle Enter the start angle of the first hole in the bolthole circle pattern refer to graphic below End Angle Enter the end angle of the last hole in the bolthole circle pattern refer to graphic below e Press the USE key Note If the tool size and type in the Tool field are incorrect change the tool settings before running your program refer to Programming a Tool Step s 90 0 Start Angle bi 90 0 O Start E e ss ae se eee Fle m f 90 0 7 Start Angle M En ERAS i Set to 0 ES l End Angle
17. l i PRESS THE CANCEL KEY TWICE TO EXIT THE KEYPAD TEST Operation Manual 7 35 SETUP MILL PWR ACU RITE Display Test The display test is used to verify that the system s sleep mode is working properly and that all of the pixels in the LCD are functioning Pressing the Sleep Test softkey will activate the sleep mode the screen will go blank Press any key or move the table to return the screen to its normal view Each time you press the Color Test softkey the display will flash a different color Keep pressing the softkey until the sequence 1s complete and the screen returns to the normal view SLEEP COLOR EXIT TEST TEST TEST To run the display test e From the Diagnostics screen highlight Display Test and press ENTER e Press either the SLEEP TEST or COLOR TEST softkey If you pressed the SLEEP TEST softkey press any key or move the table to return the screen to its normal view If you selected the COLOR TEST softkey press it repeatedly and scroll through the color sequence black white red green blue The test is complete when the normal view returns e Press the EXIT TEST softkey to close the Display Test screen e Continue with Diagnostics or press the USE NEW SETTINGS softkey 7 36 Operation Manual SETUP MILLPWH ACU RITE Disk Utilization The disk utilization screen shows MILLPWR s memory capacity and how much memory is still available Like a PC MILLPWR uses mem
18. 0 5000 INCH Took TYPE INSIDE OFFSET FEED 10 00 IPM Operation Manual PROGRAM STEPS MILLPWR ACU RITE e f you need to program a start angle and or a number of revolutions press the MORE softkey START ANGLE 0 00 00 REVOLUTIONS Start Angle Enter the angle where the helix begins 3 o clock position is O degrees 12 o clock position is 90 degrees Revolutions Enter the number of revolutions e Press the USE key Note If your tool size and type listed in the Tool field are incorrect change the tool settings before running your program refer to Programming a Tool Step Operation Manual 5 29 PROGRAM STEPS MILLPWHR 0 30 ACU RITE Hole Patterns MILLPWR includes several built in routines that let you program hole patterns quickly and easily Row of Holes A row of holes can be programmed two ways Hole Spacing Y axis From Point a se Y axis e By entering the coordinates of the 2 1 6 To Point first and last hole i ii From Point Byentering the coordinates of the X axis To Point first hole the spacing between each hole and the row s angle The From point refers to the center of the first hole while the To point is the center of the last hole Any additional holes will be spaced equally between these two You ll also be prompted for peck and tool retract values Peck lets you break
19. ACU RITE 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 To teach MILLPWR a coordinate while programming a milling function such as a line e Using the arrow keys highlight the X Y or Z axis field 004 l l As you re pro e Move your tool indicator or electronic edge finder to the position gramming you can switch between the DRO and PGM e Press the TEACH POSITION softkey to enter that location then press AE T ENTER If you use an electronic edge finder the positions will program you want to teach automatically be entered on contact even 1f 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 Opera
20. From the PGM screen press the MORE STEPS softkey Press the MORE STEPS softkey again Press the ENGRAVE ARC softkey Enter the X and Y axes coordinates for the center point of your engraving s arc Enter the character height Enter the radius Select either the UP or DOWN softkey Up means that the arc will curve upward Down means that the arc will curve downward Enter the tilt angle 1f any Enter the begin and end depths for the Z axis Enter the Z axis feed rate Highlight Font Press the ENGRAVER FONTS softkey highlight the font you want then press ENTER Highlight Modifier Press either the NORMAL or MIRRORED softkey Normal means the type will be readable from left to right Mirrored will make the engraving appear backwards Enter the table s feed rate Press the EDIT TEXT softkey PROGHAM STEPS ACU RITE Downward Arc ABODE Z ABCDES Upward Arc ENGRAVE ARC 006 TEXT CENTER 1 0000 ABS 2 0000 ABS CHARACTER HEIGHT 0 2500 3 0000 UP TILT ANGLE 0 00 00 BEGIN 0 0200 ABS END 0 0300 ABS FEED 10 00 IPM STYLE SIMPLE FONT NORMAL MODIFIER TOOL 0 0500 INCH ENGRAVE TYPE CENTER OFFSET FEED 10 00 IPM 9 4 PROGRAM STEPS MILLPWR 0 48 ACU RITE Notice that the screen is divided _ into two sections Text Block Texr Bock and Characters You can swit
21. Press the CW softkey for clockwise or the CCW softkey for a counter clockwise direction e Press the USE key Note If the tool size and type listed in the Tool field are incorrect change the tool settings before running your program refer to Programming a Tool Step 5 56 Operation Manual MILLPWR PROGRAM STEPS ACU RITE Comment Step With MILLPWR you have the ability to insert messages ATTENTION anywhere within a program These messages can be displayed during machining at run time or as Operator Intervention Messages OIM These messages become operational steps within the program and communicate pertinent information like ROTATE PART or ACTIVATE COOLANT ROTATE PART For comments that don t require an operator intervention select No when asked if you want the comment displayed at run time and MILLPWR will skip over them during machining You can always retrieve the message by highlighting the comment step in your program steps list and pressing ENTER To program a comment step From the PGM screen press the MORE STEPS softkey COMMENT MESSAGE Press the MORE STEPS softkey two more times DISPLAY AT RUN TIME Press the COMMENT softkey ini Enter your message You may include up to 20 charac ters mixing numbers letters spaces and symbols if you wish Press the ALPHABET softkey to chose alphabet character needed To add a space highlight a blank spot within the alph
22. When the GO button is pressed MILLPWR will see that step one is asking for the same tool as the current tool and will proceed on the next step When the next tool step is executed you will be prompted to change tools to the drill Simply change the tool and press GO to continue The next tool step 5 1s of unknown length When this step 1s executed and you are prompted to change tools e Press the DATUM softkey The DRO screen will appear with the set datum window e Place the counter bore in the spindle and touch the cutting edge to the top of the workpiece e Press the Z 0 softkey and then ENTER The tip of the tool is now set at datum zero e Press GO to continue with the program Since the Z axis datum was set using a tool of unknown length the programmed tool lengths will not repeat until the Z axis datum is reset again using a tool of known length This can be done when step 1 is run on the second part After the part has been changed e Press GO You will be prompted to change tools to the center drill e Press the DATUM softkey The DRO screen will appear with the set datum window e Place the center drill in the spindle and touch the tip to the top of the workpiece e Press the Z 0 softkey and then ENTER The tip of this tool is now set at datum Zero e Press GO to continue with the program Now that datum has been reset with a tool of known length all of the preset tools again relate to datum The program can continue as us
23. radius then the tool will cut from the outside in or vice you may versa teach the positions for the center point e Select the direction by pressing the CW softkey for a and depth clockwise direction or the CCW softkey for a counter clockwise direction Operation Manual 5 55 PROGRAM STEPS MILL PWR ACU RITE e Enter the sweep angle e g 180 for a half rotation 360 for one rotation 1080 for three rotations etc Use the calcula tor keys to let MILLPWAR factor e Using the softkeys choose a tool offset LEFT CENTER the angles for RIGHT INSIDE or OUTSIDE you For exam ple enter 3 5 x 360 to create a e Enter a table s feed rate spiral with three and a half rota e If you need to program a start angle or would like to Hone program a finish cut aon Start Angle CENTER You ll want to program a start angle if the beginning point of your X 0 0000 ABS is du d ee me Ae spiral on your print is tilted that is not positioned at a O degree angle 3 o clock BEGIN 0 0200 ABS No M Highlight Start Angle then enter the angle of the spiral s start FEED 10 00 IPM ing position measured from the X axis RADIUS 2 0000 START uu 5 0000 END Finish Direction Enter the amount of material to be removed during the finish cut CW SWEEP ANGLE f AAASANIAAT Enter the feed rate for the finish cut ECTS Select the direction for the finish cut
24. 25 0000 X CoMPENSATION PPM 6 0000 Y STANDARD LENGTH INCH Y COMPENSATION PPM ACU RITE Error Compensation MILLPWR is able to automatically calculate and compensate for machine tool wear If you know the error compensation value in parts per million PPM you can enter it directly Otherwise use the following procedure to determine the value for each axis Note You can only perform error compensation for one axis at a time e Set up a standard of known length e g a gage block by indicat ing it in along the axis to be measured Check that the standard is straight and parallel with the axis you re working with Enter the length of the standard If you need to touch each end of the standard using opposite edges of the electronic edge finder or mechanical indicator be 0 sure to include its diameter when entering the length of the Check between the first and second points several times note the error value to ensure repeatability i Length of standard standard Refer to the graphic below Touch one end of the standard and press the FIRST POINT softkey If you re using an electronic edge finder you won t have to press the first point softkey Touch the opposite end of the standard and press the SECOND POINT softkey If you re using an electronic edge finder you won t have to press the second point softkey MILLPWR will determine and automatically enter the
25. 47 63 Hz Current 8 5A rms nom 18A rms peak inrush Fuse 15A 250V resettable circuit breaker Encoder input Position signals channels A amp B TTL square wave signal in quadrature 90 nominal phase relationship Maximum input rate 50 kHz Reference signal TTL square wave Edge finder input Compatible with ACU RITE Electronic Edge Finder FCC compliance Class A INTRODUCTION MILLPWR ACU RITE INTRODUCTION System Overview Operator ts 4 Console Motor Drive Assemblies ACU RITE Scales Licensed under U S Patent No 5 941 663 applies to Linear Encoder systems with Z axis only Operation Manual 1 1 INTRODUCTION MILLPWR ACU RITE Front View of Operator Console Power Indicator Hard Key Milling Functions ACU RITE Hea amp 10 m S Flat panel aoa Color LCD 8 9 Display 3 PP NAYRA Too 07D T T T TABLE STOP Table Softkeys Stop 5 2 3 xX o 7 3 e E e ps De gt JC S Floppy Disk Drive Rear View of Operator Console Ground Post Power Input 1 2 TOUCH PENDANT PROBE XQ e ENCODER ENCODER EDGE FINDER 1 TEST Y AXIS SERVO o Z AXIS SERVO A RUD Operation Manual MILLPWR INTRODUCTION ACU RITE Keypad Layout Main Function Keys ABS Switch from absolute to incremental or vice versa in the DRO display and milling function numeric fields Manipulate your part graph
26. 80 e Enter the table s feed rate e f you would like to program a finish cut press the MORE softkey Enter the amount of material to be removed during the finish cut Enter the feed rate for the finish cut Select the finish cut s direction Press the CW softkey for clockwise or the CCW softkey for a counter clockwise direction Enter a stepover percentage how much you want your tool to overlap on each pass e Press the USE key Note If your tool size and type listed in the Tool field are incorrect change the tool settings before running your program refer to Programming a Tool Step Operation Manual 5 27 PROGRAM STEPS MILLPWR 0 28 Helix A helix is a spiral like form that winds at a uniform angle A helix can be defined two ways e By the radius depth and pitch e By the radius depth and number of revolutions To program a helix e Press the CIRCLE key e Press the HELIX softkey e Enter the X and Y axes coordinates for the center point e Enter the begin and end depths for the Z axis e Enter the radius e For Direction press the CW softkey for clockwise or the CCW softkey for a counter clockwise direction e Optional Enter the pitch e Choose INSIDE or OUTSIDE offset e Enter the table s feed rate ACU RITE CENTER x ABS Y ABS Z BEGIN ABS END 0 0000 ABS Ex DIRECTION PITCH REV IN
27. FUNCTIONS softkey programs so that you can easily racover Press the MERGE softkey The last directory that was opened will your original appear You can change directories 1f you need to refer to Selecting a IRAE dh uem Directory need to Using the arrow keys highlight the program that you want to merge into your program Press the MERGE softkey again The steps from the program you highlighted should now appear in your program Note The merge function does not work with G code files or DXF files Operation Manual 3 37 PROGRAMMING MILLPWR 3 38 ACU RITE Backing Up a Program With the BACKUP softkey you can make backup copies of programs that you have already saved on MILLPWH s internal memory You It s best to save the final version should keep backup copies on hand in case a program is accidentally of a program deleted or modified or you can t recover the original programs for nad dd eating a backup copy any other reason AE py you ll have to back up the program again To back up a program ale youve made any e From the PGM screen press the PROGRAM FUNCTIONS softkey changes then select the directory containing the program s you want to back up refer to Selecting a Directory Now press the BACKUP softkey The following softkey options should appear SELECT A BACKUP FUNCTION ALL SELECT USE REMOTE PROGRAMS PROGRAMS FLOPPY STORAGE Indicate where you want to back up y
28. G code program With G code files there 1s no accompanying graphics Only the program list 1s displayed Once loaded MILLPWR will indicate lines of code with invalid and unsupported blocks with an X If the line containing the code is high lighted an error message also appears 1n the message line indicating that the line contains invalid code The invalid code can be removed by disabling the corresponding functions in the CAD CAM software and re posting the G code program Simply removing the invalid code from the G code pro gram can cause unpredictable results and 1s not recommended Running a G code Program The tool path should be proofed prior to attempting to machine a part on MILLPWR Most CAD CAM Software packages have this ability When a program has been proofed and loaded into MILLPWR lower the knee and dry run the program to verify the tool path and speeds and feeds are correct Operation Manual 3 31 PROGRAMMING MILLPWR ACU RITE 3 32 Starting and Stopping a G code Program Always start the program from a place in the program where the feed rate X Y and Z axis position are known such as a tool step Alternate starting points can be programmed by placing the proper code in the desired locations Pressing the GO button will cause MILLPWR to begin executing the current G code program Always insure the program step highlighted is an appropriate starting point When a program is running pressing the STOP button o
29. Line To engrave along a line e From the PGM screen press the MORE STEPS softkey e Press the MORE STEPS softkey again e Press the ENGRAVE LINE softkey e Enter the X and Y axes coordinates for the point at the lower left corner of your engraving e Enter the character height e Enter the tilt angle 1f any e Enter the begin and end depths for the Z axis e Enter the Z axis feed rate 5 44 CHARACTER HEIGHT 0 2500 TILT ANGLE 0 00 00 Z BEGIN 0 0200 ABS END 0 0300 ABS FEED 10 00 IPM STYLE SIMPLE FONT NORMAL MODIFIER Operation Manual MILLPWR Operation Manual PROGRAM STEPS ACU RITE Highlight Font If you want to change the font press the ENGRAVER FONTS softkey highlight the font you want then press ENTER Highlight Modifier and press either the NORMAL or MIRRORED softkey Normal means that the engrav Use mirrored i ae P if you re making ing will be readable from left to right Mirrored will PUE make the engraving appear backwards Enter the table s feed rate Ole FEED 0 0 100 SCALE 1 000 0 00 INCH TEXT Block Press the EDIT TEXT softkey PART 1284 567 Uppercase Lowercase Letters Letters Notice that the screen is divided into two sections Text Block and Characters You can switch from one to the other by pressing either the TEXT BLOCK or CHAR ACTER softkey Use the arrow keys to move around within each section
30. ON OFF feed rate current tool scale job clock and the current display setting inches or millimeters 2 Information area displays information about the Job being performed e Readout DRO used as a digital readout the display will show the current position for each axis e Program PGM when programming a list of program steps milling functions and part view graphics will be displayed e Calculator CALC the geometry calculator enables you to calculate missing information and then insert it into your program s 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 1 4 Operation Manual INTRODUCTION MILLPWR ACU RITE 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 WARNING 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
31. STEPS MILLPWR ACU RITE Repeat Using this step you can repeat whole programs or sections of programs horizontally vertically or both Repeat Repeat Original rigina E 0 To program a repeat e From the PGM screen press the MORE STEPS softkey LAST 9 OFFSET SrEP RANGE E 2 e Press the REPEAT softkey Tip Use the TEACH POSITION softkey to indicate a second e Enter the number of the first step and the last step in the step range that you want to repeat e Enter the offset for the X Y and or Z axis The offset is the distance between repeats e Enter the number of times you want to repeat the original steps Note The steps being repeated must precede the Repeat step lip Entering a O zero for the number of repeats will change the location of the original steps entered in the FROM and TO fields To shift the datum of an entire program place a repeat step at the end of the program and enter the required coordinate shift s in the X Y and or Z axis fields When USE is pressed the entireprogram will shift by the entered values Operation Manual 5 39 PROGRAM STEPS MILL PWR ACU RITE 0 40 Rotate With Rotate you can rotate whole programs or sections of programs 001 TOOL 002 1 MILL LINE 003 MiLL LINE 004 LJ MILL LINE 005 POSITION DRILL 006 ROTATE Condition The steps rotated must precede the Rota
32. and retain all the features that are on the screen The RETURN FEATURE softkey transfers the object s you ve highlighted from GeoCalc and into your program or milling function freeing you from having to write the information down and then entering it in number by number from the keypad Operation Manual aC CALCULATOR MILLPWR ACU RITE Calculator Functions GeoCalc has other useful features that make programming easier like saving and loading calculations Press the CALC FUNCTIONS softkey to access the following functions LOAD SAVE CLEAR ei E es PROGRAM FLOPPY FUNCTIONS Saving Results Calculated in GeoCalc GeoCalc lets you save your calculations on MILLPWF s internal memory or on a floppy diskette so that you can retrieve them at a later time Note You may only save the results of one GeoCalc session at a time onto MILLPWR s internal memory or onto a floppy disk Use one floppy disk for each GeoCalc session you want to save To save your GeoCalc results onto MILLPWH s internal memory e From GeoCalc press the CALC FUNCTIONS softkey SELECT A CALCULATOR FUNCTION SAVE CLEAR s E PROGRAM FLOPPY e Press the SAVE softkey CALC FUNCTIONS LOADING A SAVED CALCULATOR WILL CLEAR THE CURRENT CALCULATOR PROCEED e To replace what you ve previously saved press the YES softkey If you do not wish to proceed press the NO softkey Operation Manual 6 7 CALCULATOR MILL PWR ACU RITE 6
33. axis slowly spinning the tool by hand as you go Pay close attention as the tool approaches the part you ll feel a subtle bump when they come into contact Stop the table at the moment the tool touches the part Use the MOVE TABLE softk e Using the keypad enter the radius of the tool the distance from the to help eh Kd center of the tool to the edge of your part into the X field Be sure long table to specify if it s a negative value moves Note In our example we ll need to specify a negative value because the tool s center is on the negative side of our datum refer to Axis Conventions e Press the ENTER key Now we ll set datum for the Y axis using the same procedure e Position the tool so that it is near but not touching the front face of your part The tip of the tool should fall below the top surface of the part e Move the table along the Y axis slowly spinning the tool by hand as you go Pay close attention as the tool approaches the part you ll feel a subtle bump when they make contact Stop the table at the moment the tool touches the part e Using the keypad enter the tool s radius into the Y field be sure to specify if it is a negative value e Press the ENTER key Operation Manual 3 11 PROGRAMMING MILLPWR ACU RITE Finally we ll set datum for the Z axis e Position the tool so that its tip touches the top surface of your part e Using the keypad enter 0 into t
34. before running your program refer to Programming a Tool Step Operation Manual PROGRAM STEPS MILLPWR ACU HITE ARC Arc An arc can be defined several ways Sweep Angle e With a From point To point and a radius e With a From point To point and a center point Radius e With a From To and a 3rd point along the arc 3rd Point Y eccl Y Center Point From e With a From or To point center point and a sweep angle Choose a method based upon the information available from your print While programming keep in mind that the arc s sweep angle is measured from the X axis lo program an arc e Press the ARC key e Enter the beginning coordinates for the X axis X1 and Y axis Y 1 in the From field e Enter the ending coordinates for the X axis X2 and Y axis Y2 1n the To field FEED 10 00 IPM RAADIUSE e Enter the begin and end depths for the Z axis ER DIRECTION 0 0000 ABS e Enter the Z axis feed rate e Enter the arc s radius then press either the MAJOR ARC or MINOR ARC softkey A major arc has a sweep angle greater than 180 degrees a minor arc s sweep angle is less than 180 degrees MAJOR ARC Operation Manual 5 9 PROGRAM STEPS MILLPWR ACU RITE Select the cutting direction Press the CW softkey for a clockwise direction or the CCW softkey for a counter clockwise direction
35. chips and reduce chip buildup during drilling operations Tool Retract allows you to pro eram MILLPWRAB to raise the tool at regular intervals To program a row of holes e Press the HOLES key e Press the ROW softkey e Inthe From field enter the X and Y axes coordinates for the center of the first hole Operation Manual MILLPWR e Now either Enter the X and Y axes coordinates for the center of the last hole PROGRAM STEPS in the To field or Press the MORE softkey and enter the distance you want between each hole from center point to center point in the Hole Spacing field Also enter the angle of the row of holes e Enter the begin and end depths for the Z axis e Optional Enter either the number of pecks OR the distance Drill The quill will feed down then rapidly move up Bore The quill will feed down then feed up Position You will be prompted to move the quill manually between each peck e Select the DRILL BORE or POSITION softkey e Enter the Z axis feed rate e Enter the number of holes you want to include in the row If you want the tool to retract Enter either the number of retracts OR the distance between each retract ACU RITE ROW OF HOLES END 0 0000 PECK DRILL FEED 10 00 TOOLRETRACT DISTANCE DWELL SEC HoLe SPACING j BETWEEN TiLT ANGLE 0 00 00 T MM 0 2500 I
36. direction block M3 or M4 The setting applies to current and subsequent spindle direction blocks The default is O rpm The tool selection represents the number of the tool to use at the next tool change The selection applies to current and subsequent blocks containing a tool change M6 The default is no tool selec tion The coordinates represent the destination for the GO G1 G2 or G3 command currently in effect They use the current units G20 and G21 and offset mode G90 and G91 3 35 PROGRAMMING MILLPWR ACU RITE Additional G code Conventions for MILLPWR The following lists some of the expectations and limitations of programs imported into MILLPWR 3 36 Blocks may contain multiple commands and are executed with the following precedence Messages Tool Change Spindle Control Coolant Control Dwell Motion Stop Operator comments should be enclosed in parentheses An operator comment with MSG appearing within the text is considered a message The text following MSG up to 22 characters is displayed to the operator at run time Program execution pauses until the operator acknowledges the message Arcs may only be programmed by endpoint and center Using endpoint and radius will gen erate a run time error Parametric programming use of variables or algebraic operations 1s not supported The characters lt or gt within a block will generate a run time error Program delimite
37. explode the following func tions e All Holes functions row frame array and bolt circle e Repeat Mirror and Rotate e Engrave In the example on the right a bolthole circle with eight holes has been programmed Now use the same basic pattern but with seven holes To edit the program first highlight the Bolt Circle step and then press the EXPLODE softkey 5 60 Operation Manual MILLPWR CURRENT PROGRAM SET TOOL 002 PosiTION DRILL 003 POSITION DRILL POSITION DRILL POSITION DRILL POSITION DRILL POSITION DRILL POSITION DRILL POSITION DRILL To explode a step Highlight the step Operation Manual Notice how the individual Position Drill steps replaced the Bolt Circle step Press the STEP FUNCTIONS softkey Press the EXPLODE softkey PROGHAM STEPS CURRENT PROGRAM SET TooL POSITION DRILL POSITION DRILL OSITION DRILL Position DRILL POSITION DRILL POSITION DRILL POSITION DRILL ACU RITE MILLPWR will explode the Bolt Circle steps into eight steps shown on the left above Next highlight the step that represents the hole that needs to be deleted and press the CLEAR key In the graphic above chose to delete the hole programmed in step 4 As you can see in the graphic on the right the bolthole circle pattern now has seven holes The step that you exploded will be replaced with the individual lines arcs or positions
38. for the Z axis e Enter either the number of passes OR the distance between each pass Pass refers to the cuts that are used to machine the pocket to its End depth TOOL 0 5000 INCH FL END ML TYPE FEED 10 00 IPM e Enter the Z axis feed rate e Enter the radius e For the Direction press the CW softkey for a clockwise direction or the CCW softkey for a counter clockwise direction e Enter the cutting feed rate Operation Manual PROGRAM STEPS MILLPWR ACU RITE e If you want to program a finish cut press the MORE softkey FINISH Enter the amount of material to be removed during the finish cut et DIR CW STPOVR 80 Enter the feed rate for the finish cut Select the finish cut s direction Press the CW softkey for a clock wise direction or the CCW softkey for a counter clockwise direction Enter a stepover percentage how much you want your tool to overlap on each pass e Press the USE key Note Ifthe tool size and type listed in the Tool field are incorrect change the tool settings before running your program refer to Programming a Tool Step Operation Manual 5 23 PROGRAM STEPS MILLPWR 0 24 Frame ACU RITE A circular frame is determined by its center point and radius The direction will determine if you re climb cutting or conventional cutting The tool offset will determine if you are cut ting an inside or outside frame OUTSIDE FRAME AT Ra
39. i ABS uum se 0 0000 absolute zero 0 0000 fs RETRACT lt _ iz 0 0000 ABS Zi 0 0000 0 0000 E ENTER THE NEW ABSOLUTE POSITION OF THE TOOL CENTER Operation Manual 2 3 DRO MEE S S 2 P SS LLL LI IL MILL PWH ACU RITE 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 e Press the MOVE TABLE softkey to turn the servo motors on Press it again to turn them off It s a good idea e Enter the desired feed rate or skip this step to move at a rapid to fold in the handles before feed rate novia tho table e f 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 e 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 e Press the FEED and FEED keys to adjust your feed rate SCALE 1 0000 ABS X 0 0000 0 0000 5 ABS Ys 0 0000 0 0000 E RBS Z 0 0000 0 0000 u amp CAUTION ARROW KEYS WILL MOVE TABLE 0 001 Operation Manual MILLPWR DRO
40. in addition to pressing the TABLE STOP button Operation Manual 1 5 INTRODUCTION MILLPWR ACU RITE 1 6 Conventions 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 INTRODUCTION MILLPWR ACU RITE Cartesian Coordinates A cartesian coordinate is a position that can be measured from the X and Y axes REFERENCE PONT 002 POINT 75 X 5 0000 ABS Y 22400 ABS DEPTH Iz 0 0000 ABS Polar Coordinates A polar coordinate is a position that is defined by an angle and a radius POINT 222222222272222272272 7 R 6 4000 ABS A CME ABS DEPTH Z 0 0000 ABS Operation Manual 1 7 INTRODUCTION MILLPWR ACU RITE Absolute and Incremental Dimensions Dimensions that you enter from a print are Y either absolute or incremental Abs
41. position refer to Conventions located in Section 1 Operation Manual PROGRAMMING MILLPWR ACU RITE Absolute vs Incremental Dimensions MILLPWR allows you to enter both absolute and incremental dimensions A dimension mea sured from the point you defined as datum is an absolute dimension A dimension measured from any other point is an incremental dimension In the examples below the print on the left shows datum located at the center of Hole F all dimensions are absolute The print on the right shows datum located in the lower left corner point A Most of these dimensions are incremental 3 603 3 503 2 96 DIA THRU HOLE 2 96 DIA 9 THRU 3 836 HOLE 3 936 Continuous Milling When you program a continuous contour of lines and or arcs MILLPWR will cut the contour without stopping MILLPWR will automatically recognize continuous FROM TO contours as you re programming There are no special p FROM key presses or other functions to learn For lines and arcs to be continuous they must TO e Be consecutive steps in a program e Have the same depth Be cut with the same tool Be cut using the same tool offset e Share a common From or To point one step must end at the point where another begins Operation Manual 3 3 PROGRAMMING MILLPWR ACU RITE If one step follows another MILLPWR assumes that you want them to be connected It auto matically fills in the From point
42. selected Pulsed then enter the amount of time in seconds that you want the relay to remain on The maximum amount of time that a relay can pulse is 999 0 seconds Highlight the Display User Prompt field NO If you do not want an operator prompt to be displayed press NO Before Step Pressing Before Step causes an operator prompt to display before the auxiliary function s execute The prompt will show you what each out put will do Pressing GO will execute the auxiliary function s After Step Pressing After Step causes the operator prompt to display after the auxiliary function s execute The program will pause until GO is pressed or a signal from an auxiliary device is received e Pressing Yes for the Set Continuous field allows an Auxiliary Function Step to be entered e g activate coolant without interrupting the continuous milling path e Press the USE key Note Check that the devices you are using are powered on before running your program Operation Manual 5 59 PROGRAM STEPS MILL PWR ACU RITE Step Functions Softkey Additional functions are available from the PGM screen by pressing the STEP FUNCTIONS softkey PROGRAM CLEAR STEP MORE RUN FUNCTIONS PROGRAM FUNCTIONS SIEPS OPTIONS EXPLODE REVERSE REVERSE CHANGE DELETE COPY MOVE STEP PATH STEPS STEPS STEPS Explode CURRENT PROGRAM 001 SET TOOL 002 BOLT CIRCLE This feature will explode a program step into several more detailed steps You can
43. setup or press the USE NEW SETTINGS softkey Operation Manual 7 39 REMOTE STORAGE MILLPWR ACU RITE Remote Storage When you create programs using MILLPWR you can save them on your PC using the remote storage feature The remote storage feature enables you to free up MILLPWHR s internal memory Plus your PC is the ideal place to back up important programs and organize them into one convenient location Equipment To set up remote storage you will need the following items e MILLPWR e BM compatible PC e Serial cable e Remote Storage software Choosing a Serial Cable Before MILLPWR and your PC can communicate they need to be connected to each other with a serial cable The graphic below illustrates the necessary cable wire configuration Check that the cable you purchase conforms to this wiring diagram Connector 1 Connector 2 Operation Manual 8 1 REMOTE STORAGE MILLPWR ACU RITE Connecting MILLPWH to Your PC Power down both MILLPWR and your PC before connecting the serial cable Connect one end of the cable into the serial connector located on the rear of your MILLPWR operator console Connect the opposite end of the cable into an available COM port on your PC Note The COM port must be available that 1s not already assigned a piece of hardware You cannot simply disconnect a piece of hardware and connect the serial cable If there s no COM port recognized as being available by your PC then you will need
44. that can be detected For accurate results do not run the circle test while the spindle is under a cutting load You have the option of saving the test results onto a 3 Z floppy disk for later review To run the circle interpolation test e From the Diagnostics screen highlight Circle Interpolation Test and press ENTER e Check that the table has at least 3 of clearance for each axes e Press either the SMALL CIRCLE TEST or LARGE CIRCLE TEST softkey e Optional When the test is completed insert a 3 floppy disk into the MILLPWR disk drive and press the SAVE TO FLOPPY softkey After MILLPWR has finished saving remove the disk OFF FEED 0 0 100 SCALE 1 0000 0 00 00 INCH e Press the EXIT TEST softkey Soe ee to close the Circle Inter SDN roe MS TABLE STOP TEST polation Test Screen TEST DISPLAY TEST DISK UTILIZATION SET TIME AND DATE e Continue with Diagnostics Or system statistics press the USE NEW SETTINGS softkey CAUTION PRESSING A CIRCLE TEST SOFTKEY WILL CAUSE THE TABLE TO MOVE SMALL LARGE SAVE TO LOAD FROM EXIT CIRCLE TEST CIRCLE TEST FLOPPY FLOPPY TEST Operation Manual 7 33 SETUP Examples of Circle Interpolation Test Results Please note that the graphics are exaggerated for clarity SS e Following Error caused by servo Backlash from lost motion or play gain misadjustment in the guideways AX Oe Cyclic Error caused by a flaw in the Stic
45. the quill and the bore You may have to replace the spindle bearings Perform the auto tuning pro cedures for both the X and Y axes If auto tuning your system does not correct the problem contact your ACU RITE dis tributor Operation Manual MILLPWR Symptom Quill handle is difficult to move Z axis drive system will not engage Unusual chatter from the quill Operation Manual TROUBLESHOOTING GUIDE Probable Cause Quill lock is engaged Inadequate lubrication The Begin field for the Z axis 1s blank The Z axis is disengaged The Z axis is disabled The quill has reached a limit switch The drive belt 1s loose The quill is over extended ACU RITE Recommended Corrective Action Release the quill lock Lubricate the ballscrew with a high quality Lithium grease Check that the program step is correct and that there 1s information in the Begin field for the Z axis RE define FTO position Tighten the quick release knob for the Z axis drive system refer to Z axis Conventions Enable the Z axis refer to Setup Move the quill toward the center of travel Adjust the drive belt tension Should the above recommen dations not correct the prob lem you are experiencing contact your ACU RITE dis tributor for repair and or replacement procedures Shorten the quill distance and raise the knee 9 11 TROUBLESHOOTING GUIDE MILLPWR Symptom Unu
46. time indicat ing 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 Choosea 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 45 degree angle MILLPWR will calculate the skew angle based upon a straight line between the points you ve entered CORRECT INCORRECT Y AXIS 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 3 8 Operation Manual PROGRAMMING MILLPWR ACU RITE Using an electronic edge finder From the DRO screen press the SKEW softkey e Touch off on two or more points along any single straight edge of your part You ll notice that the Points and Angle change as you enter points e Press USE to accept all of the points and return to the DRO screen Press CANCEL to return to the DRO screen without accepting any points or affecting your previous skew angle The CLEAR ANGLE softkey will reset the number of points and the skew angle to zero Using teach position e From the DRO screen press the SKEW softkey e Move the table so that a mechanical indicator re
47. tion is 0 0000 ABS for both X and Y then press the GO key Operation Manual It s a good idea to test the datum setting before beginning programming To confirm that the new datum is correct e Raise the tool and move the table until both the X and Y axes displays read 0 0000 Datum Lower the tool until it touches the part Check the tool s position The lower left corner of the part should be located directly beneath the center point of the tool Now check the readout If the Z axis display says 0 0000 then the datum is accurate and programming can begin If a value other than 0 0000 appears in the Z axis display repeat the procedure for establishing datum DRO MEE S S S ll 1 LZLOO MILL PWH ACU RITE Hard Key Milling Functions Most of the hard key milling functions can be used individually as one time milling routines That dicus 1 O means you can use these keys without creating a program POS LINE ARC BLEND The only hard key milling function you can t use as a one time milling function is BLEND The blend function inserts a connecting radius between two features steps in a program Hard key milling functions are ideal for jobs that only require one operation You provide the required information once and MILLPWR will remember it for each piece you machine Example To drill the same bolthole pattern on several identical parts instead of creating a one step program use the
48. to 999 9 seconds you define To add an auxiliary function step to your program Check that the AMI is properly connected to MILLPWR and that each device 1s connected to the AMI s J18 output connector refer to the AMI Reference Manual e From the PGM screen press the MORE STEPS soft key e Press the MORE STEPS softkey two more times 5 58 Operation Manual PROGRAM STEPS MILLPWR ACU RITE e Press the AUXILIARY FUNCTION softkey e Highlight the auxiliary relay s that you want to program For example AUX 1 refers to the output device that s connected to pins 1 and 2 on the J18 connection Select from the OFF ON and PULSED softkeys for the relay s ON When the Auxiliary Function Step is executed an output signal is generated The signal will continue until another Auxiliary Function Step programmed to turn the signal OFF is executed the TABLE STOP button is pressed an E Stop input signal is detected the program is stopped or the program ends OFF When the Auxiliary Function Step is executed any current signal is turned off Pulsed When the Auxiliary Function Step is executed an output signal is gener ated for the time duration specified The signal will continue until the time duration ends another Auxiliary Function Step programmed to turn the signal OFF is executed the TABLE STOP button is pressed an E Stop input signal is detected the program is stopped or the program ends f you
49. tool counter bore in the spindle and touch the cutting edge to Z axis Datum Zero the top of the workpiece in this example e Press the Z 0 softkey and then USE The tip of the tool is now set at datum zero e Press GO to continue with the program Now that the Z axis datum was set using a tool of unknown length tools one and two will not repeat The Z axis datum must be reset once again using a tool from the library This can be done when step is run on the second part After the part has been changed e Press GO You will be prompted to change tools to the center drill Step 1 e Press the DATUM softkey The DRO screen will appear with the set datum window e Place the center drill in the spindle and touch the tip to Z axis Datum Zero the top of the workpiece in this example e Press the Z 0 softkey and then USE The tip of the tool is now set at datum zero e Press GO to continue with the program Datum has now been reset with a repeatable tool with a programmed length offset as the current tool all of the tools with programmed length offsets again relate to datum The program can con tinue as usual Note The only information that is mandatory when entering a tool into the tool library 1s the diameter All other information is optional It is possible to establish a tool library without tool lengths Z axis datum will need to be set during each tool step execution of the program 7 10 Operation Manual SETUP MILLPWR AC
50. warned if a program already exists with the name that you have entered Saving the program means that it 1s stored and will not be lost if there is a power interruption You can retrieve the program later by pressing A the PROGRAM FUNCTIONS and LOAD softkeys oo CHARACTERS HBC OFF FEED 0 0 100 T00L 0 1250 INCH FL END ML SCALE 1 0000 0 00 00 INCH DEFGH IJKLM NOPQR STUVW XYZ DEMO SET TOOL MILL LINE MILL ARC MILL LINE MILL LINE MILL LINE BLEND MILL LINE MILL LINE SET TOOL BOLT CIRCLE SET TOOL RECTANGLE POCKET END OF 13 Bs PROGRAM CLEAR STEP MORE RUN FUNCTIONS PROGRAM FUNCTIONS STERS OPTIONS Operation Manual 4 17 DEMONSTRATION MILLPWR ACU RITE Testing Your Program It s always a good idea to test your program before you cut your part Dry Run with Graphics Only e Press RUN OPTIONS and then select both the DRY RUN and D GRAPHICS ONLY softkeys e Press RUN OPTIONS again to finish e Move to the start of the program by pressing the 1 key followed by the ENTER key e Now press the GO key Watch as MILLPWR shows you how the part will be cut at dry run speed Dry Run with Movement e Press RUN OPTIONS Press GRAPHICS ONLY to RUN OPTIONS de select it ONLY GRAPHICS Before you press the GO key to begin the dry run ensure that the tool will not touch the workpiece when the quill begins to move To avoid tool interference we suggest that you do one or more o
51. 00 ABS FEED 10 00 IPM TOOL 9 INCH TYPE 5 49 PROGRAM STEPS MILLPWHR ACU RITE If you need to program a tilt angle press the MORE softkey Tilt Angle Highlight Tilt Angle and enter the angle from the X axis Press the USE key Note Ifthe tool size and type listed in the Tool field are incorrect change the tool settings before running your program refer to Programming a Tool Step 5 50 Operation Manual PROGRAM STEPS MILLPWR ACU HITE Chamfer A chamfer is a bevel or line that s inserted between two lines to relieve sharp angles Or corners on a part You can insert a chamfer between two intersecting lines whose steps are adjacent in the program step There are three ways you can program a chamfer e With two lengths e With Length 1 and an angle e With Length 2 and an angle Length 1 Length 1 Line 1 Line 1 Line 1 Length 2 Angle Length 2 Angle E m r Ss 2 2 D D N h N Choose a method based upon information from your print You may also close a contour with a chamfer e g a triangle by inserting the chamfer step immediately after the last step in the contour To program a chamfer e From the PGM screen locate the lines you want to insert a chamfer between Highlight the second line e Press the MORE STEPS softkey Operation Manual 5 51 PROGRAM STEPS MILLPWR 5 52 Press the MORE STEPS softkey again Press the CHAMFER softkey MILLPWR will automa
52. 00 IPM AMal F e Leave the Begin field blank when you program a step EGIN ABS e Raise the quill then loosen the quick release knob located on the front of the Z axis drive system Too 0 2500 e When you run the program step or one time milling re i FEED 10 00 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 ATTENTION ATTENTION Z AXIS FAULT AxXIS DRIVE MOVE WITHIN ASSEMBLY WAS LIMIT SWITCHES DISENGAGED OF POSITION Z AT TOP OF ENGAGE Z AXIS REFERENCE MARK DRIVE ASSEMBLY PRESS FIND HOME OR AND FIND HOME CANCEL FRESS EET THEN PRESS GO 1 10 Operation Manual INTRODUCTION MILLPWR ACU RITE 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 e Leave the Begin field blank when you program a step or a one time milling function e Raise the quill then loosen the quick release knob located on the front of the Z axis drive system e 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
53. 2 6 Skewe 2G 25a uda de dee ehde sates Ghosh Poe dias tee ee OR 2 7 Establishing Datum 2224244284 ttatu he d dap senda E ol a de 2 9 Hard Key Milling Functions cece ee eee 2 12 Operation Manual TABLE OF CONTENTS MILLPWR Programming ss se RR III 3 1 Programming Considerations 25 as ura on s odds 2 ear ded to deco E al ca 3 From and To Points 0 0 ce ee eee ees 3 1 IB ongou el MP 3 POSS 3 ES CT TP 3 2 IBEnDngessun MPH 3 2 Absolute and Incremental Dimensions llle 3 3 Seonsnienchui ARP 3 3 Creating a Progra uode doa PER E PSUPIRURUHS Home Per eS PURSE PES 3 5 Ihe View Key A 3 7 FOUOW Tools eee ereraa narren ARETE EE E 3 7 Show Tool Path F PL 3 7 Zoom In Zoom Out and Restore nannaa aeaaea 3 7 Rimini a Progra 225093 932 nae een eee ea 9 3 53 9952 9 edipi tees eee 3 8 OKO WIN d POE es soe uk och ds Ghee be 1E EHROROR hte CR Sod needa cs 3 8 Establishing Datum gt 2i 45208h 6060004 EE Sb coi e OE dem do de din d 3 10 Testing Your MILLPWR Program 2 ee ee es 3 13 Jie o n 3 13 DE DOUA 3 13 Graphics ONIY 4 24244 oko coe eee Ge ae FOO Ee be ee enai 3 13 Manual Positioning 444 06 mor o8 ome beens id Dae de quA d p b e 3 14 Disable Look Ahead acs sibs nhs odd oe DR CR Re wa we ook we 3 14 Machining Your Patt 1222s me ar
54. 4 2 Beginning The Program Begin by pressing the PGM key Selecting A Tool The logical first step for most programs is to choose the tool that you want to begin with Let s use a 1 4 FLAT END MILL e Press the TOOL key e Enter a value of 0 25 The tool length 1s optional leave it blank e Arrow down to TOOL TYPE e Press the TOOL TYPES softkey e Arrow down to FLAT END MILL and press the ENTER key ACU RITE goo TOOL TYPES 4m Operation Manual DEMONSTRATION MILLPWR ACU RITE Consider entering a Tool Position This will enable you to go to a loca tion away from your workpiece to change tools e Arrow down to SPINDLE To use a forward spindle direction Press the FORWARD softkey then press the ENTER key nooo You don t have to press the ENTER key after the last e value you can just press USE e Set the cutter s spindle speed for 1300 RPM e Press the USE key Operation Manual 4 3 DEMONSTRATION MILLPWR ACU RITE Programming the Contour This part can begin at several different places Begin at the upper left corner and cut in a clockwise CW direction LINE e Press the LINE key OFF FEED 0 0 100Zz TOOL 0 1250 INCH FL END ML SCALE 1 0000 CURRENT PROGRAM MILL LINE 001 SET TOOL pou O02 x MILL LNE xti 3 0000 ABS v1 1 5000 ABS To enter a negative TEREE number use the xe M as key not the Ye ABS or
55. 5 SETUP MILL PWR ACU RITE Automatically Tuning the Servo in Console Mode 1 Make sure the axis you are tuning is roughly in the middle of its travel They will be moving approximately two 2 inches in each direction Note to Installer No RS 232 cable should not be connected to any axis Setting value tables could become contaminated SERVO TUNING X 2 Power up the MILLPWR console make sure the E Stop button is out and FOLLOWING ERROR home the axes as you would normally BALANCE a STATUS TEST COMPLETED 3 Press the Setup key 4 Arrow down to highlight Installation Setup and press ENTER 5 When prompted type in the required passcode and press ENTER SERVO TUNING X 6 Arrow down to Servo Tuning and press ENTER FOLLOWING ERROR i BALANCE 7 Select the axis you want to tune by pressing the appropriate soft key 4 STATUS 8 The prompt bar should indicate you are in Console Mode TEST COMPLETED 9 Press the AUTO TUNING soft key then press the BALANCE TEST soft key AUTO STOP GAIN BALANCE TUNING TEST TEST TEST 10 The console will begin adjusting the balance values until it finds the value that keeps the axis as motionless as possible N Do not touch the table during the balance test 11 When the Auto Tuning process is completed the prompt bar will read Test Completed Now pro ceed with the Gain Test
56. 8 To save your GeoCalc results onto a 3 floppy disk e From GeoCalc press the CALC FUNCTIONS softkey e Insert a floppy disk into the 3 4 floppy disk drive e Press the USE FLOPPY softkey e Press the SAVE softkey SELECT A CALCULATOR FUNCTION SAVE CLEAR LOAD USE PROGRAM FLOPPY If you ve already saved the results from another GeoCalc session onto the 37 floppy CALC FUNCTIONS disk you will be asked if you want to replace what you previously saved To save over the older session press the YES softkey If you don t want to save over the older session press the NO softkey Insert a new 3 7 floppy disk and repeat the procedure Loading GeoCalc Results That You Previously Saved Once you ve saved the results from GeoCalc you can reload them into GeoCalc at any time To load GeoCalc results into GeoCalc from MILLPWR s internal memory e From GeoCalc press the CALC FUNCTIONS softkey e Press the LOAD softkey To load GeoCalc results into GeoCalc from a 377 floppy disk e From GeoCalc press the CALC FUNCTIONS softkey e Insert a 3 floppy disk into the floppy disk drive e Press the USE FLOPPY softkey e Press the LOAD softkey Operation Manual MILLPWR CALCULATOR ACU RITE Loading Programs into GeoCalc You can load your current or open program directly into GeoCalc Because GeoCalc automatically recreates your program s features you don t have to reenter information To load the
57. AM STEPS MILLPWR ACU RITE 0 20 Slot You can program a slot two ways e By entering the center point of each arc and the slot s width e By entering the center point of one arc the length and width of the slot and an angle Choose a method based upon the information available from your print 1st Arc Center 2nd Arc Center To program a slot e Press the RECT key SLOT 002 1sr ARC CENTER _ e Press the SLOT softkey X1 pum ABS Y1 ABS e 64ST 2ND ARC CENTER e Enter the X and Y axes coordinates for the 15T Arc X2 ABS Y2 AB Center S BEGIN ABS e Enter the X and Y axes coordinates for the 2 Arc ME s Center or arrow down and enter the Slot Length and FEED 1000 IPM Angle 2 DIRECTION SLOT WIDTH Enter the begin and end depths for the Z axis SLOT LENGTH O e Enter either the number of passes OR the distance between each pass Pass refers to the cuts that are used to machine the pocket to its End depth e Enter the Z axis feed rate e Select the direction you want your arc to be cut Press the CW softkey for clockwise or the CCW softkey for a counter clockwise direction Operation Manual PROGRAM STEPS MILLPWR ACU RITE li e Enter the slot s width cu C FL END MILL TYPE 5 CENTER OFFSET Enter the slot s length FEED 10 00 IPM TILT ANGLE SS gt e Arrow down and enter the feed rate 0 00 00 FINISH _ _ __ g
58. Be dr 1 6 Cartesian Coordinates 4 EREETSTTTTTTITTTOOII TT 2 DIT l 7 Polar Coordinates aco xoxo euh aet wu E ac deux did x ar dac a as 1 7 Absolute and Incremental Dimensions 1 8 Z axis Conventions aie s md z qus soto tee uA Tod E E eee eee aod 1 9 Pots KREWICE 2 2 suena tice ARCUP EU E EeE dean E eee cuvas ue eae 1 9 Begin and End Depths 12 voran dran na Gina 9S Vend 99 83 ten wa 1 9 PASS cota e eed age heoen cokes ed ee ens oases Cae ee ne 1 9 Disengaging the Z axis Drive System 00006 1 10 Setting Z axis Datum when Changing Tools 1 12 Drilling COnyventiOns 2 4524 dedans e boe 08 254644 de bona ERE DA 1 12 PECK tee cueguhsbioeeas ene Feu deo ee oemndeweasneaeaaes 1 12 Tool Rendet 1 12 bor 1 12 Saving Backing Up and Creating Directories 1 13 DRO eR RRRRRRRRRRRRR RR RR n 2 1 Slat UO MeD P C rrT 2 1 ld di m 2 Vere Ee I teen caw eee ee kee COT ETT TET T TO TT 2 PInGine TOM ETERTEEETTSITTCRSICCC TO OT EO TT TT TIT 2 2 DRO PUNCHONS 5 2 Go4 0 dk bMS ESAS aS He ee ee Sadek EMS does ow ems 2 4 huh 4442844 ethene nee dhe heed eae es eee ene este aks 2 4 ZOnE AN AXIS CPP 2 5 Tchat HEIC sessen oe Gao Be ek ha oe ed ee ee ew hee oe 2 5 Teach OSHON uera dh caved ah Gown tereaneuawesdbeeveaana 2 5 Using an Electronic Edge Pinder 2 4 4 au eben m me
59. CONGRATULATIONS You have just purchased MILLPWR by ACU RITE a versatile and flexible 2 or 3 axes Control 3 axes Readout System that effectively combines powerful features and functionality with ease of use at an affordable price MILLPWR was developed to satisfy the wants and needs of tool and die makers and other machinists where manual and automated operation are both useful and needed MILLPWR will enable you to maximize your throughput by significantly reducing set up time scrap and other non productive operations thereby increasing your efficiency productivity and profitability MILLPWR was engineered and is 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 servo motors and a user friendly operator console that includes a 10 flat panel color LCD display and a built in floppy disk drive MILLPWR is a closed looped system with positioning feedback provided by ACU RITE precision glass scales 2um 0 0001 resolution MILLPWR also includes Position Trac an advanced unique feature that enables you to easily quickly and accurately re establish workpiece zero after power loss 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 simply enter part dimensions directly from th
60. D softkey If your DXF file is stored on a PC Press the REMOTE STORAGE softkey A REMTSTOR directory and any programs it contains should appear If the REMOTE STORAGE softkey does not appear then it is likely that MILLPWR and your PC have not been set up properly refer to Remote Storage and Installation Setup Press the format key until DXF is displayed The screen will display all of the DXF files stored in the directory you have chosen Using the arrow keys highlight the DXF file you want to translate Press the LOAD softkey MILLPWR will read the DXF files you selected then translate the file s lines points arcs and circles into the appropriate MILLPWR milling function steps Default values will be assigned for any information that s missing from the DXF file such as tool offset feed rate etc MILLPWR will then arrange the steps in a logical order based upon common end points and create a tool path After the tool path has been determined the program will appear on your screen We suggest that you test your program before machining to ensure that the program steps and tool path do what you want them to do You can easily edit and rearrange steps as needed refer to Step Functions Loading a G Code file Save then clear any running programs From the PGM screen press the PROGRAM FUNCTIONS softkey Select the directory containing your program refer to Selecting a Directory Pr
61. Depth and Tool Offset All you have to do is fill in the To point and press USE Note MILLPWR will allow you to program different feed rates within each step of a continuous contour CURRENT PROGRAM CURRENT PROGRAM Single lines 001 SET TOOL 001 SEI TOOL Double lines indicate an 002 F MILL LINE 002 N MILL LINE indicate a open ended EM Narr iue sis Bi closed con continuous in tool path 005 MILL LINE 005 I MILL LINE hin too 006 MILL LINE 006 II MILL LINE path 007 BLEND 007 Il BLEND 008 L MILL LINE 008 Il MILL LINE 009 LI MILL LINE Note An X before or after a step number indicates that the step 1s invalid Highlight the step press enter and correct the information as needed Press use when finished 3 4 Operation Manual PROGRAMMING MILLPWR ACU RITE Creating a Program e Press the PGM key and the following program screen will appear Programs are created by developing a list of milling steps to be performed As you add to your list each step will immediately be drawn on the screen so that you can see a graphic display of your part in progress e To enter a milling step press the appropriate hard key milling function such as Tool The milling function keys are the eight yellow keys located in the upper right corner of your keypad The function you select will appear in the program listing and will enable you to enter the information describing the step into the program
62. HOLES hard key milling function from the DRO screen e First setup the tool and workpiece Establish the skew angle af any datum and the tool retract position e From the DRO display press the HOLES key and select which hole pattern you want to drill from the available softkeys ROW FRAME ARRAY or BOLT CIRCLE e Enter the required information and press the GO key to machine the first part e Change the part Press the HOLES key then the pattern MILLPWR will automatically refer to the data you ve entered for each part thereafter 2 12 Operation Manual DRO MILLPWR ACU RITE To change the hole pattern size depth location number of holes etc press the HOLES key again Now press the appropriate softkey enter the new information and then press the GO key This also applies to rectangles circles lines and arcs The rectangle and circle milling functions require you to establish a tool offset Lines and arcs only require a tool offset if the tool follows the left or right edge It s a good idea to setup the tool before using either of these function keys Refer to Program Steps for a complete description of each function Note The Tool setting on MILLPWR s Status bar located along the top of the MILLPWAR screen will indicate which tool has been selected If there s no tool identified or if it s incorrect you ll need to start with a Set Tool step that accurately identifies the tool you re usi
63. ILLPWR 3 28 ACU RITE From your PC Save then clear any open programs From the PGM screen press the PROGRAM FUNCTION softkey then press the DIRECTORY softkey Press the SELECT DIRECTORY softkey Press the REMOTE STORAGE softkey If the REMOTE STORAGE softkey does not appear then it is likely the MILLPWR and your PC have not been set up Refer to Remote Storage and or Installation Setup Select the directory you wish to use Press the USE softkey Press the LOAD softkey Press the FORMAT key until MPT is displayed Select the directory that contains your program refer to Selecting a Directory Translating a DXF file Save then clear any running programs Locate the directory containing your DXF file refer to Selecting a Directory From the PGM screen press the PROGRAM FUNCTIONS soft key then press the LOAD softkey Select the storage location of your DXF file on a 3 42 floppy disk or on a PC If your DXF file is stored on a 3 floppy disk Insert the floppy disk containing the DXF file you want to load into the floppy disk drive located in the lower right hand corner of the operator console Press the USE FLOPPY softkey Press the FORMAT softkey until DXF is displayed The screen will display all of the DXF files stored in the directory you ve chosen Using the arrow keys highlight the DXF file you want to translate Operation Manual PROGRAMMING MILLPWR ACU RITE e Press the LOA
64. INCH FL END ML SCALE 1 0000 0 00 00 INCH DIRECTORY 001 SET TOOL 002 M MILL LINE COMPANY 1 003 MILL ARC APRILSS 004 MILL LINE COMPANY2 005 MILL LINE COMPANY3 006 MILL LINE 00 Il BLEND 008 MILL LINE 009 U MILL LINE 010 SET TOOL 011 BOLT CIRCLE 012 SET TOOL 013 RECTANGLE POCKET END OF 13 SELECT WORKING DIRECTORY SELECT PAGE USE REMOTE DIRECTORY DOWN FLOPPY STORAGE ACU RITE We recommend creating match ing directories on MILLPWR and your PC This will make it easier to keep your original programs and backup pro grams orga nized If we want we can create another subdirectory under APRIL99 layer another one under that one under that and so on The number of directories you create and how you layer them is up to you Operation Manual 3 19 PROGRAMMING MILLPWR ACU RITE To create directories for your programs e Press the PGM key the PROGRAM FUNCTIONS softkey and then the DIRECTORY softkey Now press the SELECT DIRECTORY softkey and a directory list will appear e Highlight the directory where you want to store your new subdirectory Select MILLPWR s internal memory MILLPWR and any subdirectories should appear under the Directory heading If MILLPWR does not appear check that the USE FLOPPY and REMOTE STORAGE softkeys are not selected Select a 3 42 floppy disk Press the USE FLOPPY softkey A and any subdirectories should appear under the Directory headin
65. ING MILLPWR ACU RITE Directories 3 18 One of the best ways to keep your programs organized is to save them in directories Directories are like file folders they should be clearly labeled and contain closely relat ed programs They may be used to group programs by job operator date customer or any other method you prefer e Press the PROGRAM FUNCTIONS softkey then press the DIRECTORY softkey Now you can open an existing directory create a new directory or delete a directory that you no longer need Note A directory can only be deleted if it is empty You must first delete or move all part programs from a directory prior to deleting them See Deleting a Program located in Section 3 Operation Manual PROGRAMMING MILLPWR Creating a Subdirectory The best approach to take when creating a subdirectory is to decide first where to place it You can place it on the MILLPWR directory on a flop py disk A directory or on your PC REMTSTOR directory or you can place it within subdirectories that you have already created In the example below we ve created four subdirectories in the MILLPWR folder Three of the subdirectories are named for our top customers COMPANY 1 COMPANY2 and COMPANY3 COMPANY I has placed several part orders for a single month To help us find those part programs quickly and easily we created the subdirectory APRILO99 to save them in OFF FEED 0 0 100 TOOL 0 1250
66. L key to return to the previous screen without affecting your previous skew angle The CLEAR ANGLE softkey will reset the number of points and the angle to zero Operation Manual DRO MILLPWR ACU RITE Establishing Datum Datum also known as workpiece zero or absolute zero is a point of reference that MILLPWR bases all of your part s coordinates from Datum will need to be established for every job Datum s location may be indicated on your print if it s not establish a datum that allows you to enter most of the part s dimen sions directly with the least amount of calculations When establishing datum you may find it easiest to locate a known point on each axis such as the edge of the part or a location on the vise or fixture Refer to the procedure below as a basic guide for establishing datum You may decide to touch off using an electronic edge finder a mechanical edge finder or a tool Datum may be set at a point on the top surface or a position above or beneath the surface X and Y datum may be set on an edge or offset into or off of an edge or where there s no material present such as in the center of a circular part do what s easiest for your par ticular job MILLPWR will retain datum even after your system has been powered down See Recalling A Datum Note When the Datum menu appears you will also be asked to establish a Z axis retract position The Z axis retract position 1s the position that the quil
67. LLPWR PROGRAM STEPS To create a hole frame or hole array Drill The quill will feed down then rapidly move up Bore The quill will feed down then feed up Position You will be prompted to move the quill manually Press the HOLES key Press the FRAME softkey to program a hole frame press the ARRAY softkey to program a hole array Enter the X and Y axes coordinates for your 1 corner into the From field In the Size field enter the lengths along the X and Y axes Enter the begin and end depths for the Z axis ACU RITE END 0 0000 ABS PECK DRILL FEED 10 00 IPM HOLES p Optional Enter either the number of pecks OR the distance between each peck e Select the DRILL BORE or POSITION softkey e Enter the Z axis feed rate nthe Holes field enter the number of holes you want to include along the X and Y axes f you would like to program a retract 2 corner hole spacing and or tilt angle press the MORE softkey Tool Retract Enter either the number of retracts OR the distance between each retract Enter the length of time in seconds that you want the quill to dwell pause during each retract Operation Manual TOOLRETRACT DISTANCE DwELL SEC R 2ND CORNER ABS N2 ABS HoLe SPACING BETWEEN BETWEEN ce f TILT ANGLE 0 00 00 0 2500 INCH DRILL TYPE TOOL 0 33 PROGRAM STE
68. Left Blank 5 36 Operation Manual PROGRAM STEPS MILLPWR ACU RITE Additional Milling Functions Additional milling functions are available from the PGM screen by pressing the MORE STEPS softkey PROGRAM CLEAR STEP MORE RUN FUNCTIONS PROGRAM FUNCTIONS STEPS OPTIONS CUSTOM MORE pacts REPEAT ROTATE MIRROR CONTOUR S ENGRRVE ENGRRVE ELLIPSE MORE LINE FRAME CHAMFER STEPS l REFERENCE AUXILIARY MORE Custom Pocket Condition The custom pocket step must immediately follow a closed contour You can create a custom pocket from any closed contour A closed contour is any shape consisting of lines arcs and or blends where the last step ends at the same point where the first step begins MILLPWR will indicate a closed contour with double lines to the right of the applicable steps in the program list The Custom Pocket step must be placed immediately following the last step of the closed contour MILLPWR will automatically fill in the step range for you You ll still need to fill in the Entry Point which is the plunge point for the tool and set the feed rate for the custom pocket Custom pockets can be cut from the center inside of the pocket out or from the outside edge of the pocket in towards the center The finish cut will occur after the material from the inside of the pocket has been removed The cut direction is determined by the order with which you programmed the individual contour steps Operation M
69. MILLPWR ACU RITE 8 4 Setting up Your COM Port and BAUD Rates After the Remote Storage software has been installed on your PC the following screen will appear a REMTSTOR IDE x ato E FE Peavy ewa sava 19208 Ce COMMAND TIME PROGRAM DIRECTORY ACU RITE Remote ACU RITE Remote Storage Utility v1 0 0 Utility v1 0 ee COM PORT BAUD a CF1 CF2 CF5 Now you need to identify your COM short for communication port and set the BAUD rate COM Port COM port 1 is the program s default setting You can switch to COM port 2 by pressing the F1 key on your PC s keyboard Remember that the COM port setting must be available and it must correspond with the PC port that you connected your serial cable to BAUD Rate Set the BAUD rate by pressing the F2 key on your PC s keyboard and scrolling through the list of BAUD rates available until the correct value appears Check that the BAUD rate you define for your PC matches the BAUD rate you set for MILLPWR After your COM port and BAUD rate have been set you can begin storing part programs onto your PC using MILLPWH s serial port For more information about creating saving and deleting programs refer to Programming Operation Manual REMOTE STORAGE MILLPWR ACU RITE Activating the Remote Storage Feature in MILLPWH Refer to Setup to activate the remote storage feature in your MILLPWR system Troubleshooting If the communication lin
70. MILLPWR ACU RITE 4 16 The Rectangle Pocket screen will Ier CORNER appear H Hr Size Cornel Breno Ravius In X 0 0000 In Y Tit ANGLE 2ND CounEl 0 00 00 X2 ABS FINISH amp ABS RECTANGLE POCKET O13 0 1250 INCH 10 00 IPM Toa xi ass FLEND MILL TYPE FEED 0 0000 Cur z Becin 0 2000 ABS END 0 2500 ABS PASS FEED 10 00 IPM DIRECIKON ee CCW Enter the following information IsrT CORNER X 2 0 ABS Y 1 0 ABS SIZE 0 5 ABS in X 2 0 ABS in Y Arrow down and highlight the Pass field Enter 2 for the number of passes Arrow down and enter the following information DIRECTION CCW Arrow down and enter the following information CORNER BLEND RADIUS 0 125 Press the USE key e Operation Manual DEMONSTRATION MILLPWR ACU RITE Saving Your Program Your demonstration part program is now complete e To save your program press the PROGRAM FUNCTIONS softkey EE FUNCTIONS e You can name your program by pressing the numeric keys pose or by pressing the ALPHABET softkey highlighting a letter e Press the SAVE softkey and then pressing the ENTER key You may select up to eight characters mixing numbers and letters if you wish e After you ve named your program press the SAVE softkey to swe save it SAVE PROGRAM PROCRAM Name You will be
71. NCH DRILL TYPE Enter the length of time in seconds that you want the quill to dwell pause during each retract e Press the USE key Note If the tool size and type listed in the Tool field are incorrect change the tool settings before running your program refer to Programming a Tool Step Operation Manual 9 31 PROGRAM STEPS MILL PWR ACU RITE Hole Frame and Hole Array Hole frame and hole array patterns require the same information but their patterns differ slightly Hole frames limit holes to the outside edge of a rectangular shape while hole arrays allow holes along the outside edge and throughout the center Hole Frame Hole Array 2nd Corner 2nd Corner Y axis Y axis Size in Y Size in Y Hole Spacing Hole Spacing Y Axis Ist Corner Ist Corner Hole Spacing X Axis Y axis Y axis Hole Spacing X Axis 1st Corner Size in X gt 1st Corner X axis X axis Size in X 2nd Corner les 2nd Corner gt l X axis X axis Hole frames and hole arrays can be defined three ways e By the position of the 1 Corner size and the number of holes e By the position of the 1 Corner position of the 2 diagonal Corner and number of holes e By the position of the 1 Corner hole spacing and number of holes Choose the method that s easiest for you based upon the information from your print 5 32 Operation Manual MI
72. ND FIND FIND RETURN CALC FEATURE POINT LINE ARC FEATURE FUNCTIONS 6 14 Operation Manual MILLPWR CALCULATOR ACU RITE Finding the Points of Tangency The points of tangency between the lines and the arc the coordinates for points C and D need to be determined Now that the arc is in place the coordinates of its end points are needed Use GeoCalc s Find Point feature to find the end points of the arc Highlight 001 GEOLINE and press the SELECT FEATURE softkey This will de select the line and cause the arrow to disappear Highlight 002 GEOLINE and de select it Highlight 003 GEOARC and press the SELECT FEATURE softkey to select it Press the FIND POINT softkey Three points will appear one is the center of the arc and the others are the ends of the arc The point on the right 1s the one needed it s point C on the drawing Using the arrow key scroll down through the list of GeoPoints until the point on the right is highlighted Press the KEEP ONE softkey The tangent point C is now stored in the GeoCalc as item 004 OFF FEED 0 0 100 SCALE 1 0000 0 00 00 INCH GEOMETRY CALCULATOR O01 GEOLINE 002 GEOLINE GEOPOINT GEOPOINT GEOPOINT 3 DF b CURRENT SELECTION 003 GEOARC SELECT FIND FIND RETURN CALC FEATURE LINE ARC FEATURE FUNCTIONS Operation Manual 6 15 CALCULATOR MILLPWR Returning Features ACU RITE Now bring the GeoCalc results back into the program When you press the RE
73. NE key e Enter the following information TO X2 75 INC e Now press the ABS INCR key MILLPWR assumes that you want to use the X coordinate of the From point X1 as your incremental reference which is exactly what is needed e Press ENTER to confirm this and again to accept the value e Now enter the location of Y2 in the To field TO Y2 20 ABS e Press the USE key OFF FEED 0 0 100 TOOL 0 1250 INCH FL END ML SCALE 1 0000 0 00 00 INCH 001 SET TOOL 002 F MILL LINE 003 MILL ARC 004 MILL LINE 005 MILL LINE 006 L MILL LINE END OF 6 ts PROGRAM CLEAR STEP MORE RUN FUNCTIONS PROGRAM FUNCTIONS STEPS OPTIONS Operation Manual DEMONSTRATION ACU RITE BH MILL LINE FROM X1 3 0000 ags Ti 0 8380 ABS To x2 MEE x1 Y 2 ABS Z AMENS BEGIN 0 0200 ABS END 0 2500 ABS FEED 10 00 ABS ANGLE 0 00 00 Toor 0 2500 INCH FL END ML TYPE l eFT OFFSET FEED 10 00 IPM 4 9 DEMONSTRATION MILLPWR ACU RITE 4 10 e Press the LINE key again TO X2 3 000 ABS E ENTER Y2 0 838 ABS e Press the USE key OFF FEED 0 0 100Z TOOL 001 SET TOOL O02 fF MILL LINE 003 MILL ARC O04 MILL LINE 005 MILL LINE 006 MILL LINE OO L MILL LINE END OF 7 PROGRRM CLERR STEP MORE RUN FUNCTIONS PROGRAM FUNCTIONS STEPS OPTIONS Now go back and insert a BLEND between steps 006 and 007 e Using the UP arrow key highlight the last s
74. Offset Mode INC G92 is not supported Set feed speed units sec Tool Length Offset Index X Axis Offset to Arc Center Y Axis Offset to Arc Center Z Axis Offset to Arc Center Line Number Program Number Program Stop Optional Program Stop ACU RITE Comment MILLPWR does not support tool length offsetting The offset is retrieved from MILLPWR s tool library when a tool change is exe cuted These commands are ignored MILLPWAR does not support presettable work coordinate systems Selecting a coordinate system is possible but setting it G10 or G92 will generate a run time error These commands set the path mode The setting applies to cur rent and subsequent blocks The default is G64 continuous This command cancels the current motion command mode Motion is reset to G1 X Y and Z coordinates are reset to no motion I J and K coordinates are reset to no offset MILL PWH does not support canned drilling cycles G81 through G89 These commands set the mode for interpreting coordinates In ABS mode coordinates are relative to MILLPWHF s datum In INC mode coordinates are relative to the tool s position after complet ing the previous move The setting applies to current and subse quent blocks The default is G90 ABS G92 is not supported MILL PWRH does not support per revolution units G93 or G95 will generate a run time error G 93 amp 95 are not supported All other G codes not listed will g
75. PS ACU RITE Change Steps The Change Steps feature gives you the ability to change or edit the depth offset and feed rate of several steps simultaneously Note You can use this feature from anywhere within your program you don t need to highlight a specific step within the step range To use the Change Steps feature From the PGM screen press the STEP FUNCTIONS softkey Press the CHANGE STEPS softkey Enter the first and last step numbers that you would like to change in the Step Range field Highlight each field that you want to change and enter the new data Press the USE key Note It s a beneficial to highlight the changed steps in the program sequence then press the ENTER key Each step should include the new settings Operation Manual 5 63 PROGRAM STEPS MILLPWR 0 64 ACU RITE Delete Steps MILLPWR gives you the option of deleting steps in two ways using the DELETE STEPS softkey or using the CLEAR key When you re deleting single steps we suggest highlighting the step then pressing the CLEAR key When you re deleting a range of steps after you ve merged programs for example the Delete Steps feature 1s usually your best option To delete a group of steps from your program e From the PGM screen press the STEP FUNCTIONS softkey e Press the DELETE STEPS softkey e In the Step Range field enter the first and last step numbers that you would like to delete e Pre
76. PS MILL PWR ACU RITE 2 Corner Enter the X and Y axes coordinates for the 2 Corner located diagonally from the 1 corner Hole Spacing Specify the spacing between holes along the X and Y axes Tilt Angle Enter a tilt angle 1f needed e Press the USE key Note If the tool size and type listed in the Tool field are incorrect change the tool settings before running your program refer to Programming a Tool Step 5 34 Operation Manual MILLPWR Bolthole Circle Patterns A bolthole circle pattern is defined by its center point radius and number of holes You can program partial bolthole patterns by pressing the MORE softkey and entering a start angle and an end angle To program a bolthole circle pattern Press the HOLES key Press the BOLT CIRCLE softkey Enter the X and Y axes coordinates for the bolthole circle pattern s center point Enter the begin and end depths of the cut for the Z axis Optional Enter either the number of pecks OR the distance between each peck Select the DRILL BORE or POSITION softkey Enter the Z axis feed rate Enter the radius of the hole pattern For Direction select the direction you want to cut Press the CW softkey for clockwise or the CCW softkey for a counter clockwise direction Enter the number of holes you want to include in the circle Operation Manual PROGRAM STEPS ACU RITE BOLT CIRCLE 002 CENTER x Ea Acs
77. R key e Press the RESET softkey and the job clock and Elapsed Time field will be cleared Operation Manual 7 15 SETUP MILLPWR ACU RITE Feed Rate Settings Here you can change the default settings for various speeds and feeds STEP OVERRIDE determines the percentage of change that occurs when you press the FEED and FEED keys MAX establishes the maximum feed rate percentage that the FEED key will allow MIN establishes the lowest feed rate percentage that the FEED key will allow DRY RUN SPEED is the speed that the table will move during a dry run DEFAULT FEED RATE enables you to define the table s and Z axis default feed rate for all milling functions this way if you forget to enter a feed rate MILLPWR will automatically apply your default feed rate to the milling function We suggest that you set your default feed rate to the rate that you use most often UNIT MIN lets you define your feed rate in either inches per minute or millimeters per minute FULL CUT FEED RATE is the percentage of the programmed feed rate used when the tool is making a full cut e g the beginning cut in a pocket 7 16 Operation Manual MILLPWR Installation Setup After you ve selected Installation Setup from the Job Setup list you will be asked for a passcode The passcode is located on the page before the table of con tents You can remove it and store it in a separate location to preven
78. Rd bed cwedar REOR Edw d 7 16 Derautt Peed Rare uo aser ics eu e SEDE SR WR SURE REES RENATA 7 16 Bibl PP 7 16 Full t ut Feed Rate O ens aai etur m oceans bao 5 ae eA ee EROR OUS 7 16 fstallanOM DUP ucesodheeeved an aa vecdseed en beng eseteeane nurs 7 17 Pibe NOn iy sents ee dome ee pd eae echt eee eee ee ee 7 17 Error Compensation 22e w dug dom acabo canteens oR E Vo R ow E RR 7 18 PNCOUC SUD 7 19 dravel CIMS CTT m 7 21 Error Checkin RESTITIT ITI T ER wank R E 7 22 Dena POR rr 7 23 Z axis COMPO 6 so eu Gaede edna mne nk eee deen Ue ewe das 7 23 Spindle Control iio oes 4a ve een eee 4b bo4eoee senda deh ES 7 24 DIPL ht ee4e aot kee bee nes sede earns Gate AES bo NX E 7 24 SNO FUMING serres vera ea vn SAU ERES UU RI NU d EUR stave 7 25 Automatically Tuning the Servo in Console Mode 7 26 AMI Outputs toc xara wee dee edad age AP aw anes d edad 7 28 Di eNO PTT 7 29 Motor Assembly Monitor llle 7 30 Sanal Te outs ehh echGe ae eek Goose geen eet ecaeense 7 31 Table Stop TSE AP 7 32 Circle Interpolation Test 222 22 G00 between an dd 7 33 Examples of Circle Interpolation Test Results 7 34 Keypad I6SE ss crentes feiren 9 ARERR re LP EUR EE donee 7 35 lor Mo P 7 36 Disk UDPRZIUOB Liao xs enemis TERCER E ene et aces ae G 7 37 Set Time and Date sse oua reru seh eee ese rote ones 7 38 System SIANSNCS a uoce
79. TER LINE softkey If you use an electronic edge e Locate the first edge then press the ENTER key finder the points will automatically be entered on contact even if you over travel e Locate the second edge of your part then press the ENTER key e f you re calculating the center of a circle locate then enter three points along the diameter of the circle e Press the USE key Operation Manual 5 7 PROGRAM STEPS MILL PWR ACU RITE 5 8 Line Lines are defined by their From point the point where they begin and To point the point where they end There are two ways you can program a line e With four coordinates X1 Y1 X2 Y2 e With three of the coordinates above X1 X2 Y2 or X1 Y1 X2 etc and an angle Choose a method based upon the information available from your print To program a line e Press the LINE key e Enter the beginning X and or Y axes coordinates into the From field e Enter the ending X and or Y axes coordinates into the To field e Enter the begin and end depths for the Z axis e Enter the Z axis feed rate 0 2500 FL END ML e fone of the X or Y axes fields above was left blank enter an RGHT FEED 10 00 angle e Highlight the Offset field and press the LEFT CENTER or RIGHT softkey e Enter the table s feed rate e Press the USE key Note If the tool size and type listed in the Tool field are incorrect change the tool settings
80. TURN FEA TURE softkey GeoCalc will transfer the feature you ve identified into your part program e Press the CANCEL key to return to the program Check that your cursor is just below the line previously programmed item 001 e Press the LINE key to begin a new Mill Line form The From point is automatically set at point B The X2 field should be highlighted This is point C one of the points found in GeoCalc e Press the CALC key then the GEOMETRY softkey e Highlight the GeoPoint representing point C step 004 Press the RETURN FEATURE soft key Th 1 001 GEOLINE ey e program Seren wi u ane point C s O02 GEOLINE coordinates will appear in the To field 003 m GEOARC e Press the USE key to accept the line into the part program 004 GEOPOINT Q05 GEOPOINT e Press the CALC key and then the GEOMETRY softkey The features in the calculator will not be lost until the MILLPWR is turned off or until you clear the calculator 6 16 OFF FEED 0 0 100 SCALE 1 0000 0 00 00 INCH CURRENT PROGRAM 001 SET TOOL O02 F MILL LINE 003 L MILL LINE PROGRAM CLEAR STEP MORE RUN FUNCTIONS PROGRAM FUNCTIONS STEPS OPTIONS Operation Manual a CALCULATOR MILLPWR ACU RITE e Highlight the arc e Press the RETURN FEATURE softkey MILLPWR will automatically add an arc step to your program and place the arc s information into the form e Press the USE key to accept the ar
81. U RITE Scale Factor Scale factor is simply a multiplier that lets you expand or shrink your print s dimensions without performing complex calculations or affecting the proportion of your part Simply enter the number that you d like your dimensions to be multiplied by then run your pro gram as you normally would MILLPWR will adjust the programmed dimensions but not the tool size automatically MILLPWR s scale default setting 1s 1 0000 A value greater than 1 0000 will increase your part s dimensions a value less than 1 0000 will reduce them This is saved to the configura tion block and will be remembered until it is reset by the user MILLPWR will display your current scale factor in the status bar located towards the top of your display screen To change the scale factor e From Setup highlight Scale Factor then press the ENTER key SCALE FACTOR SCALE Make the necessary changes then press the USE key e Continue with Setup or press the USE NEW SETTINGS softkey Operation Manual 1 11 SETUP MILL PWR ACU RITE 1 12 Display Options From the Setup menu select Display Options to customize your default settings for dis play resolution point entry and similar items DISPLAY OPTIONS ANGLES allows you to define how you would like to enter angle val ues as decimal degrees radians or degrees minutes seconds DMS MS INC DISPLAY You should select the angle default se
82. WR ACU RITE If the program is saved in a different directory e Press the CANCEL softkey e Press PROGRAM FUNCTIONS softkey e Press the DIRECTORY softkey e Now press the SELECT DIRECTORY softkey e Using the arrow keys highlight the directory that contains the program you want to load e Press the SELECT DIRECTORY softkey again The DIRECTORY screen will disap pear Now that you ve selected the appropriate directory you can load your program e Press the LOAD softkey The directory you chose should appear e Highlight the program you want to load then press the LOAD softkey The program you selected should now appear on your screen From a 3 floppy disk e Save then clear any open programs e From the PGM screen press the PROGRAM FUNCTIONS softkey Insert the 3 4 floppy disk containing the file you want to load into the floppy disk drive Located in the lower right hand corner of the operator console e Press the DIRECTORY softkey and then press the SELECT DIRECTORY softkey e Press the USE FLOPPY softkey The A directory and any sub directories should appear e Select the directory that contains your program and then press the USE softkey e Press the LOAD softkey e Press the format key until MPT is displayed e Using the arrow keys highlight the program you want to load Press the LOAD soft key The program you selected should now appear on your screen Operation Manual 3 27 PROGRAMMING M
83. a 0 0000 CUT e If you want to program a tilt angle and or finish cut FEED 0 00 IPM DIR CW STPOVR 80 Tilt Angle You can slant a slot by identifying a tilt angle Highlight the Tilt Angle field and enter an angle measured from the X axis Finish Enter the amount of material to be during the finish cut Enter the feed rate for the finish cut Select the finish cut s direction Press the CW softkey for a clockwise direction or the CCW softkey for a counter clockwise direction Enter a stepover percentage how much you want your tool to overlap on each pass e Press the USE key Note If the tool size and type listed in the Tool field are incorrect change the tool settings before running your program refer to Programming a Tool Step Operation Manual 5 21 PROGRAM STEPS MILL PWR ACU RITE ode Circular Milling Functions IRCLE MILLPWA offers several circular milling functions that let you program pockets frames and rings quickly and easily mw omm for foe fof Pocket Center A pocket is a cavity or area on your part where material is removed when you machine You can program a circular pocket by indicating the center point and radius Center Radius To program a circular pocket e Press the CIRCLE key e Press the POCKET softkey e Enter the X and Y axes coordinates for the pocket s center END 0 0000 ABS point 10 00 Enter the begin and end depths
84. abet box and press the ENTER key To add numbers math symbols x or a decimal point use the keypad on the operator console Press the ALPHABET softkey again when you ve finished entering your message and the alphabet box will disappear Highlight Display At Run time Press the YES softkey to display the message during machining or the NO softkey if you don t want the message displayed Press the USE key Operation Manual 5 57 PROGRAM STEPS MILL PWR ACU RITE Auxiliary Function AMI Option If you purchased an optional AMI Auxiliary Machine Interface from ACU RITE you can program coolant pumps automatic lubrication systems and other devices to turn on off or pulse automatically Simply insert an Auxiliary Function step into your program each time you want to change a device s status Note Before you can use the Auxiliary Function feature the AMI and the output devices you re controlling must be properly installed refer to the AMI Reference Manual for instructions Pausing your program won t affect the auxiliary functions Each device will continue to run normally However MILLPWR will shut off all of the relays automatically when the program ends To shut off a device earlier in the program insert another auxiliary step with the appropriate relay turned off Devices programmed to switch on will run continuously as you machine devices set to pulse will run for the length of time up
85. al TROUBLESHOOTING GUIDE Probable Cause LCD display failure A floppy disk is in the floppy disk drive System begins to power up but cannot get past flashing cursor The floppy disk drive is not functioning properly ACU RITE Recommended Corrective Action Contact your ACU RITE dis tributor for repair and or replacement procedures Remove the floppy disk from the disk drive and cycle power to the system Remember to use the Find Home routine The system software has been corrupted or may not have been properly installed Re install the system soft ware and power up the sys tem again Remember to use the Find Home routine Power up the system again and check that the LED located on the front of the floppy disk drive is illumi nated Also listen for the spinning sound that a floppy disk drive makes when it 1s being accessed Should the above recommen dations not correct the prob lem you are experiencing contact your ACU RITE dis tributor for repair and or replacement procedures 9 9 TROUBLESHOOTING GUIDE MILLPWR Symptom Operator console keypad does not function properly System powers up but motor s will not move 9 4 Probable Cause System needs to be reset Table stop button has been pressed GRAPHICS ONLY selected in Run Options MANUAL POSITIONING selected in Run Options Improper Scale Connection ACU RITE Recommended Corrective Action
86. all performance OFF FEED 0 0 100 SCALE 1 000 0 00 INCH DIAGNOSTICS MOTOR ASSEMBLY MONITOR SIGNAL TEST TABLE STOP TEST CIRCLE INTERPOLATION TEST KEYPAD TEST DISPLAY TEST DISK UTILIZATION SET TIME AND DATE SYSTEM STATISTICS Operation Manual 7 29 SETUP MILL PWR ACU RITE Motor Assembly Monitor When the motor assembly monitor is enabled it shows the real time operating status of each axis on the DRO screen MOTOR ASSEMBLY MONITOR X PowER ON Y PowERON Z POWER ON INC 0 0000 INC 0 0000 INC 0 0000 ABS 0 0000 ABS 0 0000 ABS 0 0000 MONITOR Eee STATUS OFF STATUS OFF STATUS OFF TEMP 15 C TEMP 14 C TEMP 15 C CURRENT 24 CURRENT 17 CURRENT 13 Top Bar Reports on the AC power status On or Off also reports system Power Status l failures and emergency stop conditions when they occur i Displays the table s incremental position its position relative to incremental zero ABS Displays the table s absolute position its position relative to datum Status Reports on each motor s operating status On Off Not Present or Fault Temp Shows the internal air temperature for each motor Temperatures should not exceed 75 C Current Monitors the motor s current voltage An X after the value indi cates that the voltage inrush bypass circuit is active It can also be seen when the E stop button is pressed and then released The X should disappear within 2 3 sec
87. 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 Operation Manual 1 13 DRO MILLPWR ACU RITE 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 OFF FEED 0 0 100 SCALE 1 0000 0 00 00 INCH ABS X 0 0000 n nnnn ABS Y 0 0000 0 0000 a ABS 5 0 0000 0 0000 LI A CAUTION POSITION Z AT TOP OF REFERENCE MARK NEED AT LEAST Z INCHES TnavEL IN X amp Y AXES WICEN TOOL IS CLEAN PRESS FIND HOME OR CANCEL PuHEH las Orr Finu Hume iU RECRLL PuEvIUUS DRIUM CANCEL Screen Saver 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 illumi nated Press any key on the operator console or move the table and the display will reappear If the Power Indicator light is not illuminated yel low then power to your MILLPWR system ha
88. anual 5 37 PROGRAM STEPS MILLPWR 0 38 ACU RITE To program a custom pocket CUSTOM POCKET 006 STEP RANGE Create a closed tool path FIRST LAST Position the cursor immediately below the closed tool Entry POINT th ABS poss ABS PASS FEED 10 00 IPM TABLE FEED 10 00 IPM START FROM OUTSIDE Press the MORE STEPS softkey LP Press the CUSTOM POCKET softkey MILLPWR will automatically fill in the step range for you Enter the X and Y axes coordinates for the entry plunge point Enter either the number of passes OR the distance between each pass Pass refers to the cuts that are used to machine the pocket to its End depth Enter the feed rate for the Z axis Enter the table s feed rate Press either the OUTSIDE or INSIDE softkey Outside clears the custom pocket from the outside in Inside clears the custom pocket from the inside out Press USE or continue on to finish cut If you would like to program a finish cut press the FINISH MORE softkey then mom FEED 0 00 IPM Enter the amount of material to be removed during the finish cut in the Cut field Enter the feed rate for the finish cut For Direction press either the CW softkey for clockwise or the CCW softkey for a counter clockwise direction Enter the stepover percentage how much you want your tool to overlap on each pass Press the USE key Operation Manual PROGRAM
89. any dimension you have programmed will be preset into the readout display Every move will end at zero If you wish you can setup MILLPWR to display incremental ATTENTION travel refer to Display Options in Section 7 In this view HOLE 1 OF 5 every move will end at the programmed depth DEW THEN RAISE QUILL PRESS G This Operator Intervention Message will appear for optional Z axis Linear Encoder systems only ATTENTION PRESS Gco Operation Manual PROGRAMMING MILLPWR ACU RITE Program Functions Accessing Load Save Delete Merge Backup and Directory Options MILLPWR offers several versatile features for loading saving deleting merging and backing up your programs You can also easily organize your programs by creating directories To access these features from the PGM screen press the PROGRAM FUNCTIONS softkey OFF FEED 0 0 100 TOOL 0 1250 INCH FL END ML SCALE 1 0000 0 00 00 INCH SET TOOL MILL LINE MILL ARC MILL LINE MILL LINE MILL LINE BLEND MILL LINE MILL LINE SET TOOL BOLT CIRCLE SET TOOL RECTANGLE POCKET END OF 13 PROGRAM CLEAR STEP MORE RUN FUNCTIONS PROGRAM FUNCTIONS STEPS OPTIONS You may load a program save the program you ve been working with delete programs merge a saved program into your current one create a backup copy or select create or delete a directory SELECT A PROGRAM FUNCTION DELETE MERGE BACKUP DIRECTORY Operation Manual 3 17 PROGRAMM
90. asus mE adt RUE Sed EOS S ee ded Vus p P 7 38 Max Servo DOCU ueuxweexesESEUSASqE ETaSq3eeS aedes 7 39 Remote Storage seseesee n enna 8 1 ls etim co 8 1 Choosing a Serial Cable 0 0 0 0 ce ee eens 8 1 Operation Manual TABLE OF CONTENTS MILLPWHR ACU RITE Connecting MILLPWR to Your PC 1 ee eee 8 2 Installing the Remote Storage Program onto Your PC 8 3 For Windows 95and 98 0 6 eects 8 3 FOr WS DOS ee cys ny een rA ua poeta wes saes ans 8 3 Setting Up Your COM Port and BAUD Rates 8 4 Activating the Remote Storage Feature in MILLPWR 8 5 THOUDIESHOOUNS ui adeo a ds ee he Ed ERE E RE onto Ree ede ees PE BE 8 5 Troubleshooting Guide 0 0 9 1 INMOGUCHOM sor sario coh om ae pm ee eh SUR wee eee em a 9 Using the Table see DTP 9 1 PDE uso rer E E G 9 2 Re aligning Tramming the Spindle 0 00002 eee 9 15 2013 178 Ed A Operation Manual vii A This symbol alerts you to important information concerning the operation of your MILLPWR system MILLPWR System Specifications Characteristic Specification Operating conditions O 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 Input requirements Voltage 115V 420 single phase Frequency
91. ay from the workpiece if necessary You can program a position move prior to the tool step to automatically move off the part before changing the tool e Press the GO key to confirm that you have installed the tool The program will resume Changing to a Tool of unknown but repeatable length when executing a program When running a program it is easy to use tools of unknown but repeatable lengths such as a counter bore placed in an end mill holder As long as the counter bore does not leave the end mill holder its length will repeat each time it is placed in the spindle Since the tool length remains the same you can teach this length to MILLPWR when creating the program without having to enter the tool into the Tool Library e Be sure the Z axis datum was set using a tool from the library See Using Your Tool Library above e When programming the tool step enter the tool diameter then place the tool in the spin dle and touch Z datum e Highlight the length field and press the TEACH TOOL LENGTH softkey The tool length offset will appear in the length field NND Z Axis Datum Zero e Enter any of the remaining information you need in the tool step and press USE When this tool step is executed the length offset will take effect and the tool tip will be offset correctly WORKPIECE Changing to a Tool of unknown non repeatable length when executing a program When running a program it is possible to switch between too
92. c step into your part program e Press the LINE key This line ends at datum so enter X2 0 and Y2 0 for the To point and press the USE key to keep the line The contour is now complete OFF FEED 0 0 100 SCALE 1 0000 0 00 00 INCH CURRENT PROGRAM 001 SET TOOL 002 f MILL LINE 003 MILL LINE 004 MILL ARC 005 M MILL LINE END OF 5 PROGRAM CLEAR STEP MORE RUN FUNCTIONS PROGRAM FUNCTIONS STEPS OPTIONS Operation Manual 6 17 CALCULATOR MILL PWR ACU RITE RPM Functions MILLPWR includes a built in RPM calculator that allows you to make RPM calculations in seconds It calculates the RPM based upon the tool diameter and surface speed If your cursor is in the RPM field of a Set Tool step before you open the RPM calculator MILLPWR can transfer the result directly into the field for you To use the RPM calculator RPM CALCULATOR DIAMETER t____________ e Press the CALC key then the RPM softkey 0 0000 INCH SURFACESPEED e Enter the diameter of your tool EEMI VALUE 0 e Enter the surface speed for the material and cutter type Press the SURFACE SPEED TABLE softkey to view a list of recommended surface speeds f you need to switch from feet per minute to meters per minute or vice versa use the FEET MIN and METERS MIN softkeys SURFACE e Press the ENTER key MILLPWR will calculate the RPM value f your cursor was in the RPM field of a set too
93. ch iae from one to the other by pressing presa Tetere either the TEXT BLOCK or CHAR ACTER softkey Use the arrow keys to move around within each section In the Character section high light a letter number symbol or a space Press the ENTER key to make a Selection The alphabet block on the left side represents capital let ters the block on the right side represents lowercase letters To add a space move your cursor to a blank spot anywhere within the Characters box and press the ENTER key You can edit text by pressing the TEXT BLOCK softkey Highlight the character you want to edit and then press one of the following The CLEAR key will delete a character The DELETE LINE softkey will erase the entire line of text that the cursor is in and move all following text lines up The INSERT LINE softkey will insert a blank text line moving existing text lines down The CLEAR ALL softkey will erase all of the text in the text block When you ve finished creating editing your text press the EDIT TEXT softkey or press the USE key to return to the Engrave screen MILLPWR will display the text that you ve created on the right Press the EDIT TEXT softkey if you want to make changes or press the USE key to add the engraving step to your program Highlight a letter number or symbol Press the ENTER key after each selection The alphabet block on the left represents capital letters th
94. ch time has elapsed since the clock was started Every time you stop the job clock the time will be added to the Elapsed Time field on the Job Clock menu and the value in the Status bar will be reset to zero You can use the job clock to time each step of a project and then refer to the Elapsed Time for the total time spent on the job Operation Manual SETUP MILLPWR ACU RITE OFF FEED 0 0 100z To0L 0 0000 INCH SCALE 1 0000 0 00 00 INCH JOB SETUP JOB CLOCK TOOL LIBRARY STATUS SCALE FACTOR STOPPED DISPLAY OPTIONS ELECTRONIC EDGE FINDER ELAPSED TIME Job Clock JOB CLOCK 0 00 00 FEED RATE SETTINGS INSTALLATION SETUP Note The maximum amount of time that the job clock will record is 99 hours 59 minutes and 59 seconds The value will then roll over to zero and con tinue counting USE NEN CANCEL SETTINGS CHANGES To start the job clock From Setup highlight Job Clock then press the ENTER key e Press the START softkey and the job clock will begin To stop the job clock e From Setup highlight Job Clock then press the ENTER key e Press the STOP softkey and the job clock will stop The job clock s current time will be added to the value in the Elapsed Time field To restart the job clock press the START softkey To reset the job clock and the Elapsed Time field From Setup highlight Job Clock then press the ENTE
95. check if the precision glass scales count If a precision glass scale doesn t count follow the instructions for The scale s miscount in certain areas only below Next swap the X and Z axes servo connections and continue to check for a scale counting error If a precision glass scale doesn t count follow the instructions for The scale s miscount in certain areas only below Do not release the table stop button until you have restored the X Y and Z axes servo connectors to their proper locations 9 9 TROUBLESHOOTING GUIDE MILLPWR Symptom Probable Cause System powers up but The scale s miscount in motor s will not move certain areas only cont d Improper X and or Y axes servo connection Motors are not receiving power 9 6 ACU RITE Recommended Corrective Action For Z axis Optional Linear encoder Remove the X or Y axis scale s Clean the glass located inside the aluminum extrusion and the reading head elass using a cotton swab and denatured alcohol or acetone Re install the scale s and realign the reading head s Do not attempt to remove the Z axis scale Contact your ACU RITE distributor for repair and or replacement Should the above recommenda tion not correct the problem you are experiencing contact your ACU RITE distributor for repair and or replacement pro cedures Message bar reads X Y OR Z SERVO UNPLUGGED FAULT Check the X Y and Z axe
96. correct com pensation factor in parts per million Continue with Setup or press the USE NEW SETTINGS softkey Length of standard Diameter of Probe rena of Standara Length of Standard 7 18 Operation Manual SETUP MILLPWR ACU RITE Encoder Setup When your MILLPWR system was installed the encoder type should have been established To change the encoder type select the appropriate softkey Also when your MILLPWR system was installed the encoder count direction should have been established for each axis Each scale should have been assigned to move in either a posi tive or negative count direction depending on how and where the scales were mounted to your machine You shouldn t have to change your X and Y axes encoder directions Should you want your count directions changed please contact your ACU RITE distributor You can change the count direction for the Z and W axes The Z axis measures the movement along the quill and the W axis measures movement along the knee l i Be careful With MILLPWR s coupling feature you can add subtract or average the about changing movements of two parallel axes in this case the Z and W axes Coupling the count direc tion and then the Z axis with the W axis allows you to maintain your Z axis datum and running an old tool offsets whether you move the Z axis or the W axis When the axes are program you could get some coupled both change t
97. current proeram s features 1nto GeoCalc e From GeoCalc press the CALC FUNCTIONS softkey SELECT A CALCULATOR FUNCTION LOAD USE SAVE CLEAR PROGRAM FLOPPY e Press the LOAD PROGRAM softkey CALC FUNCTIONS Clearing GeoCalc Once you re finished working in GeoCalc you can clear the screen To clear GeoCalc e From GeoCalc press the CALC FUNCTIONS softkey e Press the CLEAR softkey e Press the YES softkey to clear the screen If you do not wish to proceed press the NO softkey Operation Manual 6 9 CALCULATOR MILLPWHR ACU RITE Example Problem Occasionally a print will not provide all of the dimensions needed to program the part In the illustration below for example the coordinates of points C and D where the arc is tan gent to the sides are unknown The coordinates will have to be identified before lines B C and A D and the arc that extends from point D to point C can be programmed Strategy First program the line from A to B directly from the print provided Then use GeoCalc to calculate the rest The strategy will be e Enter the line from A to D e Enter the line from B to C e Select lines A D and B C and then use the FIND ARC function e Calculate points C and D then return their coordinates and the arc into the program 6 10 Operation Manual a CALCULATOR MILLPWR ACU RITE Starting the Program In this example point A is shown as datum Its absolute coordinates a
98. d Y axes coordinates for the axis of reflection Enter an offset for the Z axis Press the USE key Operation Manual Original MIRROR 006 STEP RANGE FIRST LAST FIRST AXIS POINT X1 2 0000 ABS Y1 0 0000 ABS SECONDAXIS POINT X2 2 0000 ABS Y2 3 0000 ABS Z OFFSET 0 0000 5 41 PROGRAM STEPS MILL PWR ACU RITE Contour The Contour step enables you to approach and or depart from your part on a straight line or with an arc Conditions 1 The contour step must immediately follow the contour steps 2 Contours can only be associated with lines and arcs By adding contours before and or after a contin uous tool path you ll avoid starts and stops striking against the workpiece edge With an arc approach departure the tool will take a rounded tum as it nears or exits the workpiece The curved dotted line on the left Zu X of the graphic represents an arcing approach to DS the workpiece With a straight approach departure the tool path 1s extended away from the workpiece The dotted line on the right of the graphic shows a straight contour at the end of the cutting path The step range can include one or more steps If you re planning to add a contour to an individual step the first and last steps in the range will be the same Because the approach and departure fields are independent of each other you may select one or both for the step range you ve ch
99. d ek 9o obo ves Andes 3 15 Feed Mud A 3 16 Manually Positioning the Quill 244 200 uar RR ERREUR 3 16 Program Functions sco op tue 3 9 379 utd bodes tad dh tore Gl 9 es 3 17 Ber Ar 3 18 Creating a Sub directory llllllllleee lee 3 19 Selecting a Directory M ad ote ene eed aaki hoe eee ee ae ee 3 21 Deleting a Directory uu wae enw oe ee ias beh ed od oe Oe od 3 23 Saying a DEOOTO ss oes 2 E109 1E cR 9 508 933 e rhe cd E EN RU ee 3 24 Naming a Program occa Sb eke uem SX UE Pra haw E RA acp OR Rod wed 3 25 Loading a MILLPWR MPT Program llle 3 26 From MILLPWHR s internal memory 0 000 ues 3 26 From a 3 floppy disk 2 0 0 0 0000 cee eee eee eee 3 27 zr od PPP 3 28 Translating DXF file 22 6 esee on ee oe mmm de ead sew mon 3 28 ACU RITE Operation Manual TABLE OF CONTENTS MILLPWHR ACU RITE Loading a G codefile llle 3 20 Running a G code Program ac vc ax cade 29 307 Sca dc Ree EOS ACE enin 3 31 MILLPWR G code Conventions 0 0c eee eee eee 3 33 Merging Programs sacc gees wed ace Reb eR ACRIOR 3 37 Backing Upa Prostam 22 uox nce ead urarter XO ALS YE t Eid Ix Rie E dO 3 38 Deleting a Program peau ket 24 be aud beau tu tou 279 Rd 9 3 RR aoa 3 30 Demonstration Program seen 4 1 Sclec ng Dalii H 4 DecmiMine tne PEOSEOI awed eee ne daw wees dd eee Re Pe e
100. d in Setup Press the GO key to begin GRAPHICS ONLY With this activated the table and quill will not move The graphics screen will show you how your part will be cut You can see all the normal feed rates tool changes and so on Press the GO key to begin Note Dry Run and Graphics Only can be used to quickly verify your program Operation Manual 3 13 PROGRAMMING MILLPWR ACU RITE 3 14 MANUAL POSITIONING Use this option if you want to position the table using the handles MILLPWR will operate just like a programmable readout each target position will be preset into the readout and you will be prompted to position the table manually This feature is especially useful when you re navigating around islands Press the GO key to begin DISABLE LOOK AHEAD Normally MILLPWR checks each step in a continuous tool path with other steps to determine if there is an intersection in the tool s cutting path such as in the number 8 This is called look ahead If you press the DISABLE LOOK AHEAD softkey your program will run with out performing this function Press the GO key to begin Operation Manual MILLPWR PROGRAMMING Machining Your Part Whenever you are about to run a program check that the handles are recessed Before you run a program step check the Status bar located along the top of the MILLPWR screen to ensure that the tool identified by MILLPWR matches the tool in the spindle If there s no tool ide
101. d to Change your PC s COM port setting _OR Disconnect the cable from the COM port that it is connected to and connect it to a different COM port Change the PC s COM port setting and connect the serial cable into the appropriate port _OR Exit the remote storage program on your PC then refer to your PC s opera tion manual for instruc tions on how to enable a COM port Check that the serial cable is properly connected to MILLPWR and to your PC Operation Manual TROUBLESHOOTING GUIDE MILL PWH ACU RITE Re aligning Tramming the Spindle Note This does not require re aligning the quill casting Note The Z axis 1s still fully functional in a tilted position When the head has been re angled the following procedure should be performed so the original accura cy can be re established Do not loosen casting bolts or hex nuts loosen the tramming hex stand offs only You will need the following components Box or open ended wrench Dial indicator Crow s foot torque wrench 7 8 Dial holder 1 When the head is re positioned to mill certain angles see Figure 1 torque the four 4 coupling nuts that secure the Z axis casting to the head to 50 ft Ibs while the head 1s in that position see Figure 2 2 When the milling head is repositioned to 0 degrees use a dial indicator to fine tune the accu racy of the head s position see Figure 3 3 Ensure the knee lock clamps on the machine saddl
102. d to see your part graphic in more detail press the VIEW key This enables you to access the following softkeys FOLLOW SHOW ZOOM ZOOM RESTORE The FOLLOW TOOL SHOW TOOL PATH and ZOOM functions may be used simultaneously Press the VIEW key or the CANCEL key at any time to return to the PGM screen FOLLOW TOOL Press both the FOLLOW TOOL and ZOOM IN softkeys to see a close up of the tool s path MILLPWR will automatically adjust the part graphic so that the tool is always in view SHOW TOOL PATH The SHOW TOOL PATH softkey shows the tool s cutting path as you run the program With this feature enabled you can see where the tool has been ZOOM IN ZOOM OUT and RESTORE The ZOOM IN softkey will magnify the part graphic The arrow keys will enable you to adjust the view up down left and right The ZOOM OUT softkey will de magnify your part graphic RESTORE will return the part graphic to its original size Operation Manual 3 7 PROGRAMMING MILLPWR ACU RITE Running a Program There are a few things you ll need to do before running a program such as skewing the part and establishing datum Skewing a Part Note Itis important to skew a part prior to establishing datum for accuracy 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
103. d will appear under the DIRECTORY heading On your PC Press the REMOTE STORAGE softkey REMTSTOR and any The REMOTE STORAGE soft subdirectories you have created will appear under the key will only DIRECTORY heading appear if MILL PWR has been Using the arrow keys highlight the directory you want to delete india I OI Press the ENTER key Press the YES softkey to erase the directory or the NO softkey to cancel Operation Manual 3 23 PROGRAMMING MILL PWR ACU RITE Saving a Program You can save your programs in any of three places on MILLPWR s internal memory on a 3 2 floppy disk or on your PC It is always a good idea to save your programs often to avoid losing valuable information From the PGM screen press the PROGRAM FUNCTIONS softkey then select the directory where you want to save your program refer to Selecting Directories e Return to the PGM screen then press the PROGRAM FUNCTIONS and SAVE softkeys You will be asked to name your program refer to Naming a Program OFF FEED 0 0 100X TOOL 0 1250 INCH FL END ML SCALE 1 0000 0 00 00 INCH SAVE PROGRAM SET TOOL PROGRAM NAME MILL LINE MILL ARC MILL LINE MILL LINE MILL LINE BLEND MILL LINE MILL LINE SET TOOL BOLT CIRCLE SET TOOL ALPHABET RECTANGLE POCKET F CHARACTERS END OF 13 ENTER A NAME FOR THE PROGRAM FORMAT USE REMOTE SAVE ALPHABET MPT FLOPPY STORAGE e Press the SAVE softk
104. directory that was selected Selecting a Directory The SELECT DIRECTORY softkey allows you to open any of the directories that you ve previ ously created on MILLPWRH s internal memory on a 3 floppy disk or on your PC You may use this feature any time you save or load a program e Press the PROGRAM FUNCTIONS softkey then the DIRECTORY softkey Press the SELECT DIRECTORY softkey a directory list will appear OFF FEED 0 0 1004 TOOL 0 1250 INCH FL END ML SCALE 1 0000 0 00 00 INCH DIRECTORY SET TOOL MILL LINE COMPANY 1 MILL ARC APRIL99 MILL LINE COMPANY2 MILL LINE COMPANYS MILL LINE BLEND MILL LINE MILL LINE SET TOOL BOLT CIRCLE SET TOOL RECTANGLE POCKET END OF 13 SELECT WORKING DIRECTORY SELECT PAGE PAGE USE REMOTE DIRECTORY UP DOWN FLOPPY STORAGE Operation Manual 3 21 PROGRAMMING MILLPWR 3 22 ACU RITE Indicate where the directory you want to select 1s located On MILLPWR s internal memory MILLPWR and any subdirectories that you have created should appear under the DIRECTORY heading On a 3 4 floppy disk Insert the 3 floppy disk containing the directory into the floppy disk drive located in the lower right hand corner on the front of the operator console and press the USE FLOPPY softkey A and any subdirectories you have created should appear under the DIRECTORY heading On your PC The REMOTE Press the REMOTE STORAGE softkey REMTSTOR and any
105. dius Radius To program a circular frame e Press the CIRCLE key e Press the FRAME softkey e Enter the X and Y axes coordinates for the center point e Enter the begin and end depths for the Z axis e Enter either the number of passes OR the distance between each pass Pass refers to the cuts that are used to machine the pocket to its End depth SN INSIDE DT FRAME O Q CIRCLE FRAME CENTER X pu ABS Y ABS Z BEGIN ABS END 0 0000 ABS PASS FEED 10 00 IPM RADIUS mE DIRECTION mE CENTER OFFSET TooL 0 5000 INCH FL END ML TYPE FEED 10 00 IPM Operation Manual PROGRAM STEPS MILLPWH ACU RITE e Enter the Z axis feed rate e Enter the radius e For the direction press the CW softkey for clockwise or the CCW softkey for a counter clockwise direction e Select the appropriate tool offset e Enter the table s feed rate f you would like to program a finish cut press the MORE FINISH 0 0000 CuT softkey FEED 0 00 IPM DIR CW Enter the amount of material to be removed during the finish cut Enter the feed rate for the finish cut Select the finish cut s direction Press the CW softkey for a clockwise direction or the CCW softkey for a counter clock wise direction e Press the USE key Note If the tool size and type in the Tool field are incorr
106. dpoint between the given points Line between the given Given a radius all arcs through the given points points The Auto Radius softkey gives you two arcs each tangent to both points with the midpoint as its center point Point on the given line which with the given point would Lines through the given Given a radius all arcs through the given point one parallel and one perpendicular to the given point and tangent to a given line form a line perpendic line The Auto Radius softkey gives you two ular to the given line arcs each tangent to the given line with the given point as its center point Point Points which with Lines through the given Given a radius all arcs through the given Arc the given point point tangent to the given point and tangent to the given arc would form lines tan arc and the shortest line gent to the given arc through the given point to The Auto Radius softkey gives you all and the shortest line the given arc arcs tangent to the given arc with the from the given point given point as its center point to the given arc 1 Line End points of the Given a distance lines paral given line lel to the given line lines perpendicular to the given line through its end points Intersection point of Line that bisects the angle Given a radius all arcs tangent to both given lines
107. e Press the DELETE softkey You will be asked if you are sure that you want to delete the pro gram Press the YES softkey to continue or the NO softkey to cancel IMPORTANT By answering Yes you will erase the highlighted program from memory Deleted programs cannot be recovered unless a backup file was previously created Operation Manual 3 39 PROGRAMMING MILLPWR This page intentionally left blank ACU RITE Operation Manual MILLPWR DEMONSTRATION ACU RITE Demonstration Program The following steps and key stroke sequences will guide you through creating a demonstration program based upon information from the print below This will help introduce you to MILLPWR and familiarize you with how it operates 0 25 THRL TYP 5 0 250 DEEP R 0 125 CORNERS Selecting Datum Although there is no clear zero point identified on this print use the center of the bolthole pattern as datum There are several advantages to using this location it is the center of the bolt hole pattern it is the center of the large arc making it easy to calculate the arc s start and end points the pocket is dimensioned from this point nearly all of the dimensions on the print originate from this point This print could also be programmed using another point the upper left corner for example as datum The datum will be ready to set just before running a program Operation Manual 4 1 DEMONSTRATION MILLPWR
108. e Press the TOOL key and enter 0 25 for the diameter Again skip the tool length e Press the TOOL TYPE softkey e In the Tool Type field arrow down to Drill and press ENTER e Adjust the spindle direction and speed as needed e Press the USE key ACU RITE CURRENT PROGRAM 001 SET TOOL 002 fl MILL LINE 003 IIl MILL ARC 004 Il MILL LINE 005 II MILL LINE 006 II MILL LINE 007 Il BLEND 008 II MILL LINE 009 LI MILL LINE TooL TYPES c Operation Manual MILLPWR e Press the HOLES key and then press the BOLT CIRCLE softkey The following screen will appear BOLT CIRCLE Toc Renzaci Uum E DISTANCE k eE ABS DWELL SEC n 0 0000 ABS START ANGLE z BEGIN 0 2000 ABS EHDBJAHGLE END 0 2500 ABS TA 0 2900 INCH CRILL TYPE Rannus 1 5000 Dic TION Notice that the CENTER DIRECTION and Z BEGIN are carried forward from the arc that were programmed earlier Enter the depth of cut peck radius and tool retract values e Arrow down to the Z End field and enter a value of 0 4 e Enter 6 in the Peck field e Arrow down again and enter a radius of 0 75 Operation Manual DEMONSTRATION ACU RITE agoz 6 add noag3 4 13 DEMONSTRATION MILLPWR 4 14 e Press the down arrow key again then enter 5 for the numb
109. e are tight 4 Follow the machine manufacturer s procedure for proper milling head calibration and alignment 5 Once the dial indicator shows a 0 reading in several locations of the table and the head is trammed in re torque the four 4 coupling nuts to 50 ft Ibs see Figure 4 As you tighten make sure the dial indicator maintains its O reading Note If the 50 ft Ibs torque specification is not applied the engage disengage mechanism may not engage the Z axis ballscrew nut correctly This may also create a binding and or undue wear to the spindle within the mill head Operation Manual TROUBLESHOOTING GUIDE MILLPWR 9 16 ACU RITE Operation Manual
110. e block on the right represents lowercase letters Operation Manual MILLPWR PROGRAM STEPS ACU RITE To add a space move your cursor to a blank spot anywhere within the Characters box and press the ENTER key e Press the EDIT TEXT softkey when entering your characters e Press the USE key Ellipse Frame An ellipse frame is a closed curve with an oval shape The only offset available for this is center offset Due to the nature of an ellipse when the center of the tool tracks an ellipse its edge will have some error To minimize the amount of error and cut the most accurate possible ellipse use the smallest tool diameter available To cut an inside ellipse subtract the tool diameter from the size in both X and Y AXCS Y Center X Center e Size in Y To cut and outside ellipse add the tool diameter to the size in both X and Y axes To program an ellipsed frame From the PGM screen press the MORE STEPS softkey Press the MORE STEPS softkey again Press the ELLIPSE FRAME softkey Enter the location of the center point for the X and Y axes Enter the size along the X and Y axes Enter the depth Select the cutting path direction Press the CW softkey for a clockwise direction or the CCW softkey for a counter clock wise direction Enter the feed rate Operation Manual ELLIPSE FRAME 001 CENTER X E c Y ABS PASS NUMBER FEED 10 00 IPM BEGIN ABS END 0 00
111. e current tool tools do not match the operator is prompted to manually change the tool MILLPWR retrieves the tool length offset from the tool library If the system does not have repeatable tooling the operator must establish the Z axis datum for the new tool before continuing If the AMI hardware is present the coolant is turned on or off auto matically If the hardware is not present the operator is prompted to turn the coolant on mist on flood or off MILLPWH does not support control of a pallet changer This code has the same effect as M2 Enable Speed Feed Override lt is not possible to disable feed rate override on MILLPWRH These Disable Speed Feed Override commands are ignored Program Stop w Pallet Shuttle Dwell Time Spindle Speed Tool Selection X Axis Coordinate Y Axis Coordinate Z Axis Coordinate Operation Manual MILLPWH does not support control of a pallet changer This code has the same effect as MO All other M codes not listed will generate a run time error The dwell time is specified in seconds The setting applies to cur rent and subsequent dwell blocks G4 The default is 0 0 sec The spindle speed is set to the specified speed rpm If automatic spindle control hardware is present the spindle speed is set imme diately If not present or not enabled the user is prompted to set the speed If the spindle is currently off M5 it will not be turned on unless accompanied by a spindle
112. e 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 one 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 that you did Sincerely ACU RITE MILLPWHR Setup Access Code An access code must be entered before the installation setup parameters can be accessed or changed IMPORTANT The access code is 8891 Refer to Section 7 Setup IMPORTANT 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 TABLE OF CONTENTS MILLPWHR ACU RITE Introduction ssssseeee II 1 1 Sytem OVElVICW A P ET 1 1 Operator Console Overview ease wx caciuonc ux dede RASSE EUR E d 1 2 Kopad EOU A v 1 3 roscm o MMC 1 4 Table Stop Button 6 caus Shab ode dds Phe Reus 93 bee hd Re dud a 1 5 COY DLOS oss sea taaehe ees cee NERS sent PIE SE Ad GE 1 6 Axis Conventions 4 24248 15 85 2 9 9 29 9 6 3 999 9 279 3 RP QUESO a oie baw ee 1 6 Count Diech asus edes siak dieni E CE MUS een RHS Rc
113. ect change the tool settings before running your program refer to Programming a Tool Step Operation Manual 5 25 PROGRAM STEPS MILLPWR 0 26 ACU RITE Ring A ring is a circular pocket with a circular island in the center A ring is determined by its center point outside radius radius of the pocket and inside radius radius of the island X EUN The direction of the cut on the inside radius will determine whether you are climb cutting yrs or conventional cutting MILLPWR will reverse the tool direction on the outside radius so that the cutting direction stays the same zoey E Final Pass Z End To program a ring e Press the CIRCLE key CENTER x Sass e Press the RING softkey ABS Z e s 1 BEGIN ABS Enter the X and Y axes coordinates for the center dm B point PASS FEED 10 00 IPM e Enter the begin and end depths for the Z axis RADIUS OUTSIDE INSIDE zu DIRECTION e Enter either the number of passes OR the distance between each pass Pass refers to the cuts that are used to machine the pocket to its End depth 0 5000 INCH FL END ML TYPE FEED e Enter the Z axis feed rate 10 00 IPM e Enter the circle s outside and inside radii Operation Manual PROGRAM STEPS MILLPWR ACU RITE e For Direction press the CW softkey for clockwise or the m CCW softkey for a counter clockwise direction ous DIR CCW STPOVR
114. ection or the CCW softkey for a counter clockwise cutting direction e Arrow down and enter the table s feed rate The corner blend radius defaults to the last radius entered Check the value to ensure that it is correct If you need to program a corner blend radius tilt angle and or finish cut Corner Blend Radius You can add a corner blend radius to the corners of a rectangular pocket Highlight the Corner Blend Radius field and enter a radius Tilt Angle You can tilt a rectangular pocket by identi fying a tilt angle Highlight the Tilt Angle field and enter an angle measured from the X axis Finish TOOL 0 1250 INCH FLENDMILL TYPE CENTER OFFSET FEED 10 00 IPM CORNER BLENDRADIUS 0 0000 TILT ANGLE 0 00 00 FINISH 0 0000 CuT FEED 0 00 IPM DIR CW STPOVR 80 Finish allows you to leave some excess material that will be removed during the finish cut reducing if not eliminating tool marks The fin ish cut will automatically arc on and arc off Enter the amount of material to be removed during the finish cut Enter the feed rate for the finish cut Operation Manual PROGRAM STEPS MILLPWH ACU RITE Select the finish cut s direction Press the CW softkey for a clockwise direction or the CCW softkey for a counter clockwise direction Enter a stepover percentage how much you want your to
115. ed xaxa ESSA SS SUFRE a Bet 6 14 Finding the Points or Tangency iuum md 6 15 Returning Features 33 992 99 22x dey oe oh edhe weed 6 16 RPM Functions 6204604620460 0rbe dow adnan ee uke meee Os ARBRE OES d 6 18 dou A T C s 7 1 JOD SUD M 7 2 gol cU MC 7 2 Using the Tool Library with Tool length offsets 7 4 Entering the First Tool sox on ee aed ood oud 9 ewe beuse ee wane 7 5 Using the Tool Library aci uan gem oath has iode baa nes 7 7 PCC LAA T nmm 7 11 Display OPUOns 2420004 rure 9 de dead ee evarannavecdiucnts son ne 7 12 PONS rp 7 12 INC Display A C Dsum 7 12 Display Resol on us ugs m A X 1 ee canes one TIDEN ENE aX RR 7 12 Port EHI oes EQ sdb S quu en S up EP uS Sq E Nd 7 12 From PON 2 205 REOR UE M ORUR RR RURCU HE on dee REUS BR US m ee ROB S 7 13 SEPOV ENUY ache ua a vom Era 2 9 NCRCUR dose dic een eed 7 13 Pass Peck Retraet ouenou A Ra 060600 mk y esas 7 13 Electronico Baec Finder uus sos aps dob edo fos ee REX SEP Eus EAS A 7 14 JOD CIOCK Lorena E RAVRELRPISEURE NUR ERN RP ESPERE RS ES 7 14 Feed Rate Se bille S 22 iorund 2 13 9 SAH HORREA TEEN arbe des 7 16 SED OVCHI owt oman ceo ede eee hee eee hee he 7 16 IIE ETE 7 16 Operation Manual V TABLE OF CONTENTS MILLPWR ACU RITE hun P r PR 7 16 Dey RUN SCE os uuu qui bares
116. ee 4 2 Select a TOOL s geet ends OEE RS RP RR XE AS SAREE EU E a Eu es 4 2 Programming the Contour aos oscuro BORRCPHR OPE Qe UR did CE 39 9 89 Er E 4 4 Programming the Bolthole Pattern 0 00 0005 4 12 Programming the Rectangular Pocket 00008 4 15 Saving Your Program 231g qs 29 9708 3 253 ge R8 ee HEU eH er ee ee 4 17 Testing Your Program llleeeeeeeee teens 4 18 Running the Program sona eucpg 2 9 93 oO SUR Phe 0E 6 rd R Ro d de apa d M d RUE 4 9 TOODX Dale uou puce onse 9E E Ba RedUP one hee ROT RUP T Rud 4 20 Clearing the Progra conc oe ke doen RO CEPR CURE HR ORC deae a ERGS 4 20 Program Steps sssssseeeeee eens 5 1 Simple Milling and Drilling ellen 5 1 Programming a Tool Step w Repeatable Tool Length Offsets 5 2 Entering the First TOOL uai 008 4 uox alee a Hae ex 3 RP Bae a HAH 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 P 5 6 eon CPI 5 7 IF r L rp 5 8 EC 5 0 ii L 5 11 Rectangular Milling Functions 0 0 0 0 ee eens 5 13 gc 2osc5 55644605 oe uetete E seu ea ener ns ee eeteue se 5 13 lon 2695 o war chek tee ean bane Anwar ons hewd Gee ean ee 5 16 ln A rrr 5 18 Jn M
117. em has been properly installed by a factory trained and certified technician IMPORTANT Do not attempt to make any repairs to the operator console and or motor assemblies on your own Please contact your ACU RITE distributor for repair and or replacement assistance Operation Manual 9 1 TROUBLESHOOTING GUIDE MILLPWR Symptom Operator console displays a blank screen 9 2 Probable Cause System has been idle for approximately 20 minutes and is 1n screen saver mode No power ACU RITE Recommended Corrective Action Check that the power indica tor light located in the upper left corner of the operator console is illuminated If the power indicator light is illuminated either move the table or press any key on the operator console to restore the display If the power indicator light is not illuminated power has been interrupted Follow the recommendations for No Power Check that the power switch located on the rear of the operator console is on Check that the power cord is properly connected Check that there are no blown fuses or tripped breakers Check that your power source meets the specifica tions required of the system In the event of a power inter ruption you simply have to wait until power is restored Operation Manual MILLPWR Symptom Operator console displays a blank screen cont d Operator console displays a flashing cursor Operation Manu
118. enerate a run time error MILLPWH does not support H code tool length offsetting The off set is retrieved from MILLPWHR s tool library when a tool change is executed This command has no effect and is ignored The offset applies to current and subsequent arc blocks G2 and G3 The default is offset Line numbering is optional and for readability only MILLPWR does not make use of this information Program number is optional MILLPWHR does not make use of this information This command stops the program after completion of the block The cursor moves to the subsequent program block The cur rent settings remain in effect This command is ignored MILLPWR does not have a switch for selecting whether to stop on this command Operation Manual PROGRAMMING MILLPWR ACU RITE Code Description Comment M2 Program End This command stops the program after completing the block The M3 M4 M5 M6 M7 M8 M9 M30 M48 M49 M60 M N lt X opindle On CW opindle On CCW Spindle Off Tool Change Coolant On Mist Coolant On Flood Coolant Off Program End w Pallet Shuttle cursor moves to the beginning of the program The current settings are reset to default values If spindle control hardware is present the spindle is turned on or off automatically If the hardware is not present the operator is prompt ed to turn the spindle on or off and or to set the speed If the tool specified is not th
119. ength field Highlight the unit field If the diameter you entered is metric press the MM softkey Highlight the Type field Press the TOOL TYPES softkey Highlight the type of your tool from the list of available tool types and press ENTER Press USE and repeat this procedure for each additional tool in the program If your Z axis datum is not located at the top of your workpiece you will need to reset your Z axis datum Be sure to set your Z axis datum using the tool shown in the current tool box located in the status bar on the top of the screen If the tool doesn t match the datum will not be correct After the tool information is established in the program later you can edit the values as needed to adjust for accuracy and wear Operation Manual 5 3 PROGRAM STEPS MILLPWR 5 4 ACU RITE Changing to a Tool of unknown length when in the DRO If you are using the DRO and need to set a new tool follow the procedure below Be sure to reestab lish the tool length offset for your program before running it as described below From the DRO view press the TOOL key Enter the tool diameter clear any length and if you wish the type Press the GO key An Operator intervention message will appear asking you to use the selected tool Place the selected tool in the spindle Press the GO key to confirm that you have installed the tool Set the Z axis datum following the instructions found in your operatio
120. er of holes e Highlight the Number field in tool retract then enter a value of 3 e In the Dwell field enter 5 seconds as the length of time needed for the quill to pause during the retract cycle e Press the USE key ACU RITE o In this example the starting and ending angles were not changed As a result your first hole will be placed at zero degrees If you were to look at the face of a clock zero degrees will be at 3 o clock Without a specified ending angle MILLPWR will space the number of holes entered evenly around a full circle If a counter clockwise direction was applied to the hole pattern the second hole of our five hole pattern will be between 12 o clock and 1 o clock The holes contin ue around the circle as shown below 2 aT 0 N 1 decode ha fili a ma aa nan an Operation Manual DEMONSTRATION MILLPWR ACU RITE Programming the Rectangular Pocket First let s enter the tool that is needed to machine the pocket e Press the TOOL key and enter the data for a 0 125 diameter flat end mill BUBBDZ e Arrow down and highlight the Tool Type field e Press the TOOL TYPE softkey TOOL TYPES e Press the ENTER key K Highlight Flat End Mill e Adjust the spindle direction and speed e Press the USE key e Press the RECT rectangle key then press the POCKET softkey POCKET la c Operation Manual 4 15 DEMONSTRATION
121. ess the CANCEL key and check that the continuous tool path for the island is correct and or the correct step has been highlighted STEP RANGE FIRST 2 LAST 5 5 54 Operation Manual MILLPWR PROGRAM STEPS ACU RITE Spiral A spiral is a winding and gradually widening curve or coil Spirals are defined by their center point beginning and end ing radii and sweep angle The center point is the X Y coordinate at the core of the spiral The beginning radius is the distance from the spiral s c fiim center point to its starting point and the ending radius is the distance from the spiral s center point to its ending point To program a spiral S e From the PGM screen press the MORE STEPS softkey X 0 0000 ABS Y 0 0000 ABS e Press the MORE STEPS softkey two more times 5 BEGIN 0 0200 ABS END 0 5000 ABS 2 e Press the SPIRAL softkey PASS FEED 10 00 IPM i RADIUS Enter the spiral s center point TUNES 5 0000 END e Enter the begin and end depths for the Z axis TEN CW e Enter either the number of passes OR the distance picasa between each pass Pass refers to the cuts that START ANGLE are used to machine the pocket to its End depth 0 00 00 e Enter the Z axis feed rate e Enter a start radius and an end radius measured from the As you re pro gramming keep center point If the ending radius is less than the start Tand na
122. ess the load softkey Press the format softkey until G Code is displayed Using the arrows highlight the program you wish to load Press the LOAD softkey Operation Manual 3 29 PROGRAMMING MILLPWR ACU RITE If your G code file is stored on a 3 floppy disk Insert the floppy disk containing the G code file you want to load into the floppy disk drive located in the lower right hand corner of the operator console Press the USE FLOPPY softkey Using the arrow keys highlight the G code file you wish to load Press the LOAD softkey If your G code is stored on a PC Press the REMOTE STORAGE softkey A REMTSTOR directory and any programs it contains should appear If the REMOTE STORAGE softkey does not appear then it is likely that MILLPWR and your PC have not been setup properly refer to Remote Storage and Installation Setup Select the directory containing your program refer to Selecting a Directory Press the format key until G code is displayed softkey The screen will display all of the G codes files stored in the directory you ve chosen Using the arrow keys highlight the DXF files you wish to translate Press the LOAD softkey Note G code files are run only No editing can be done to the file at the MILLPWR All editing should be done within your CAD CAM program refer to MILLPWR G code Conventions 3 30 Operation Manual PROGRAMMING MILLPWR ACU RITE Runn
123. ey The program s name should now appear in the left column above the program steps If you make any changes make sure that you save your program again 3 24 Operation Manual MILLPWR Naming a Program Before you can save a program MILLPWR requires you to name it e f you want to use letters press the ALPHABET softkey An alphabet menu will appear below the Program Name field e Using the arrow keys move the cursor from one letter to the next Press the ENTER key to select a letter To add numbers to your program name simply press any of the number keys on the keypad You may choose up to eight characters for your program name mixing numbers and letters if you wish e Press the SAVE softkey MILLPWR will store your program in the directory you have selected A message will alert you if the program was not saved properly or if the name that you ve chosen already exists Operation Manual PROGRAMMING ACU RITE SAVE PROGRAM PROGRAM MAME ALPHABET CHARACTERS ABC DEFGH IJK LM NOPQR STUVW XYZ If you have accidentally selected the wrong letter or number press the CLEAR key and rename your program 3 29 PROGRAMMING MILLPWR Loading a MILLPWR MPT Program The LOAD softkey allows you to open programs that have already been saved The steps below tell you how to load a program from MILLPWR s internal memory a 3 floppy disk or your PC From MILLPWF
124. f the following Lower the knee e Remove the tool or workpiece Reestablish datum away from the part refer to Kstablishing Datum located in Section 2 4 18 Operation Manual MILLPWR If your cursor is positioned past the last step MILLPWR will automati cally go to step 001 when you press GO DEMONSTRATION ACU RITE e Now press the GO key and check that the Z axis is engaged e Press the GO key again MILLPWR will run each step at dry run speed without stopping If the part falls entirely within the workpiece you can cut the part Running the Program The first step in running a new program is to establish datum Remember to chose the center of the bolt circle as datum e Place your workpiece into a vise e Place the tool you want to use first into the spindle e Using the MOVE TABLE softkey and the arrows position the tool over the workpiece where you want the center of the bolt circle s datum to be TABLE e After you ve finished moving the table press the MOVE E TABLE softkey again to de select it TABLE e Touch the tool to the top surface of your workpiece e From the DRO screen press the DATUM softkey Datum e Press the X 0 Y 0 and Z 0 softkeys to establish the current tool position as datum e Press the ARROW DOWN softkey e Set the Z retract position 1 above the workpiece e Press the USE key e Return to your program by pressing the PGM key Perform a second dry r
125. g Select your PC The REMOTE STORAGE soft Press the REMOTE STORAGE softkey REMTSTOR key will only and any subdirectories should appear under the appear if MILL Dj t h di PWR has been irectory heading ep o remote storage e Using the arrow keys highlight the existing directory you want to put your new subdirectory in In our example we highlighted MILLPWR then created a subdirectory entitled COMPA NY1 e Press the SELECT DIRECTORY softkey again to verify your choice The Directory screen will disappear e Now press the DIRECTORY softkey e Press the CREATE DIRECTORY softkey You will be asked to name your directory e You can name your directory using the numeric keys on the operator console or by selecting letters from the ALPHABET option Use the arrow keys to move from letter to letter then press the ENTER key to make a selection Program names are limited to eight characters consisting of numbers and or letters 3 20 Operation Manual PROGRAMMING MILLPWR ACU RITE e After you have named your directory press the CREATE DIRECTORY softkey again to enter your choice The Directory screen will now disappear Additional directories may be added at any time IMPORTANT Creating a directory does not mean that the directory is selected If you plan to save your current program in the directory you just created you must select the new directory first Otherwise your program will be saved in the last
126. ghlight the Type field TooL DESCRIPTION DIAMETER e Press the TOOL TYPES softkey LENGTH 0 0000 e Highlight the tool type that describes the tool you re using Press ENTER UNIT INCH TvPE O t e Press the USE key e Continue with Setup or press the USE NEW SETTINGS softkey Operation Manual 7 3 SETUP MILL PWR ACU RITE To edit an existing tool e From Setup highlight Tool Library then press ENTER e Highlight the tool you want to edit then press ENTER e Make the necessary changes then press USE e Continue with Setup or press the USE NEW SETTINGS softkey Using the Tool Library with Repeatable Tool Length Offsets If you have repeatable tooling keeping a tool library for your frequently used tools saves you time by not requiring you to enter the tool information every time you program the tool When running G code programming the tool length for each tool in the program is retrieved from the library For example in a G code program T1 M6 will cause MILLP WR to prompt the operator to load tool into the spindle The tool length offset from tool 1 in the MILLPWR tool library is retrieved and used to adjust the Z axis position The code T2 uses the length offset of tool 2 etc This feature takes advantage of your repeat able tooling systems freeing the operator from having to reset the Z datum for each tool change If your Tooling is not repeatable you should not p
127. hat let you program pockets frames faces and slots quickly and easily ewe ome mx om o Pocket A pocket is a cavity or area on your part where material is removed when you machine You can program a rec tangular pocket two ways e Using the coordinates of two diagonal corners e Using the coordinates of one corner and the size of the pocket To program a rectangular pocket e Press the RECT key e Press the POCKET softkey e Enter the X and Y axes coordinates for the pocket s 1 Corner e Now enter either the size of the pocket or the coordinates for the 2 Corner Size Enter the length of the pocket along the X and Y axes 2 Corner Enter the X and Y axes coordinates for the 2 Corner The 2 Corner must be located diagonally from the 1 Corner Operation Manual Size in X RECT RECTANGLE POCKET 002 1ST CORNER X1 ll ABS l No ABS SIZE IN X IN Y i 2ND CORNER ABS h ABS Z BEGIN ABS END 0 0000 ABS PASS FEED 10 00 IPM DIRECTION PROGRAM STEPS MILL PWR 5 14 e Enter the begin and end depths for the Z axis e Enter either the number of passes OR the distance between each pass Pass refers to the cuts that are used to machine the pocket to its End depth Final Pass e Enter the Z axis feed rate ACU RITE e For Direction press either the CW softkey for a clockwise cutting dir
128. he Z field or press the Z 0 softkey e Press the ENTER key e Highlight the Z Retract field e Either Enter the Z axis retract position the position that you want the quill to return to between steps it must be located above the top surface of your part OR Raise the quill to the desired position then press the TEACH softkey e Press the USE key Datum and the Z axis retract position have now been established It s a good idea to test your datum set ting before you begin programming To confirm that your new datum is correct You can quickly move to datum for X and Y by pressing the POS key Check that your go to position is 0 0000 for both X and Y then press the GO key Datum e Raise the tool and move the table until both the X and Y axes dis plays read 0 0000 e Lower the tool until it touches your part e Check the tool s position the lower left corner of the part should be positioned directly beneath the center point of the tool e Now check the readout screen If the Z axis says 0 0000 then your datum is accurate and you can begin programming If a value other than 0 0000 appears in the Z axis display repeat the procedure for establishing datum Operation Manual PROGRAMMING MILLPWR ACU RITE Testing Your MILLPWR Program Whenever you are about to run a program check that the handles are recessed Before you machine a part it is always a good idea for you to test
129. he Z axis DRO count value pretty strange results Operation Manual 7 19 SETUP MILLPWR 7 20 ACU RITE To change the encoder direction and coupling settings From Installation Setup highlight Encoder Setup and press ENTER Highlight the axis you wish to change and press ENTER Now use the NEGATIVE and POSITIVE softkeys to change the count direction Highlight Coupling and use the OFF COUPLE Z W and COUPLE Z W softkeys to change coupling Press the USE key Continue with Setup or press the USE NEW SETTINGS softkey To change the direction of the encoder phase From within the Encoder Setup menu arrow down and highlight the Encoder Phase field Now use the NEGATIVE and POSITIVE softkeys to change the phase direction Press the USE key Continue with Setup or press the USE NEW SETTINGS softkey Operation Manual SETUP _MILLPWR Travel Limits ACU RITE Travel limits define how far you will allow the table to move along the X and Y axes and how far up and down the quill can be positioned along the Z axis Note You must find home before you can establish your travel limits To set your travel limits From Installation Setup highlight Travel Limits and press ENTER The X axis Travel field should be high lighted Move the table to the position where you want your right table travel limit set Press the SET RIGHT LIMIT softkey Move the table to the positi
130. ic Display the digital readout Display the program screen Exit from a milling function Add a step to your program once you ve completed an entry form EOD QD QD Special Function Keys p Dres 1n INFO Access information about any MILLPWH function MM Switch from inches to millimeters or vice versa SETUP Add to your tool library set your feed rates change your display options and define other system para meters CALC Perform standard x trigonometry geometry and RPM calculations Operation Manual Cursor and Motion Control FEED GO Start your program STOP Press this key once to pause your program twice to exit FEED Increase or decrease your feed FEED rate ARROWS These keys enable you to posi tion your table or move your Cursor 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 Numeric Keypad and Calculator Enter program data and perform math calcula tions Press the CLEAR key to delete informa tion from a data field Press the ENTER key to accept the informa tion you ve entered INTRODUCTION MILLPWR ACU RITE Screen Layout The MILLPWR display screen is divided into four sections ABS X 0 0000 0 0000 a ABS rs 0 0000 0 0000 m ABS Zi 0 0000 0 0000 m ZERO X ZERO Y ZERO Z Status bar displays the servo motor status
131. ing a G Code Program Considerations when creating a G code Program MILLPWR has the ability to read and execute Numerical Code G Code files however those files can not be edited from the controller It is important to create and proof the G code file before attempting to machine a part The use of CAD CAM Software is strongly recommended Tool Offsetting No programmed cutter compensation is used so the tool path should be based on the center and tip of the tool Do not establish tool length offsets within CAD CAM software For repeatable tooling tool length offsets can be established in the tool library Diameter offsets are not used Using the Tool Library Each T block refers to the corresponding number in the Tool Library For example T1 will cause MILLPWRAB to retrieve the tool length offset from tool 1 of the Tool Library MILLPWR will then offset the spindle by this amount T2 will cause MILLPWR to retrieve the tool length offset from tool 2 of the Tool Library etc To set up a Tool Library refer to Setup N It is very important not to have any tool length offsets in the Tool Library if the tooling is not repeatable Failure to maintain the Tool Library can cause unpredictable results Verifying tool length offsets prior to program execution is strongly recommended Loading a Program A G code program can be loaded into MILLPWR in the same manner as MILLPWR programs Refer to Loading a Program for instructions on loading a
132. ing a G code program Operation Manual 2 7 DRO MILLPWR 2 8 ACU RITE To skew a part or vise Using an electronic edge finder Press the SKEW softkey Touch off on two or more points along any single straight edge Here ye used of your part You ll notice the Points and Angle change as a workpiece as le you enter points MILLPWR will calculate the angle to the ribus as closest axis line and compensate for the offset of the workpiece touch off on a vise or fix ture Press the USE key to accept all of the points and return to the DRO screen Press the CANCEL key to return to the DRO screen without accepting any points or affecting your previous skew angle The CLEAR ANGLE softkey will reset the number of points and the skew angle to zero Using teach position Press the SKEW softkey Move the table so that a mechanical indicator rests against any straight edge on the part Press the TEACH POSITION softkey to enter your coordinate You ll notice that the Points change Now move the table so that the mechanical indicator touches another point on the same straight edge Press the TEACH POSITION softkey You ll notice that the Points and Angle change Repeat this process for any additional points MILLPWR will calculate the angle to the closest axis line and compensate for the offset of the workpiece Press the USE key to accept all of the points and return to the DRO screen Press the CANCE
133. ions As we showed above when you re entering data for a milling or positioning function your print may not provide you with all of the information you need If an unknown value can be expressed as a trigonometry function square root or the square of a number MILLPWR can calculate the dimension for you in the trigonometry calculator Using the trig calculator e While in a numeric field such as the To field for a Line press the CALC key and then press the TRIG softkey The following softkeys will appear ene Cos SIN TAN SQR ROOT ARC Cos ARC SIN ARC TAN SQR Operation Manual aC CALCULATOR MILLPWR ACU RITE e Enter a number and then press the softkey with the appropriate trigonometry math function Press the SHIFT softkey to switch between the upper and lower functions For example to enter a radius that has a value equal to the square root of 2 follow this procedure Highlight the radius field Press the 2 key Press the CALC key Press the TRIG softkey Press the SQR ROOT softkey A value of 1 4142 will appear Whenever you re calculating the SIN COS or TAN of WE an angle enter the angle first and then oe te press the appropriate softkey If you were to enter a value L X Gn of 30 into a numeric field then press the SIN softkey a eer VALUE value of 0 5000 the SIN of 30 degrees would appear Continuing with the example on the right let s assume a that we are trying t
134. itive negative sign The calculator is accessible from nearly any screen or field Press the CALC key to access the stand alone calculator and the TRIG GEOMETRY and RPM softkeys Calculations can be entered directly into a highlighted field OFF FEED 0 0 100 TOOL 0 1250 INCH FL END ML SCALE 1 0000 CALCULATOR ABS X s 0 0000 0 2258 z ABS Y 0 0000 0 3815 z BOOD CALCULATOR ACU RITE NJ efo og Be xO BOO INCH ABS 2 0250 a Operation Manual 6 1 CALCULATOR MILL PWR ACU RITE 6 2 Math Functions X Math functions may be performed separately in the stand alone calculator or directly in the field you re working in For example let s say we need to enter the radius of a circle pocket but your print only shows the diameter 6 25 Here s an easy way to figure out the radius e Highlight the radius field for the circular pocket e Using the keypad enter the value for the Raous diameter 6 25 e Press the key e Press the 2 key e Press the ENTER key The answer 3 125 will appear in the Radius field When you need to enter more than one calculation into a numeric field the calculator will perform multiplication and division before it performs addition and subtraction If you were to enter 3 1 8 MILLPWR will divide one by eight then add three for an answer of 3 125 Trig Funct
135. ive value will need to be specified because the tool s center is on the negative side of the datum refer to Axis Conventions located in Section 1 Press the ENTER key Position the tool so that it is near but not touching the front face of the part The tip of the tool should fall below the top surface of the part Slowly move the table along the Y axis spinning the tool by hand as you go Pay close attention as the tool approaches the part you ll feel a subtle bump when they make contact with each other Stop the table at the moment the tool touches the part Using the keypad enter the radius of the tool into the Y field be sure to specify if it is a negative value Press the ENTER key Operation Manual MILLPWR DRO ACU RITE Setting datum for the Z axis e Position the tool so that its tip touches the top surface of the part e Using the keypad enter 0 into the Z field or press the Z O softkey e Press the ENTER key Highlight the Z Retract field e Either Enter the Z axis retract position the position that you want the quill to return to between steps it must be located above the top surface of the part OR Raise the quill to the desired retract position then press the TEACH softkey e Press the USE key Datum and the Z axis retract position have now been established You can quickly move to Datum for X and Y by pressing the POS key Check that your posi
136. k Slip of an axis esp at low ballscrew or ballscrew mounting speeds in this case Y axis O Ke Machine Vibration in an axis Axis Reversal Spike shows an axis in this case Y axis sticking when velocity reaches zero in this case Y axis 7 34 Operation Manual SETUP MILLPWR ACU RITE Keypad Test The keypad test verifies that all of the keys the remote pendant switch and the optional electronic edge finder are functioning properly When you press a key the corresponding graphic should shrink when you release the key the graphic should return to its full size If the graphics don t change at all it is likely that the key is not functioning properly If the graphic shrinks but does not return to normal when the key is released the key may be sticking Bullets mark the keys that have already been tested To run the keypad test e From the Diagnostics screen highlight Keypad Test and press ENTER e Press the key s on the keypad that you want to test Press the remote pendant or use the electronic edge finder to test their status e Press the CANCEL key on the keypad twice to exit the Keypad Test screen e Continue with Diagnostics or press the USE NEW SETTINGS softkey OFF FEED 0 0 100 SCALE 1 0000 0 00 00 INCH DIAGNOSTICS MOTOR ASSEMBLY MONITOR SIGNAL TEST TABLE STOP TEST CIRCLE INTERPOLATION TEST IKEYPAD TEST DISPLAY TEST DISK UTILIZATION SET TIME AND DATE SYSTEM STATISTICS
137. k between MILLPWR and your PC is disrupted an error message will appear on the MILLPWR screen Settings that do not match and an improper serial cable connection are the most common problems and are the easiest to correct Refer to the general Troubleshooting Guide section for details Operation Manual 8 5 REMOTE STORAGE MILLPWR This page intentionally left blank 8 6 ACU RITE Operation Manual TROUBLESHOOTING GUIDE MILLPWR ACU RITE Troubleshooting Guide Introduction This troubleshooting guide is intended to assist you with diagnosing problems should you experience any difficulties with your MILLPWR system Using the Table This troubleshooting guide is arranged in three columns entitled Symptom Probable Cause and Recommended Corrective Action The Symptoms are listed in the order of most common easiest to check and least expensive to correct First locate the symptom that best describes the problem that needs to be corrected Then identify the probable cause that most closely matches the problem that you are experiencing and implement the recommended corrective action This troubleshooting guide pertains to the ACU RITE MILLPWR system specifically and on occasion the machine tool itself It does not fully address problems associated with inadequate tooling improper feed rates and or spindle speeds etc Note This troubleshooting guide has been written with the understanding that your ACU RITE MILLPWR syst
138. l returns to between program steps refer to Conventions located in Section 1 To establish datum Where and how datum is established will vary from job to job The following is one of the most common methods of establishing datum These basic principles can be applied when setting datum for your parts making adjustments to the procedure as needed First establish datum at the corner where the left front and top surfaces of the part inter sect This is accomplished by touching each face with the tool that is being used for cutting Define datum one axis at a time Begin here with the X axis From the DRO screen press the DATUM softkey o Insert the tool Operation Manual 2 9 DRO MILLPWR Now set datum for the Y axis using the same procedure 2 10 ACU RITE Position the tool so that it is near but not touching the left side of the part Lower the tip of the tool so that it falls below e the top surface of the part Slowly move the table along the X axis spinning the tool by hand as you go Pay close attention as the tool approaches the part you ll feel a subtle bump when they come into contact Stop the table at the moment the tool touches the part Using the keypad enter the radius of the tool the distance from the Use the MOVE center of the tool to the edge of your part Be sure to specify if it s res P o help wi a negative value jong A ble moves Note In this example a negat
139. l step before you accessed the RPM calculator press the USE key and MILLPWR will transfer the result directly into the RPM field for you 6 18 Operation Manual SETUP MILLPWR ACU RITE Setup Press the SETUP key to access the setup parameters The setup parameters are grouped into two categories Job Setup and Installation Setup Job Setup parameters can easily be changed to accommodate specific machining requirements for each job Installation Setup parameters on the other hand are established during the initial installation and with few exceptions should not be changed For this reason the installation setup parameters are protected by a passcode The passcode is located on the page before the table of contents You can remove it and store it in a separate location to prevent accidental or unauthorized adjustments to your system OFF FEED 0 0 100 TOOL 0 0000 INCH SCALE 1 0000 JOB SETUP SCALE FACTOR DISPLAY OPTIONS ELECTRONIC EDGE FINDER JOB CLOCK FEED RATE SETTINGS INSTALLATION SETUP USE NEM CRNCEL SETTINGS CHRNGES To change your setup parameters e From Setup highlight a topic then press ENTER Change the settings then press the USE NEW SETTINGS softkey to activate them Or press the CANCEL CHANGES soft key to exit Setup and return to the previous screen without making any changes Operation Manual 7 1 SETUP MILLPWHR ACU RITE Job Setup Tool Library MILLPWR contains a tool
140. lace any length information into the tool library 7 4 Operation Manual SETUP MILLPWR ACU RITE L1 t E a Length offset Length offset Length offset Using an electronic E B edge finder as Zero A f All tool lengths originate from datum There are several different ways to establish datum such as touching off with an empty spindle using a repeatable standard or using an electronic edge finder refer to Establishing Datum If you begin setting the tool length offsets by setting Datum using an electronic edge finder it must have a fixed and repeatable length The current tool information cannot have a length value All of the tool length offsets in the program will be the difference in length between the tool and the edge finder When defining tool length offsets in the Tool Step touch each tool to the same surface and press the TEACH TOOL LENGTH softkey to establish the tool length Once you have identified the tools you will be using you can program the length offsets into the tool steps Entering the first tool Decide on a method that you will use to set your Z axis datum You can choose to set your Z axis datum with the spindle nose without a tool inserted using a repeatable standard or using a 3 D electronic edge finder To begin your Tool Library set the current tool information in the status bar so the tool length is zero In our example we begin with the spindle nose to set datum zero If you wish t
141. ld appear as the first step in all of your programs You should also insert a Set Tool step anywhere you want to change tools MILLPWR will apply your latest tool setting to the program steps that follow To program a Set Tool step Note If you leave the Diam field blank you SET RORIS SEE L DIAM 0 5000 INCH LENGTH TOOL TYPE FL ENO ML Press the TOOL key Enter the tool s diameter SPINDLE OFF ey will be prompted to provide a diameter SPEED RPM Position Drill once the program is running TOOL POSITION Set Tool step Note Tool length offsets are mentioned later on i TO D DODD B This will enable within this section oO you to go to a REQUIRE CHANGE location away e Highlight the Tool Type field i from your work piece to change e tools If you press the TOOL LIBRARY softkey high light a tool and press ENTER MILLPWR will fill in the Diam Length and Tool Type fields for you Operation Manual Press the TOOL TYPES softkey for a list of available tool types Highlight a tool type then press the ENTER key For spindle control select from the OFF FORWARD and REVERSE softkeys If you selected Forward or Reverse enter a spindle speed An Operator Intervention Message OIM will prompt you to set the speed and direction when you run your program If your machine s set up to control the spindle MILLPWR will adjust the speed and direction for you To
142. le face e Press the RECT key e Press the FACE softkey e Enter the X and Y axes coordinates for the face s 1 Corner e In the Size field enter the length of the face along the X and Y axes unless you re programming a 2 Corner Enter the begin and end depths for the Z axis e Enter either the number of passes OR the distance between each pass Pass refers to the cuts that are used to machine the pocket to its End depth RECTANGLE FACE j END 0 0000 PASS FEED 10 00 0 5000 FL END MILL CENTER 10 00 Operation Manual PROGRAM STEPS MILLPWR ACU HITE e Enter the Z axis feed rate e Select a tool offset by pressing the appropriate softkey e Enter the table s feed rate e If you wish to program a 2 Corner and or a tilt angle or would like to program a finish cut press the MORE softkey x2 ABS Te ABS 2ND Corn er TILT age rc Enter the X and Y axes coordinates for the 2 Corner mE AM INISH The 2 Corner must be located diagonally across from strove 80 the 1 Corner Tilt Angle Enter the tilt angle Finish Enter a stepover percentage how much you want your tool to overlap on each pass e Press the USE key Note If the tool size and type listed in the Tool field are incorrect change the tool settings before running your program refer to Programming a Tool Step Operation Manual 5 19 PROGR
143. library that can store the diameter length unit of measure and tool type for up to 99 tools MILLPWR only requires that Set up your tool you provide the tool s diameter however it s a good idea to provide Pied P that a l l l l the tools you additional information so that each tool is easier to identify from the tool Hea moet Gon list appear first You can sort your tool library by number or type Pressing the RESET softkey will clear all of the tools that are programmed in the tool library Only use this key when you want to start over 0 0 100 SCALE 1 0000 TOOL LIBRARY 0 2500 Z 0 4275 INCH FLAT END MILL 0 3750 0 2995 INCH FLAT END MILL 0 5000 0 5485 INCH FLAT END MILL 0 7500 0 0275 INCH ROUGHING MILL 3 0000 1 4879 INCH FLY CUTTER 0 1875 Z 0 2626 INCH PILOT DRILL 0 2500 3 6568 INCH DRILL 0 3875 2 3578 INCH TAP 0 1250 Q 0000 INCH FLAT ENO MILL 0 1875 Z 0 0000 INCH FLAT END MILL 0 2500 0 0000 INCH FLAT END MILL SORT BY SORT BY USE NEW CANCEL NUMBER TYPE SETTINGS CHANGES 1 2 Operation Manual SETUP MILLPWH ACU RITE Using the tool library without repeat able tool lengths If you need to To enter a tool into the Tool Library change the units inches or mm for the tool e From Setup highlight Tool Library then press ENTER you re using before you set the length e Highlight a blank row in the Tool Library and press ENTER e Enter the tool s diameter e Hi
144. lly fills in the From point the depth and tool information for you e Enter the following information into the To and Radius fields TO X2 0 ABS mEHBHE RADIUS 1 5 MINOR ER m 5 Since this arc will be starting at the top and moving around to the bottom choose CW for the direction DIRECTION CW cw cw e Press the USE key use 4 6 Operation Manual DEMONSTRATION MILLPWR ACU RITE OFF FEED 0 0 100 TOOL CURRENT PROGRAM 001 SET TOOL l l 002 F MILL LINE Notice the lines 003 L MILL ARC 3 connecting steps _ _ SP 002 and 003 in the program list This indicates that the line and arc forma continuous con tour MILLPWR will cut them without stopping PROGRAM CLEAR STEP MORE RUN FUNCTIONS PROGRAM FUNCTIONS STEPS OPTIONS Operation Manual 4 7 DEMONSTRATION MILL PWHR ACU RITE Next enter the line that starts at the bottom of the arc e Press the LINE key and enter the following information ag TO X2 3 0 ABS 72 c casam Hong e Press the USE key e Press the LINE key to add another line Now enter the following information TO X2 3 0 ABS E enren Y2 0 838 ABS xi lelle e Press the USE key OFF FEED 0 0 100 TOOL 001 SET TOOL 002 F MILL LINE 003 MILL ARC O04 MILL LINE 005 L MILL LINE PROGRAM CLEAR STEP MORE RUN FUNCTIONS PROGRAM FUNCTIONS STEPS OPTIONS 4 8 Operation Manual MILLPWHR e Press the LI
145. ls of known length from the library to tools that have a non repeatable length such as a counter bore held in an R 8 collet Follow this program as an example Step 1 is a tool step tool 1 a center drill programmed from the tool library and is repeat able Step 2 in the program is a bolthole pattern Step 3 1s a tool step using tool 2 a drill from the library and 1s also repeatable Step 4 1s the same hole pattern repeated Step 5 1s a tool step programmed as a counter bore of unknown length and does not repeat Step 6 1s the same hole pattern repeated Operation Manual 7 9 SETUP MILLPWH ACU RITE For this example two identical parts are being machined The first part 1s in place and datum has been set using tool 1 from the library as the current tool The top of the workpiece is Z zero When the GO button is pressed MILLPWR will see that step one is asking for the same tool as the current tool and will proceed to the next step Step 2 and drill the holes When the next tool step Step 3 is executed you will be prompted to change tools to the drill Simply change the tool and press GO to continue The programmed tool offset will compensate for the difference in tool length as it drills the holes Step 4 The next tool Step 5 is of unknown length When this step is executed and you are prompted to change tools With this tool change e Press the DATUM softkey The DRO screen will appear with the set datum window e Place the
146. n manual At this point your program s tool length offsets are no longer valid Follow the steps below to reestablish the Z axis datum and tool length offsets for your program From the PROGRAM view highlight any tool step Press the GO key An Operator intervention message will appear asking you to use the programmed tool Place this tool in the spindle Press the DATUM softkey Reset the Z axis datum following the instructions found in your operation manual By resetting Datum during a tool step within the program all of the tool offsets in the program become valid again Changing to a Tool of unknown length in program When running a program it is easy to switch between tools of known length to tools that have a non repeatable length such as a counter bore held in an R 8 collet For example let s say a program is being run that has tool 1 a center drill in a repeatable holder as the first step Step 2 in the program is a bolthole pattern Step 3 1s a tool step using tool two a drill in a chuck that also repeats Step 4 1s the same hole pattern repeated Step 5 1s a tool step programmed as a counter bore of unknown length Step 6 1s the same hole pattern repeated For this example if two identical parts are being machined The first part 1s in place and datum has been set using tool one from the program as the current tool Operation Manual PROGRAM STEPS MILLPWH ACU RITE The top of the workpiece 1s Z zero
147. ng refer to Programming A Tool Step Operation Manual 2 13 PROGRAMMING MILLPWR ACU RITE PROGRAMMING Programming Considerations From and To Points Lines and arcs are defined by their From point the point where they begin and To point the point where they end ABS FROM e TO X1 Y1 X2 Y2 END 0 0000 ABS FEED 10 00 IPM 0 2500 FL END ML RGHT 10 00 Depth of Cut When you re programming the depth of cut you ll be prompted to provide the Begin and End locations for the Z axis The location that you enter into the Begin field tells z EGIN eles aad MILLPWR where you want the quill to begin cutting at Surface the programmed feed rate The End location defines the depth of the cut Always check that the Begin location is above the sur face of the workpiece Pass Pass refers to the number of cuts that are used to machine an area to its End depth You can control the number of passes 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 Operation Manual 3 1 PROGRAMMING MILLPWH ACU RITE Tool Offset LEFT OFFSET RIGHT OFFSET With MILLPWR you never have to calcu 4 3 2 late the actual tool path By using left and right offsets you can program the dimensions of the part as identified on your print When you program a line arc frame
148. nic Edge Finder ELECTRONIC EDGE FINDER DIAMETER An 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 even if you ve over traveled 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 into MILLPWR MILLPWR will automatically compensate for the radius of the tip of the electronic edge finder when performing any of the operations mentioned above To define the diameter and unit of measure for an electronic edge finder e From Setup highlight Electronic Edge Finder then press the ENTER key e Enter a value for the electronic edge finder s tip diameter and unit of measure either inches or millimeters then press the USE key e Continue with Setup or press the USE NEW SETTINGS softkey Job Clock MILLPWR includes a job clock that can be used to keep track of the time you spend on each job The job clock works like a stopwatch counting in one second intervals after you ve pressed the START softkey and stopping after you ve pressed the STOP softkey The job clock appears in the Status bar and is visible from both the PGM and DRO screens It reflects how mu
149. ntified or if it s incorrect you ll need to start with a Set Tool step that accurately identifies the tool you re using refer to Set Tool After you ve highlighted the step that you want to begin with press the GO key An Operator Intervention Message OIM will ask you to con firm this tool 1s correct Check that the correct tool 1s being used then press the GO key again to begin milling If your tool is positioned above the Z axis retract position before you begin to run a program the table will rapidly move to position and then the quill will rapidly move to the retract position If the tool is below the retract position the quill will move first 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 refer to Begin and End Depths If the travel limit for the Z axis 1s set below the established retract posi tion a travel limit fault will occur and the program will stop ACU RITE To move quick ly to a step key in its number look in the message bar and press ENTER The remote STOP GO switch acts as PAUSE if the table is moving and as GO if the machine is paused or stopped MILLPWR will automatically pause at points that require you to take action e g change tools After each task has been completed press the GO key If you press the STOP key once while cutting your tool will pause in its cutting pa
150. o set up a 4 SIN plate at a 30 angle VALUE 2 0000 ENTER and need to know how tall the block underneath it should be If we multiply 0 5000 by 4 we know that we need to use a 2 block The parentheses softkeys can be used to group calculations within an arithmetic equation For example 2 1 16 equals 2 0625 but 2 1 16 equals 0 1875 The parentheses are not always displayed during the keystroke sequence but they are remem bered by MILLPWR as it calculates the correct answer Operation Manual 6 3 CALCULATOR MILL PWR ACU RITE Geometry Functions Working with the Geometry Calculator To open the geometry calculator GeoCalc press the CALC key and then press the Geometry softkey OFF FEED 0 0 100 TOOL 0 1250 INCH FL END ML SCALE 1 0000 0 00 00 INCH GEOMETRY CALCULATOR 001 GEOLINE 002 GEOLINE GEOARC GEOARC GEOARC GEOARC Feature List CURRENT SELECTIONS 001 GEOLINE AND O02 GEOLINE CLEAR CALC RESULTS FUNCTIONS With MILLPWR s GeoCalc you can calculate missing coordinates such as the tangent point between a line and an arc using the information that appears on your print 6 4 Operation Manual CALCULATOR MILLPWR ACU RITE The kinds of calculations that GeoCalc performs depends on the items you select and whether you re trying to find a point line or arc The table below lists all of the points lines and arcs that can be found by GeoCalc 2 Points Mi
151. o use a 3 D electronic edge finder or tool holder with a repeatable standard then place it into the spindle instead and set datum Then you find the tool length offset for tool 1 as well Operation Manual MILLPWR PROGRAM STEPS ACU RITE From the DRO screen press the TOOL key Enter the diameter and then enter zero for the tool length Press GO An Operator intervention message will appear asking you to use the entered tool Place your first tool in the spindle and press GO again MILLPWR is now set with a zero tool length offset Press the DATUM softkey Touch the current tool to the top of the workpiece Press the Z 0 softkey then the USE key Use this same location to teach each tool length in the program Press the PROGRAM key and highlight the first tool step Press ENTER Use the numeric keypad to enter the tool s diameter Highlight the length field and insure the length offset 1s zero If you used a 3 D electronic edge finder or tool holder with a repeatable standard to set datum then touch tool 1 to the same surface you used to set the Z axis datum above and teach its tool length here Highlight the next tool step and press ENTER Use the numeric keypad to enter the tool s diameter Place this tool into the spindle and touch its tip to the same surface you used to set the Z axis datum Zero above Press the TEACH TOOL LENGTH softkey The length offset for this tool will appear in the l
152. o use the ACU RITE 3 D electronic edge finder or a tool holder with a repeatable standard then place it into the spindle instead Operation Manual 7 5 SETUP MILL PWR ACU RITE e Remove any tool from the spindle e From the DRO screen press the TOOL key e Enter zero for the diameter and zero for the tool length e Press GO e An Operator intervention message will appear asking you to use the entered tool e Press GO again e MILLPWAR is now set with a zero tool length offset e Press the DATUM softkey e Touch the spindle nose to a solid surface such as the top of a vice or your workpiece e Press the Z 0 softkey then the USE key Datum zero for the Z axis 1s now Set to the surface that the spindle nose touched Use this same loca tion to teach each tool length in the tool library e Press the SETUP key and highlight tool library e Press ENTER e Highlight the tool number in the tool library list for the tool you are setting up and press ENTER Use the numeric keypad to enter the tool s diameter Highlight the unit field If the diameter you entered is metric press the MM softkey e Highlight the length field e Place this tool into the spindle and touch its tip to the same surface you used to set the Z axis datum Zero e Press the TEACH TOOL LENGTH softkey The length offset for this tool will appear in the length field e Highlight the Type field e Press the TOOL TYPES sof
153. ol Position allows the operator to enter a position to which the tool will move so you can perform a tool change while running a program Required Change is used if the operator for any reason wants to move the tool into position for a tool change even if there is no tool change actually required Pressing YES for Required Change field will activate this prompt Press the USE key 5 1 PROGRAM STEPS MILL PWR ACU RITE 5 2 Programming a Tool Step with Repeatable Tool Length Offsets See the graphic below to identify the tools you will be using L1 a a Length offset Length w offset Length offset Using an electronic J edge finder as Zero tool length Jj If you begin setting the tool length offsets by setting Datum using an electronic edge finder it must have a fixed and repeatable length The current tool information cannot have a length value All of the tool length offsets in the program will be the difference in length between the tool and the edge finder When defining tool length offsets in the Tool Step touch each tool to the same surface and press the TEACH TOOL LENGTH softkey to establish the tool length Once you have identified the tools you will be using you can program the length offsets into the tool steps Entering the first tool Set your Z axis Datum with a tool or standard using no tool length offset In our example we use the first tool in the program to set datum zero If you wish t
154. ol to overlap on each pass e Press the USE key Note If the tool size and type listed in the Tool field are incorrect change the tool set tings before running your program refer to Programming a Tool Step Operation Manual 5 15 PROGRAM STEPS MILL PWR ACU RITE Frame When you program a rectangular frame you define it by its first corner and its size or diagonal corner Inside Frame Outside Frame Size in Size in Pass Final Pass Size in Z End Size in To program a rectangular frame e Press the RECT key 1st CORNER e Press the FRAME softkey 3 SIZE e Enter the X and Y axes coordinates for the frame s 157 Corner e In the Size field enter the length of the frame along the END 0 0000 ABS X and Y axes unless you re programming a 2 Corner Bos TIE CORNER BLEND RADIUS e Enter the begin and end depths for the Z axis 0 0000 DIRECTION Enter either the number of passes OR the distance CCW between each pass Pass refers to the cuts that are used to machine the pocket to its End depth e Enter the Z axis feed rate e Optional Enter a corner blend radius 5 16 Operation Manual PROGRAM STEPS MILLPWR ACU RITE e For Direction press either the CW softkey for clockwise or the CCW softkey for a counter clockwise direction e Arrow down and select a tool offset by pres
155. olute 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 0250 INC 002 This indicates that the X position will Y 1 5000 ABS increment from the X value in Step 2 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 1 8 Operation Manual INTRODUCTION MILLPWR ACU RITE Z axis Conventions Z axis Retract The Z axis retract 1s 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
156. on not correct the prob lem you are experiencing contact your ACU RITE dis tributor for repair and or replacement procedures Run the Circle Inter polation Test refer to Diagnostics Section 7 Check that the knee ram and head bolts turret to column bolts and head to knuckle bolts are properly fastened and secure 9 7 TROUBLESHOOTING GUIDE MILLPWR Symptom Probable Cause System not repeating or Machine tool related prob circles are not round lems cont d cont d Improper position feedback from precision glass scales or Z axis Rotary encoder 9 8 ACU RITE Recommended Corrective Action Check the gibs for wear and proper adjustment Refer to the machine tool operation manual Align the spindle Lower the quill full travel with a sturdy tool inserted into the spindle Set up a dial indicator to check movement of the spin dle then move the tool side to side Total movement should be within the machine tool manufacturer s specifications between the spindle and the spindle bear ings and between the quill and the bore You may need to replace the spindle bear ings Machine tool wear MILLPWR can compensate for machine tool wear through its linear error com pensation LEC feature refer to Setup Check that the mounting brack ets and fasteners are tight and secure For Z axis Optional Linear encoder Check the X and Y axis preci sion glass scale and reading head for pr
157. on where you want your left table travel limit set Press the SET LEFT LIMIT softkey Note The X axis travel field will update to show you the maximum allowable traveling distance between the left and right table travel limits Now highlight the Y axis Travel field Move the table away from you until you ve reached the position where you want the inside table travel limit set Press the SET INSIDE LIMIT softkey Y AXIS TRAVEL Z Axis TRAVEL TRAVEL LIMITS 4 0275 Use the handles or the MOVE TABLE feature to position your table If you use MOVE TABLE a caution mes sage will inform you that the table travel lim its are not acti vated Move the table towards you until you ve reached the position where you want the outside table travel limit set Press the SET OUTSIDE LIMIT softkey Note The Y axis travel field will update to show you the maximum allowable travel distance between the inside and outside table travel limits Operation Manual 16 0787 1 21 SETUP MILLPWR Highlight the Z axis Travel field Move the quill up until you have reached the position where you want the top travel limit set Make sure FTO position 1s located Press the SET TOP LIMIT softkey ACU RITE You may change your table travel lim its at any time Move the quill down until you have reached the position where you want the bottom travel limit set Make sure FTO position is located
158. onds after the system is powered up 7 30 Operation Manual SETUP MILLPWH ACU RITE To enable or disable the motor assembly monitor e From the Diagnostics screen highlight Motor Assembly Monitor and press ENTER e Press either the ENABLED or DISABLED softkey If the ENABLED softkey is selected the motor assembly monitor display will appear on the DRO screen e Press the USE key e Continue with Diagnostics or press the USE NEW SETTINGS softkey Signal Test The signal test shows when an axis was last tuned and whether or not the digital to analog converter is emitting an analog signal When the test is complete either Pass or Fail will appear in the Signal Test Result field If a failure is reported check the message bar prompt for details To display the signal test TSS ATES LAST GAIN TUNING DATE e From the Diagnostics screen highlight Signal Test 01 30 2000 and press ENTER LAST BALANCE TUNING DATE 01 30 2000 SIGNAL TEST RESULT PASS e Press the softkey for the appropriate axis e Press the EXIT TEST softkey to close the Signal Test screen e Continue with Diagnostics or press the USE NEW SETTINGS softkey Operation Manual 7 31 SETUP MILLPWR ACU RITE Table Stop Test The table stop test shows whether or not an emergency stop E stop condition has been detected or the internal switch has been pressed E stop Signal Reports on whether or not the s
159. oper installation Operation Manual MILLPWR Symptom Incorrect dimensions Poor finish Operation Manual TROUBLESHOOTING GUIDE ACU RITE Probable Cause System is out of tune Dull tool Incorrect feed rates and or spindle speeds Gibs are worn or are out of adjustment Recommended Corrective Action Check that the proper dimen sions were entered for each step of your program Check that the correct tool information was entered for each step of the program Measure the tool diameter to check for tool wear Check that the correct scale factor is being used Perform the auto tuning pro cedures for all three axes If auto tuning your system does not correct the problem contact your ACU RITE dis tributor Replace or sharpen the tool Check that the correct feed rates have been entered for each step of your program Check your spindle speed setting Refer to the machine tool operation manual 9 0 TROUBLESHOOTING GUIDE MILLPWR Symptom Probable Cause Poor finish cont d Worn spindle bearings System is out of tune 9 10 ACU RITE Recommended Corrective Action Lower the quill full travel with a sturdy tool inserted into the spindle Set up a dial indicator to check movement of the spindle then move the tool side to side Total movement should be within the machine tool manufactur er s specifications between the spindle and the spindle bearings and between
160. or when each hole of a hole pattern 1s reached a signal 1s sent for output This signal will continue to be output until the GO button is pressed a GO signal 1s received through the AMI the table stop is activated the program is stopped or the program ends OFF No signal is sent Pulsed With this option the signals will only be sent for the timed intervals that you establish Enter a time interval between 0 1 and 999 9 seconds When the X Y coordinates for the position drill step or when each hole of a hole pattern 1s reached a pulsed signal will be sent This signal will continue until either the pulse time interval expires the GO button is pressed a GO signal is received through the AMI the table stop button is activated an E Stop input is detected the program 1s stopped or the program ends FEED 0 0 100 SCALE 1 0000 INSTALLATION SETUP AMI OUTPUTS PROTECTION IN POSITION RELAY ERROR COMPENSATION or ENCODER SETUP TRAVEL LIMITS ERROR CHECKING SERIAL PORT Z ARIS CONTROL SPINDLE CONFIG ERROR LOG SERVO TUNING AMI OUTPUTS DIAGNOSTICS MAX SERVO SPEED AMI OUTPUTS IN POSITION RELAY PULSED EN Sec AOR SETS USE MEW CANCEL 7 28 Operation Manual SETUP MILLPWR ACU RITE Diagnostics The diagnostics section houses information about your system s mechanical operations memory availability and machine usage Tests are also available to help you monitor your system s over
161. ore times e Press the REFERENCE POINT softkey e Enter your reference point s position for X Y and Z e Press the USE key Operation Manual REFERENCE POINT POINT X p ABS Y ABS DEPTH 1 z 0 0000 ABS 9 99 PROGRAM STEPS MILL PWR ACU RITE Island An island is a raised area within a custom pocket that remains after material has been removed from around all of its sides Though islands are easy to program they must be placed correctly within the program sequence Steps for the island s continuous tool path must appear first followed by the island step Steps for inii the custom pocket s continuous tool path must appear next followed by the custom pocket step You may program more than one island within the custom pocket CURRENT PROGRAM To program an island 001 SET TOOL 002 N MILL ARC e Program a continuous tool path for the island Ea 005 II e From the PGM screen place the cursor below the 007 N 008 II MILL LINE last step of the island s continuous tool path AOS Rt DINE 010 II MILL LINE 011 U CUSTOM POCKET e Press the MORE STEPS softkey e Press the MORE STEPS softkey two more times e Press the ISLAND softkey e Check that the first and last steps listed in the step range match the first and last steps for the island s continuous tool path If they re correct press the USE key if they re not pr
162. ory each time a file 1s saved onto the system s internal memory When a file is deleted memory is restored Total Clusters Tota number of clusters available on the MILLPWR system One cluster equals 8 192 bytes of memory Available Number of clusters still available for use Clusters Total Bytes Total amount of memory measured in bytes shipped with the MILLPWR system Available Amount of memory measured in bytes still available for use Bytes To view the disk utilization screen Sar TOTAL CLUSTERS e From the Diagnostics screen highlight Disk 81954 AVAILABLE CLUSTERS Utilization and press ENTER 10073 TorAL BvTES e Press the EXIT TEST softkey to close the Disk o 2988512 Utilization screen TOTAL BYTES AVAILABLE O 20629504 e Continue with Diagnostics or press the USE NEW SETTINGS softkey Operation Manual 7 37 SETUP MILLPWR 7 38 Set Time and Date ACU RITE The time and date appear on the error log and on any saved part program You can reset the time and date at any time Enter four digits for the year To change a setting e From the Diagnostics screen highlight Set Time and Date and press ENTER Highlight the field you wish to update Using the keypad enter the appropriate number e Press the USE NEW SETTINGS softkey to close the Set Time and Date screen e Continue with Diagnostics or press the USE NEW SETTINGS softkey again
163. osen Select None as the type for whichever option you don t want 5 42 Operation Manual MILLPWR PROGRAM STEPS ACU RITE To program a contour From the PGM screen highlight the step below the last step in the continuous contour Press the MORE STEPS softkey Press the CONTOUR softkey You ll notice that First and Last in the Step Range field will be filled in for you If you wish to program an approach press the STRAIGHT or ARC softkey as your approach type Otherwise press the NONE softkey Enter how far from the part you want the approach to begin To program a departure press the STRAIGHT or ARC softkey as your departure type Otherwise press the NONE softkey Enter how far from the part you want your tool to travel If you would like to program a finish cut enter the amount of material to be removed during the finish cut Enter the feed rate Using the softkeys select the finish pass direction FORWARD or REVERSE Press the USE key Operation Manual 5 43 PROGRAM STEPS MILL PWR Engrave ACU RITE With MILLPWR you have the ability to engrave letters numbers and symbols along a straight line or on an arc Choose from a simple stick or stencil font The character height font and modifier settings you select will define your engraving s appearance Condition The tool diameter being used establishes the spacing between letters PART 1234 56 a AD et LH Engrave
164. our program s onto a 3 floppy disk press the USE FLOPPY softkey or onto your PC press the REMOTE STORAGE softkey Determine which program s you want to back up To back up all of your programs in the directory e Press the ALL PROGRAMS softkey MILLPWR will store a backup copy of each program in the directory you ve selected To back up only one or just a few programs e Press the SELECT PROGRAMS softkey e Highlight each program you want to back up press the SELECT PROGRAM softkey again An arrow will appear beside each program name you ve selected Operation Manual PROGRAMMING MILLPWR ACU RITE e Now press the BACKUP PROGRAMS softkey MILLPWR will highlight each program as a backup copy is saved in the directory you ve selected Note If a program with the same name is already stored in the directory you ve chosen MILLPWR will ask you if you want to replace the old copy with the latest copy Choose the YES softkey or YES TO ALL softkey to continue or the NO softkey to cancel Deleting a Program You can delete any program that has been saved To delete a program e Select the directory that contains the program you want to delete refer to Selecting a Directory e From the PGM screen press the PROGRAM FUNCTIONS softkey then press the DELETE softkey SELECT A BACKUP FUNCTION ALL SELECT USE REMOTE PROGRAMS PROGRAMS FLOPPY STORAGE e Using the arrow keys highlight the program you want to delete
165. pe e Press the GO key e An Operator intervention message will appear asking you to use the selected tool e Place the selected tool in the spindle e Press the GO key to confirm that you have installed the tool e Set the Z axis datum following the instructions found in your operation manual At this point your tool library length offsets are not in effect Re establishing the Z axis datum with a tool from the tool library will reestablish the tool length offsets e From the DRO view press the TOOL key e Press the TOOL LIBRARY softkey e Highlight the tool you would like to use from the tool library list and press enter e Press the GO key e An Operator intervention message will appear asking you to use the selected tool e Place the selected tool into the spindle e Press the GO key to confirm that you have installed the tool e Reset the Z axis datum following the instructions found in your manual Using your tool library within a program When programming press the TOOL key e Press the TOOL LIBRARY softkey e Highlight the tool you would like to use from the tool library list e Press the ENTER key then the USE key When the program is executed and the tool step is reached an Operator intervention message will appear asking you to use the programmed tool 7 8 Operation Manual SETUP MILLPWR ACU RITE e Place the selected tool in the spindle A MOVE TABLE softkey is available to help you move aw
166. pear OFF FEED 0 0 100 SCALE 1 0000 0 00 00 INCH GEOMETRY CALCULATOR 001 GEOLINE J I I J I I I I J LI LI I I LI I I LJ LI LI I I LI LI SELECT RETURN CALC FEATURE FEATURE FUNCTIONS 6 12 Operation Manual MILLPWHR Next enter the dimensions for the line that reaches from point B through point C e Press the LINE key e In the From field enter point B s coordinates X1 2 and bap Enter the To point Use polar coordinates since the angle is known and the radius can be estimated e Press the POLAR softkey Estimate 5 for the radius R2 e Press the ABS INCR key to switch to incremental measuring because the measurement is taken from point B not from datum Highlight the A2 field The print shows that the angle is 70 But if 70 is entered the line will slant the wrong way The complementary angle 1s needed instead Figure it out by subtracting 70 from 180 the total angle of the line e You can either enter the answer 110 directly into the A2 field or you can calculate the answer using the keypad 180 70 e Since the angle is measured from point B incremental zero press the ABS INCR key again e Press the USE key and line B C will appear Operation Manual CALCULATOR ACU RITE Fria X1 2 0000 ABS Y1 0 0000 ABS To R2 5 0000 INC R1 A2EILETIIHNC A1 ANGLE 110 00 00
167. perly during file transfers Press the ENABLED softkey Press the USE key Continue with Setup or press the USE NEW SETTINGS softkey Z axis Control Operation Manual ___Z AXIS CONTROL Your MILLPWR is shipped with Z axis control enabled Axis CONTROL 4 However you can easily disable the Z axis control at your con ENABLED venience for example when you want to run a program that RETRACT AFTER DISABLED was created using a two axes system To operate MILLPWR as a three axes system with X Y and Z motion control select the ENABLE softkey To use MILLPWR as a two axes system with only X and Y motion control select the DISABLE softkey 7 23 SETUP MILL PWR ACU RITE 7 24 Spindle Control If you re using a milling machine that has an electronic variable speed spindle MILLPWR may be able to control the spindle for you through the Auxiliary Machine Interface option With the spindle control enabled MILLPWR will apply the direction and speed parameters you enter into the Set Tool step of a program Depending on your spindle s motor you may be able to control the spindle s speed and direction or just the direction If the spindle control is disabled the settings you program in Set Tool will be displayed in an Operator Intervention Message OIM when you run the program You ll be prompted to set the speed and direction manually Error Log MILLPWR includes a built in e
168. r the remote pendant will cause the program and all axis motion to pause Pressing the remote pendant switch again or the GO button will cause the program to resume Pressing the STOP button a second time will halt the program execution Operation Manual PROGRAMMING MILLPWR ACU RITE MILLPWR G Code Conventions Table of G amp M Codes This table lists both the supported and unsupported codes Non supported codes are shown in gray Code Description Comment D Tool Diameter MILLPWH does not support automatic cutter compensation opecifying a tool diameter index while cutter compensation is in effect will generate a run time error Specifying a diameter index while cutter compensation is off has no effect and is ignored F Set Feed Rate The feed rate uses the current program units in effect ipm or mmpm The setting applies to current and subsequent blocks The default is determined from MILLPWH s configuration setup GO Linear Interpolation Rapid These commands generate table quill motion The motion com 31 Linear Interpolation Feed mand applies to current and subsequent blocks containing at G2 Circular Interpolation CW Mn one X Y us ue The default motion command is G3 Circular Interpolation a linear move at feed G1 CCW G4 Dwell This command causes the system to pause for a specified period of time prior to any motion commands within the blocks The period of time is determined by the P value G10 Offset Value Set
169. re 0 0 In the part program draw the line by entering the absolute coordinates for point A 0 0 in the From field and point B 2 0 in the To field Enter the Z axis and offset infor mation as needed OFF FEED 0 0 100 SCALE 1 0000 0 00 00 INCH CURRENT PROGRAM 001 SET TOOL rie S 002 MILL LINE d X1 0 0000 ABS EE EE l 0 0000 ABS 0 0000 ABS 0 2000 ABS MILL LINE 0 1000 ABS 0 2500 ABS 10 00 IPM 0 0000 0 2500 FL END ML RIGHT 10 00 END OF 2 PROGRAM CLEAR STEP MORE RUN FUNCTIONS PROGRAM FUNCTIONS STEPS OPTIONS e Press USE to finish programming the line Now use GeoCalc to find the coordinates for points C and D Entering the Lines Press the CALC key and then press the GEOMETRY softkey Now press the LINE key and construct the line from A to D e Press the LINE key e Enter the coordinates for the From point point A X 0 Y 0 Operation Manual 6 11 CALCULATOR MILL PWR ACU RITE e The polar coordinates are R2 Feo 2 X1 0 0000 ABS Y1 0 0000 ABS a polar coordinate is a position r To defined by an angle and a radius R __ 5 0000 ABS R BRUM ABS ANGLE radius and A2 angle Remember 70 00 00 e Since GeoCalc doesn t need the length of the line enter a radius value of 5 e The angle of the line from datum is 70 e Press the USE key and a line starting at point A and traveling through point D will ap
170. release knob for the Z axis drive is loose MILLPWR and PC BAUD rate settings do not match MILLPWR and PC BAUD rate settings do not match BAUD rate 1s too slow or too fast MILLPWR and PC BAUD rate settings do not match Incorrect serial cable ACU RITE Recommended Corrective Action Tighten the quick release knob Should the above recommen dations not correct the prob lem you are experiencing contact your ACU RITE dis tributor for repair and or replacement procedures Change one of the settings so that the BAUD rates for MILLPWR and your PC are the same Change one of the settings so that the BAUD rates for MILLPWR and your PC are the same Adjust the BAUD rates on both MILLPWR and your PC Check that they match when you re finished adjusting them Change one of the settings so that the BAUD rates for MILLPWR and your PC are the same Verify that you are using the correct type of serial cable Refer to page 8 1 choosing a serial cable 9 13 TROUBLESHOOTING GUIDE MILLPWR Symptom No response from PC cont d Time out error 9 14 Probable Cause Your PC s COM port setting is different from the COM port that your serial cable is connected to The selected COM port is disabled Loose serial cable ACU RITE Recommended Corrective Action If the COM port setting 1 or 2 on the PC screen does not correlate with the COM port that the serial cable 1s connecte
171. ronic 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 find er is active whenever an entry field is highlighted Operation Manual DRO MILLPWR ACU RITE 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 indi cator 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 CORRECT INCORRECT SKEW SKEW POINT 14 287 ANGLE ANGLE 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 runn
172. rror log that will record system assertion failures If an assertion failure 1s detected MILLPWR will automatically record the date along with a brief description of the failure Messages can be cleared by pressing the CLEAR key then pressing YES to proceed or NO to cancel It s best to let messages accumulate to establish a history To save these records for future reference place a 3 floppy disk into the disk drive and press the SAVE FLOPPY softkey Operation Manual SETUP MILLPWR ACU RITE Servo Tuning The servo motors for each MILLPWR system are properly tuned upon installation However you can fine tune your system periodically using the Auto Tuning feature Before beginning the Auto Tuning procedure first make sure your MILLPWR system software is version 3 2 8 or higher The Auto Tuning method is done completely through the MILLPWR console Therefore there is no need to open the servo motors Since all adjustments are made from the console the changes will not affect the original amplifier setting values When using the Auto Tuning feature you should tune each axis X Y and Z individually to achieve optimal performance Both the Balance and the Gain for the axis will need to be adjust ed If the servo motors cannot be tuned auto matically the following mes sage will appear Not enough adjust ment please use manual mode Please contact your ACU RITE distributor Operation Manual 7 2
173. rs are ignored Text following the delimiter is ignored Text following a programming comment character is ignored White space is ignored between parameters but not within a numeric value or message If a coolant command M7 M8 and M9 appears in the block the Operator Intervention Message is displayed regardless of the current coolant setting If AMI hardware is present the block will execute without the need for any operator intervention or acknowledgement All tool diameter compensation must be made in CAD CAM however the tool length off set is read from MILLPWR s tool library For example In a G code file T1 will use the tool length offset from Tool 1 in the tool library T2 will use tool length offset from tool library tool 2 etc The skew feature does not work with G code programs Remove any skew angle prior to running a G code program Operation Manual PROGRAMMING MILLPWR ACU RITE Merging Programs The MERGE softkey allows you to merge two MILLPWR programs together With this function all of the program steps within the program you selected will be copied into your current or open program Keep in mind that you can edit any of the new steps if you need to refer to Step Functions To merge programs From the PGM screen highlight the step in your current open de Me program where you want the new steps to be inserted good idea to save your work before merging Press the PROGRAM
174. ry list and press enter e Press the GO key An Operator intervention message will appear asking you to use the selected tool e Place the selected tool in the spindle e Press the GO key to confirm that you have installed the tool e Follow the instructions for setting datum in your operation manual Once Z axis datum is set with a known tool from the tool library all of the tools in the tool library can be used without the need to reset datum It is extremely important to set Z axis datum on a solid surface with a tool from the library after running a tool step with this tool or by using the identical method used when setting your first tool before you input additional tools to the library If this is not done your tool length cannot be determined correctly Operation Manual 7 7 SETUP MILL PWR ACU RITE Changing between Tools in the Tool Library when in DRO view To change tools when in the DRO view e From the DRO view press the TOOL key e Press the TOOL LIBRARY softkey e Highlight the tool you would like to use from the tool library list and press enter e Press the GO key e An Operator intervention message will appear asking you to use the selected tool e Place the selected tool in the spindle e Press the GO key to confirm that you have installed the tool Changing to a Tool of unknown length when in DRO view e From the DRO view press the TOOL key e Enter the tool diameter and if you wish the ty
175. s been interrupted Operation Manual 2 1 DRO S S S ll 1 LZLOO MILL PWHR ACU RITE 2 2 Finding Home Rotary Encoder 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 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 technolo gy 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 Operation Manual MILLPWHR
176. s internal memory e Save then clear any open programs e From the PGM screen press the PROGRAM FUNCTIONS softkey then press the LOAD softkey The last directory that was selected and any programs it contains will appear If the program is saved in the MILLPWR directory e MILLPWR should appear at the top If it doesn t check that the USE FLOPPY and REMOTE STORAGE softkeys are not selected e Press the format button until MPT is displayed e Using the arrow keys highlight the program you want to load then press the LOAD softkey The program you ve selected should appear on your screen OFF FEED 0 0 100 TOOL 0 1250 INCH FL END ML SCALE 1 0000 0 00 00 MILLPWR 001 SET TOOL BOLTPRGM 002 M MILL LINE 003 MILL ARC MILL 1 004 MILL LINE MILL2 005 MILL LINE PART242 006 MILL LINE 007 Il BLEND 008 MILL LINE 009 U MILL LINE 010 SET TOOL 011 BOLT CIRCLE Oi SET TOOL 013 RECTANGLE POCKET END OF 13 ED PICK A PROGRAM TO LOAD FORMAT G CODE FORMAT DXF 3 26 LORD PAGE FORMAT USE REMOTE DOWN MPT FLOPPY STORAGE ACU RITE If you re loading a program that was created on a two axes sys tem you will have to add Z axis information before you run the program If you don t want to add the Z axis information consider dis abling the Z axis control and run ning in 2 axis mode Refer to Setup for further instructions Operation Manual PROGRAMMING MILLP
177. s servo connections located on the rear of the Operator Console Check that the power connec tions for each motor assembly and that the Servo Power con nector located on the rear of the operator console are prop erly seated Enable the Motor Monitor refer to Diagnostics Section 7 Operation Manual MILLPWR Symptom Table run away For Z axis Optional Linear encoder Table or Quill will move in only one direction Table has stiff movement System not repeating or circles are not round Operation Manual TROUBLESHOOTING GUIDE Probable Cause The X and Y axes servo connections located on the rear of the Operator Console are not connected to the correct axes For Z axis Optional Linear encoder Position is beyond travel limits Table 1s locked Gibs are worn or are out of adjustment Not enough oil in oil reser voir or oil lines are blocked or disconnected Machine tool related prob lems ACU RITE Recommended Corrective Action Check that the cables are properly connected to the correct axes For Z axis Optional Linear encoder Move within the travel lim its You may want to consid er adjusting your travel lim its refer to Diagnostics Section 7 Check the table locks and loosen as needed Refer to the machine tool operation manual for adjust ment procedures Check that there 1s sufficient oil in the oil reservoir Should the above recommen dati
178. sing the appropriate Too softkey 0 1250 INCH FLENDMILL TYPE CENTER OFFSET FEED 10 00 IPM e Enter the table s feed rate 2ND CORNER x2 ABS D Y2 ABS e If you need to program a 2 Corner tilt angle and or finish TILT ANGLE cut 0 00 00 FiNisi 2 Corner dd pray Enter the X and Y axes coordinates for the 2 Corner The 2 Corner must be located diagonally across from the 15T Corner 0 0000 CuT Tilt Angle Enter the tilt angle Finish Highlight Cut in the Finish field Enter the amount of material to be removed during the finish cut Enter the feed rate for the finish cut For Direction press either the CW softkey for clockwise or the CCW softkey for a counter clockwise direction e Press the USE key Note If the tool size and type listed in the Tool field are incorrect change the tool settings before running your program refer to Programming a Tool Step Operation Manual 5 17 PROGRAM STEPS MILLPWR 0 18 Face ACU RITE The Rectangle Face step provides a quick way to face off your workpiece Simply enter the coordinates from one corner and either the size of the area to be faced off or the coordinates for a diagonal corner MILLPWR will position your table at the lower left end of the area you ve programmed Stepover To program a rectang
179. ss the USE key Operation Manual PROGRAM STEPS MILLPWR ACU RITE Copy Move Steps Copy Move operations make it easy for you to duplicate or rearrange steps within your program You ll find the Move feature especially useful for editing steps generated from a DXF file After you press the COPY MOVE STEPS softkey you ll be asked to enter a step range then either copy or move the steps Press the MOVE softkey to relocate the steps Press the COPY softkey to create an identical copy of the steps you ve chosen the original steps will remain in place After you press the USE key the new steps will be inserted into your program To copy or move steps e From the PGM screen highlight a step where you would like to add or insert the step s that you want to move or copy e Press the STEP FUNCTIONS softkey e Enter the first and last step numbers that you would like to move or copy e Press the COPY MOVE STEPS softkey e Press either the MOVE or COPY softkey e Press the USE key Operation Manual 5 65 PROGRAM STEPS MILLPWR This page intentionally left blank ACU RITE Operation Manual MILLPWR Calculator MILLPWR s built in calculator is capable of handling everything from simple arithmetic to complex trigonome try geometry and RPM calculations The numeric keypad resembles a standard calculator with keys for numbers 0 through 9 four math function symbols 4 x and a decimal point and a pos
180. sts against any straight edge on the part Press the TEACH POSITION softkey to enter your coordinate You ll notice that the Points change e Now move the table so that the mechanical indicator touches another point on the same straight edge Press the TEACH POSITION softkey You ll notice that the Points and Angle change Repeat this process for any additional points e Press USE to accept all of the points and return to the DRO screen Press CANCEL to return to the previous screen without affecting your previous skew angle The CLEAR ANGLE softkey will reset the number of points and the angle to zero Operation Manual 3 9 PROGRAMMING MILLPWR ACU RITE 3 10 Establishing Datum Datum also known as workpiece zero or absolute zero 1s a point of reference that MILLPWR bases all of your part s coordinates from You will need to establish datum for every job Datum s location may be indicated on your print if it s not then establish a datum that allows you to enter most of your part s dimensions directly with the least amount of calculations When establishing datum you may find it easiest to locate a known point on each axis such as the edge of your part or a location on your vise or fixture Refer to the example below as a basic guide for establishing datum You may decide to touch off using an edge finder instead of a tool Datum could be set at a point on the top surface a position beneath the surface or at a poin
181. sual chatter from the quill cont d Z axis engage disengage mechansim will not re engage ballscrew nut or quill does not move freely Poor dimensional accuracy 9 12 Probable Cause The feed rate and or spindle speed require adjustment The tool is worn The tool diameter is too small for the depth of cut The tool is not secure in the tool holder The machine s ram and or head is loose The spindle bearings are worn The machine s head has been moved and is out of alignment The machine s head is out of alignment The head has been moved or re angled ACU RITE Recommended Corrective Action Adjust the feed rate and or spindle speed Sharpen or replace the tool Increase tool diameter or reduce the depth of the cut Check that the tool 1s secure in the tool holder Tighten the nut s on the ram and or head as required by the manufacturer Replace the spindle bearings as instructed in the milling machine s reference manual Re tram the machine s head Re tram the head and re tight en the four 4 head coupling nuts to 50 ft Ibs of torque Re tram the machine s head Re tram the head and re tight en the four 4 head coupling nuts to 50 ft Ibs of torque Operation Manual MILLPWR Symptom Poor dimensional accuracy cont d BAUD rate error Check sum error No response from PC Operation Manual TROUBLESHOOTING GUIDE Probable Cause The quick
182. sub STORAGE soft directories you have created will appear under the DIRECTORY key will only headin appear if MILL 8 PWR has been set up for remote Using the arrow keys highlight the directory you want to open If storage the list is long use the PAGE UP and PAGE DOWN softkeys to scroll through the list more quickly Press the SELECT DIRECTORY softkey again The DIRECTORY list will disappear indicating that your directory has been selected You can now save your program in the directory you have chosen or if you prefer load an established program from the directory you selected refer to Program Functions Operation Manual MILLPWR PROGRAMMING ACU RITE Deleting a Directory MILLPWR will not delete directories that contain programs You must delete each program and subdirectory stored within the directory first refer to Deleting a Program To delete a directory From the PGM screen press the PROGRAM FUNCTIONS and DIRECTORY softkeys then press the DELETE DIRECTORY softkey Identify where the directory you want to delete 1s located On MILLPWR s internal memory MILLPWR and any subdirectories you have created should appear under the DIRECTORY heading On a 3 4 floppy disk Insert the 3 floppy disk containing the directory into the disk drive located in the lower right hand corner on the front of the operator console and press the USE FLOPPY softkey A and any subdirectories you have create
183. 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 ATTENTION Z AXIS FAULT MOVE WITHIN LIMIT SWITCHES OF ENGAGE Z AXIS DRIVE ASSEMBLY AND FIND HOME PRESS G Operation Manual 1 11 INTRODUCTION MILLPWR ACU RITE 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 TABLE 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 NE the surface of a known depth on your workpiece Ea Press the DATUM softkey Datum Position your tool so that it touches a known surface If the surface is at datum 0 then enter that position into the Z axis datum use the Z 0 softkey 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 freq
184. t accidental or unauthorized adjustments to your system Once you ve entered the passcode the Installation Setup screen will appear Protection FEED 0 0 100 INSTALLATION SETUP PROTECTION ERROR COMPENSATION ENCODER SETUP TRAVEL LIMITS ERROR CHECKING SERIAL PORT AXIS CONTROL SPINOLE CONFIG ERROR LOG SERVO TUNING AMI OUTPUTS DIAGNOSTICS MAX SERVO SPEED SCALE PREVIOUS Protection enables you to prevent unauthorized access to your part programs and tool library With Part Program and Tool Library set to Yes your part programs and tool library cannot be altered without first changing your Part Program and or Tool Library setting s to No To change your protection settings From Installation Setup highlight PROTECTION then press ENTER PART PROGRAM TOOL LIBRARY SETUP ACU RITE 1 0000 CANCEL CHANGES USE MEW SETTINGS PROTECTION No No Use the NO and YES softkeys to disable or enable protection for both the Part Program and Tool Library e Press the USE key e Continue with Setup or press the USE NEW SETTINGS softkey Operation Manual 7 17 SETUP MILL PWR Before perform ing linear error compensation you need to ensure that your machine is properly adjust ed Refer to the manufacturers instructions for proper adjust ment proce dures ERROR COMPENSATION X S TANDARD LENGTH INCH
185. t where there s no material present such as in the center of a circular part The possibilities are endless do what s easiest for your particular job MILLPWR will retain the datum you ve set after your system has been powered down Note When the Datum menu appears you will also be asked to establish a Z axis retract position The Z axis retract position is the position that the quill returns to between program steps refer to Conventions located in Section 1 To establish datum As we ve already mentioned where and how you establish datum will vary from job to job Here we ll walk you through one of the most common methods of establishing datum Once you ve learned the basics apply the same principle when setting datum for your own parts making adjustments to the procedure as needed We ll establish datum on the corner where the left front and top surfaces of our part inter sect We ll accomplish this by touching each face with the tool that we re planning to cut the part with Define datum one axis at a time Here we ll begin with the X axis e From the DRO screen press the DATUM softkey e Insert the tool you are planning to cut the part with into the spindle Operation Manual PROGRAMMING MILLPWR ACU RITE e Position the tool so that it is near but not touching the left side of your part Lower the tip of the tool so that it falls below the top surface of the part e Move the table along the X
186. table will rapidly move to position and then the quill will rapidly move down to the retract position If the tool 1s 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 1s 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 1s 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 Operation Manual 1 9 INTRODUCTION MILLPWR ACU RITE 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 or a one time milling function END 0 0000 ABS FEED 10
187. te step To program a rotate e From the PGM screen press the MORE STEPS softkey e Press the ROTATE softkey e Enter the first and last steps in the range of steps that you would like to rotate e Enter the X and Y axes coordinates for the center point of rotation e Enter an offset for the Z axis Enter the angle for each rotation e Enter the number of times you want to rotate the shape If you just want to rotate the original program or sections of your program you re working with enter 0 If you want additional rotations of your original enter the number of rotations that you want in addition to your original e Press the USE key Operation Manual MILLPWR Mirror PROGRAM STEPS ACU RITE Condition The steps being mirrored must precede the Mirror step With Mirror you can create a mirror image of an entire program or a section of a program 001 TooL 002 1 MILL LINE 003 MILL LINE 004 LI Mitt LINE 005 POSITION DRILL 006 MIRROR To program a mirror e From the PGM screen press the MORE STEPS softkey e Press the MIRROR softkey e Enter the number of the first step and the last step in the step range that you want to mirror Define the axis of reflection a line that separates the mirrored image from the original one For 15 Axis Point enter the X and Y axes coordinates for the axis of reflection For 2X Axis Point enter the X an
188. tep 007 Mill Line e Press the BLEND key BLEND You can see in the program list that step 007 has moved to step 008 and that the blend will be inserted into step 007 Notice the Steps field is indicating that steps 6 and 8 will be blended Operation Manual DEMONSTRATION MILLPWR ACU RITE e Enter a radius of 0 25 and press the USE key OFF FEED 0 0 100 TOOL 0 1250 INCH FL END ML SCALE 1 0000 0 00 00 INCH DEMO 001 SET TOOL 002 F MILL LINE 003 MILL ARC 004 MILL LINE 005 MILL LINE 006 MILL LINE 007 BLEND PROGRRM CLEAR STEP MORE RUN FUNCTIONS PROGRAM FUNCTIONS STEPS OPTIONS Notice how the last two lines are now blended together with a radius The BLEND step could just as easily have been inserted immediately after line 006 In doing so the BLEND step would show up in the listing but it would not be displayed graphically until the step that follows is added e Press the down arrow key once to reach the end of the program Now more steps can be entered e Press the LINE key TO X2 3 0 ABS LINE Ej Y2 1 5 ABS e Press the USE key oog Operation Manual 4 11 DEMONSTRATION MILLPWR Notice how the lines next to the program steps have changed They now indicate that the contour is closed This happens when the To point of the last step is the same as the From point of the first step Programming the Bolthole Pattern Begin by changing the tool
189. th and an OIM will appear Press GO to resume machining or STOP again to end the program Note If you wish to start machining from the middle of a program and the tool in your spindle does not match the tool information displayed in the current tool field you must start the program at the programmed tool step for that tool Operation Manual 3 15 PROGRAMMING MILLPWR ACU RITE 3 16 Feed and Feed The FEED and FEED keys will change your feed rate by a certain percentage with each key press The feed rate percentage will be displayed in the status bar at the top of the screen A feed rate percentage of 100 means that actual feed rates will run at 100 of the programmed feed rates If the feed rate percentage 1s 50 actual feed rates will run at half of the pro grammed feed rates You can press the FEED and FEED keys at any time even while the table or quill is moving Manually Positioning the Quill Optional Linear Encoder Only Programs that do not include a Begin depth will require you to manually position the Z axis during machining The same is true when the Z axis has been disengaged during setup refer to Setup If you have programmed an End depth when it is time for you to manually position the Z axis MILLPWR will preset the value into the readout s Z axis display The DRO screen will appear along with the prompts shown below MILLPWR is factory set in a distance to go display view This way
190. that made up the step 5 61 PROGRAM STEPS MILLPWR 0 62 ACU RITE Reverse Step The reverse step option instantly switches the From and To points and tool offset To reverse a milling function e From the PGM screen use the arrow keys to highlight the step that you want to reverse e Press the STEP FUNCTIONS softkey e Press the REVERSE STEP softkey Reverse Path With the reverse path option you can reverse any continuous tool path This will espe cially come in handy when you re working with DXF files As you import these types of files MLLPWR will sort and then group the steps into a logical order creating continu ous paths In some cases the paths may need to be reversed after they ve been imported so that your tool s offset direction and beginning and end points satisfy your machining requirements As you become more familiar with this feature you ll find other creative ways to use it to your advantage For instance you can save time as you re cutting a part by using a heavy cutting tool and a conventional cut for a rough first pass On the second pass switch to a finish cutter then copy and reverse the path for a climb cut on the finish pass To reverse a continuous tool path e From the PGM screen highlight any step within the continuous tool path that you want to reverse e Press the STEP FUNCTIONS softkey e Press the REVERSE PATH softkey Operation Manual MILLPWR PROGRAM STE
191. tically fill in the From and To fields in Steps for you Press the CLOSE CONTOUR softkey if you want to chamfer the end of a contour with the beginning Enter the distance from the common point of both lines Length 1 refers to the line identified in the From field Length 2 refers to the line identified in the To field If you plan to use an angle enter only one length If you entered one length above highlight the Angle field and enter the chamfer s angle from the X axis otherwise leave it blank Adjust the feed rate if necessary Press the USE key ACU RITE CHAMFER STEPS FROM 2 TO 4 SIZE m LENGTH 1 LENGTH 2 ANGLE o FEED RATE 10 00 IPM Operation Manual MILLPWR Reference Point PROGRAM STEPS ACU RITE Depicted as a plus sign on your PGM screen a reference point 1s a graphical representation of a coordinate in your program Reference points are commonly used to identify center points tangent points and other part features They can even be used as the basis for incremental moves As you program note that placing a reference point in a continuous tool path will break the path Otherwise reference points do not affect your program s performance in any way in fact MILLPWR will skip over them altogether when you run a program To program a reference point e From the PGM screen press the MORE STEPS softkey e Press the MORE STEPS softkey two m
192. tings G10 is not supported G17 XY Plane Selection These commands set the plane in which arcs are executed G18 XZ Plane Selection The setting applies to current and subsequent blocks The G19 YZ Plane Selection default is G17 XY G20 Set Program Units Inch These commands set the unit of measure The setting applies 321 Set Program Units MM to current and subsequent blocks The default is G20 INCH G28 Return to Home MILLPWR does not have a method for establishing a home G30 Reference position If one or more coordinates are specified in the block the table quill will rapidly move to that location Program execu tion will continue with the next program block G40 Cancel Cutter Compensation G41 Cutter Compensation Left MILLPWR does not support automatic cutter compensation G42 Cutter Compensation Enabling compensation G41 or G42 while a diameter D is not Right equal to 0 is in effect will generate a run time error Enabling compensation with no tool diameter specified D 0 has no effect and is ignored Operation Manual 3 33 PROGRAMMING MILLPWR Code G43 G44 G49 G54 to G59 G61 G64 G80 G81 tO G89 G90 G91 G92 G94 G MO M1 3 34 Description Tool Length Offset Tool Length Offset Cancel Tool Length Offset Work Coordinate System Set stop Path Mode Set continuous Path Mode Cancel Motion Mode Canned Cycles Set Offset Mode ABS Set
193. tion Manual SETUP MILLPWR ACU RITE FROM POINT allows you to determine whether your From point will appear as an absolute value or an incremental value Absolute values are based upon the distance from datum Incremental values are based upon the distance from one feature or step in a program to another No matter which you choose as your default setting the other will always be avail able by pressing the ABS INCR key Absolute From points will appear like this MILL LINE 002 From XI 4 0050 ABS Y 2 5025 ABS Incremental From points will appear like this MILL LINE 003 From XI 0 0000 INC 002 Y1 0 0000 INC 002 STEPOVER ENTRY enables you to define how much material your tool will remove as it cuts a pocket slot or ring To enter a value as a decimal press the DECIMAL softkey To enter a value using whole numbers press the PERCENTAGE softkey PASS PECK RETRACT establishes the units that are applied to the Pass Peck and Tool Retract features during programming Pass refers to the number of cuts that are used to machine an area to its End depth Peck lets you break chips and reduce chip buildup during drilling operations Tool Retract allows you to program MILLPWR to raise the tool at regular intervals Using the softkeys select either NUMBER OF CYCLES or DISTANCE Your selection will be applied to all three features Operation Manual 7 13 SETUP MILL PWR ACU RITE Electro
194. tion Manual 2 5 DRO MEE S S S ll 1 LZLOO MILL PWH ACU RITE 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 To define the diameter and unit of measure e Press the SETUP key and highlight Electronic Edge Finder e Press the ENTER key e Enter a value for the edge finder s diameter select a unit of measure inches or mil limeters then press the USE key e 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 elect
195. tkey e Highlight the type of your tool from the list of available tool types and press ENTER e Press USE e Repeat this procedure for all additional tools then press USE NEW SETTINGS to com plete the setup After the tool information is established in the library you can edit the values as needed to complete the setup 7 6 Operation Manual SETUP MILLPWR ACU RITE Using the Tool Library Whenever you program a tool step you will see a TOOL LIBRARY softkey Press the TOOL LIBRARY softkey and highlight the tool you wish to use Press ENTER then USE and the tool step is pro grammed It is important to understand that the tool information that 1s retrieved from the library remains in the program If you change a tool in the tool library the tool information in all of your programs will not change Your programs will continue to prompt for the tools you originally programmed If you wish to update a tool step in a program highlight the tool step you wish to change press ENTER press the TOOL LIBRARY softkey and highlight the tool you wish to use Press ENTER then USE and the tool step 1s updated for the new tool Setting Datum Once you have a library of tools established you can use any one of the known tools to establish Datum To establish Datum with a tool from the tool library e From the DRO view press the TOOL key e Press the TOOL LIBRARY softkey e Highlight the tool you would like to use from the tool libra
196. to make one available consult your PC owner s manual Your PC COM 1 COM 2 8 2 Operation Manual MILLPWR REMOTE STORAGE ACU RITE Installing the Remote Storage Program onto Your PC You can install the Remote Storage program onto your PC using either Microsoft Windows 95 98 or MS DOS operating systems Choose the system you will use then follow the applica ble steps below For Windows 95 98 1 Power up your PC 2 Insert the Remote Storage disk into your PC s floppy disk drive 3 Click on START 4 Click on Run then type a install and click OK This copies all of the files from the disk and onto your PC 5 Instructions on how to use Remote Storage will be displayed on your PC screen 6 Close the DOS window A Remote Storage icon should now appear on your PC screen Double click on the icon to run the Remote Storage program For MS DOS 1 Power up your PC 2 Insert the Remote Storage installation disk into your PC s floppy disk drive 3 At the CX prompt type a then press ENTER 4 After the A gt prompt type install and press ENTER again This command tells the PC to copy all the files from the disk onto your PC 5 Atthe next prompt type c then press ENTER 6 After the C prompt type cd remtstor and press ENTER 7 CAREMTSTOR will appear Type remtstor and press ENTER Your PC should now display the Remote Storage Utility screen Operation Manual 8 3 REMOTE STORAGE
197. tting that satisfies your need most INCREMENTAL TRAVEL often In other words if your angles are usually dimensioned in deci ai ron ae IN MM mal degrees you should make DECIMAL DEGREES your default set ting CARTESIAN FROM POINT ABSOLUTE INC DISPLAY enables you to define how you want your incremental STEPOVER ENTRY values to be displayed You may select either Incremental Travel or E Pass PECK RETRACT Distance to Go NUMBER OF CYCLES e INCREMENTAL TRAVEL In this view the dimensions you program will end at their programmed distance If you program a 1 4 move the incremental display will read 0 2500 when you reach the end of your move e DISTANCE TO GO In this view the dimensions you program will be preset into the readout display Every move will end at zero If you program a 1 4 move the incremen tal display will read 0 0000 when you reach the end of your move 0 0001 IN 0 0002 IN 0 0005 IN 0 0010 IN Use NEW CANCEL 0 002 MM 0 005 MM 0 010 MM 0 020 MM SETTINGS CHANGES DISPLAY RESOLUTION lets you select the resolution you want to display in the DRO POINT ENTRY lets you decide what your default setting will be for entering dimensions for both From and To points as either Cartesian X and Y or Polar radius and diameter coordinates The method that you do not select will be available as a softkey when you re defining From and To points Opera
198. ual Operation Manual 5 5 PROGRAM STEPS MILLPWHR Position Drill o The position drill function will move your table to the position you want based upon your X and Y axes coordinates To program a position drill step e Press the POS key e Enter the X and Y axes coordinates e Enter the begin and end depths for the Z axis e Optional Enter either the number of pecks OR the distance between each peck e Select the DRILL BORE or POSITION softkey Enter the Z axis feed rate e If you want the tool to retract Enter either the number of retracts OR the distance between each retract Enter the length of time in seconds the quill should dwell pause during the retract cycle Enter the lenght of time in seconds the tool should dwell at the end depth before the final retract e Press the USE key ACU RITE m Pu omm LE NN Drill The quill Will feed down then rapidly move up Bore The quill Will feed down then feed up Position You will be prompted to move the quill manually Note If the tool size and type listed in the Tool field are incorrect change the tool settings before running your program refer to Programming a Tool Step 5 6 Operation Manual PROGRAM STEPS MILLPWR ACU RITE Center Line With the position drill feature you can also locate the midpoint of two points or the center line of a circle To locate a center line e Press the CEN
199. uently 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 Operation Manual INTRODUCTION MILLPWR ACU RITE Saving Backing Up and Creating Directories for Programs When you create programs with MILLPWR you can save them in any of If you re creat ing a long pro or on your PC using Remote Storage Saving your work means it will gram don t wait until the end to save your work three places within MILLPWR s internal memory on a 3 floppy disk not be lost if MILLPWR is powered down or if there 1s a power interrup tion Frequent saving l l l reduces the risk MILLPWR is also equipped with a back up feature that enables you to of losing your make duplicate copies of your saved programs to floppy disc or Remote BON d ped Storage We recommend that you back up your programs regularly to tion 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 follow ing three main directories MILLPWR A
200. un this time allowing the table to move to see if there is enough material to run the program Set zero om BB 8 Ha Operation Manual 4 19 DEMONSTRATION MILLPWR ACU RITE Tool Changes 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 e Use the MOVE TABLE softkey and arrow keys to move the tool TABLE away from your workpiece e Insert the required tool into the spindle e Using the MOVE TABLE feature position the tool over the surface of a known depth on your workpiece DATUM e Press the DATUM softkey e Position your tool so that it touches a known surface If the surface is then enter that position into the Z axis at datum 0 use the Z 0 soft key e Press the USE key e Raise the tool and press the GO key to continue the program O Clearing the Program e From the PGM screen press the CLEAR softkey CLEAR PROGRAM ie e Press the YES softkey The PGM screen will be cleared and ready for another program YES 4 20 Operation Manual MILLPWR PROGRAM STEPS ACU RITE Simple Milling amp Drilling Most of the program steps described in this section can be performed as one step milling functions from the DRO screen or included as steps in a program press the PGM key Set Tool TOOL Set Tool defines your tool and shou
201. your program for things like the correct tool path count direction feed rate and sequence of operations MILLPWR provides several run time options to assist you From the PGM screen press RUN OPTIONS to display the following softkeys SINGLE DRY GRAPHICS MANUAL DISABLE RUN STEP RUN ONLY POSITIONING LOOK AHEAD OPTIONS Press any softkey to activate the option press it again to deactivate it Note Before you press the GO key to begin the Single Step Dry Run or Manual Positioning features check that the tool will not touch the workpiece when the quill begins to move To avoid interference we suggest that you do one or more of the following Lower the knee e Remove the tool or workpiece e Reestablish datum away from the part refer to Establishing Datum SINGLE STEP Normally a continuous contour will be machined without stopping With To test your Single Step activated MILLPWR will stop after each step This enables program quick you to check the position of the Z axis relative to your part and ensure that ly press both the DRY RUN the tool path and other program details are correct Press the GO key to and GRAPHICS begin ONLY softkeys DRY RUN With Dry Run activated MILLPWR will run your entire program at high speed without stopping You can visually follow the position of the tool relative to your part and ensure that the tool path and other program details are correct The dry run speed is define
202. ystem detects an emergency stop eae condition An E stop condition can originate from the operator console Z axis or optional AMI Table Stop Button Displays the status of the table stop button Pressed or Released on the operator console Z Limit T Z axis control is enabled a Fault or No Fault message will appear A fault indicates that at least one of the limit switches on the spindle has been disengaged To display the table stop test ahs Th LAST GAIN TUNING DATE e From the Diagnostics screen highlight Table 01 30 2000 Stop Test and press ENTER The test will run Last BALANCE TUNING DATE 01 30 2000 automatically SIGNAL TEST RESULT PASS e When the test is complete press the EXIT TEST softkey to close the Table Stop Test screen e Continue with Diagnostics or press the USE NEW SETTINGS softkey 7 32 Operation Manual SETUP MILLPWR ACU RITE Circle Interpolation Test MILLPWR includes two circle interpolation tests The small circle test checks for machine related problems an unbalanced ballscrew or poor gib adjustment for example The large circle test checks whether or not the motors are in tune The circle should maintain its original shape fluctuations up to 0 0005 are normal If fluctuations exceed 0 0005 the system may require adjustment refer to the Trouble shooting Guide for recommended solutions The examples on the next page illustrate some of the problems

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