AUXILIARY MACHINE INTERFACE REFERENCE MANUAL
Limited Warranty The ACU-RITE Auxiliary Machine Interface (AMI) has a limited warranty against defects in material and workmanship for a period of one (1) year from the original date of purchase. ACU-RITE will, at its option and expense, repair or replace any component(s) of the Auxiliary Machine Interface in question which fails to satisfy this warranty provided that ACU-RITE shall have received notice of the claimed defect(s) during the limited warranty period.
Table of Contents Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Tools ........................................1 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 AMI System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Connector Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction This manual discusses how the Auxiliary Machine Interface (AMI) system works in conjunction with the ACU-RITE® MILLPWR® system. Preparation Read and understand all instructions in this manual before beginning the installation. Each item has an overview section which will explain their capabilities and will help ensure that each system is installed properly.
Components There are two types of AMI systems currently available from ACU-RITE. One supports 115 volts and the other one supports 230 volts of power. Both AMIs include a cable for connecting the system to MILLPWR. The 115V AMI also includes a cord for connecting the system to a MILLPWR servo motor.
AMI System Overview The following is a quick reference guide with each connectors name, the page where its description appears, and their most common uses. Figure 1 on the next page shows all connector locations. There are five connectors available. Four of them are to be used for multiple applications, while the J16 is limited to wiring an external 230V/115V AMI to a power source.
Fig.
Input Devices (J2) The J2 input connector is commonly used to: • Monitor the position of machine guards • Monitor the oil level of an automatic lubrication system • Remote Go Input Table 1 (J2) Pin # 1 2 3 4 5 6 7 8 Description Machine Guard input Machine Guard input Low Oil input Low Oil input Remote Go input Remote Go input Not active Not active Pin # 9 10 11 12 13 14 15 16 Description Not active Not active Not active Not active Not active Not active Not active Not active Do not apply power directly t
Figure 2 shows a typical wiring diagram for machine guards. As the diagram illustrates, the machine guard switch should be wired to pins 1 and 2. When the machine guard switches are open, the contacts to those pins will open, and an Operator Intervention Message (OIM) message will appear on the MILLPWR screen. Fig. 2 Note: If guards are not used then pin 1 and pin 2 of J2 must be jumpered.
Remote Go provides a switch input that can be used in place of the operator pressing the GO key. Pins 5 and 6 (J2) are reserved for this function. Note: The Remote Go input signal must be held for a minimum of 0.2 seconds in either ON or OFF mode in order for it to be recognized by the AMI. If you are not using the J2 or J4 connector on the AMI, you must wire a jumper at this time to close the circuitry.
Output Devices (J18) The J18 output connector is commonly used to: • • Control up to five devices (i.e., coolant pumps and rotary indexers) from within a MILLPWR program. Activate external devices during hole patterns and position/drill steps.
AMI Output Device Overview MILLPWR AMI interface allows it to control four (4) separate functions such as mist and flood coolant, indexers,etc. There are three (3) programmable options available when programming an AMI step: • • • PULSE - Sends a signal to a device for a programmable length of time. (The pulse duration can not exceed 999.9 seconds). ON - Sends a signal until program signals off, or at the completion of the program. OFF - Sends a signal to turn device off.
Connection Definitions Auxiliary Outputs 1-4 are four sets of general purpose relay contacts. 1) These relay contacts can only be controlled through a MILLPWR program. 2) They must be set (programmed) to be either ON, OFF or PULSED. 3) Devices programmed to switch “on” will remain “on” for entire program, unless they are programmed to turn “off” later in the program. 4) Devices set to “pulse” will run for the length of time you define (refer to page 23 for auxiliary function programming).
Here is an example of how the Auxiliary Output functions work in conjunction with a rotary indexer: 1) Use Aux 3, Output #3 as the Cycle Start relay. 2) When the AMI Output #3 relay is pulsed, pins 7 and 8 of J18 are momentarily shorted for the amount of pulse time entered. This activity initiates the “Cycle Start” relay in the rotary indexer control, to start a cycle or step index. Note: The pulse time must not exceed the indexer positioning time to start the next cycle.
Devices that are connected to auxiliary outputs 1-4 (pins 1 through 12) on the AMI’s J18 connector are programmable (refer to Table 2). Figure 3 shows an example of AMI output wiring that would control a pump. All of the J18 outputs will automatically return to their default settings (refer to Table 2) any time the Emergency Stop button on the front of the MILLPWR operator console is pressed, when an emergency stop input (via J4) occurs or when the software detects another emergency stop condition. Fig.
Emergency Stop Inputs (J4) The J4 connector is commonly used to: • Add table limit switches to the emergency stop circuitry • Add an Emergency Stop button to the emergency stop circuitry Table 3 (J4) Pin # 1 2 3 4 5 6 Description 115V (for E-stop relay coil only) Auxiliary E-stop relay coil (K1) Auxiliary E-stop relay coil (K1) AC Common (for E-stop relay coil only) Table limit switch contact Table limit switch contact An emergency stop condition normally occurs when the system overheats, a fault occu
Figure 4 illustrates how a table limit switch can be wired into the emergency stop circuitry. Notice that the switches have been connected to pins 5 and 6, which are the table limit switch contacts (refer to Table 3). Because the table limit connections operate on internal 12V DC power, it’s important to use a table limit switch with a 12V DC @ 100mA minimum rating. Do not apply voltage directly to pins 5 or 6 on the J4 connector. Fig.
Note: If the existing emergency stop system is any other voltage than 115V AC, you must use the AMI as the power source (described above) for the AMI emergency stop input. Do not use the 115V AC connection for any other circuitry. 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 Status Reports on whether or not the system detects an emergency stop condition.
Emergency Stop Output (J17) The J17 connector is commonly used to: • Add other devices to the emergency stop circuitry. Table 4 (J17) Pin # 1 2 3 Description Normally closed relay contact Common relay contact Normally open relay contact The emergency stop outputs are not programmable. Do not wire external devices that you wish to control (pumps, automatic lubrication systems, etc.) directly into MILLPWR’s emergency stop circuitry.
AMI Installation The installation procedure is divided into three sections—Connecting to MILLPWR, General Wiring Procedure, and Connecting to a Power Source. Refer to the General Wiring Procedure section anytime you are installing a new input or output device. Unless indicated otherwise, each section applies to both AMI versions (115V and 230V). All wiring should be performed by a qualified electrician. Connecting to MILLPWR • Power down the MILLPWR system and disconnect it from its power source.
Fig. 8 Fig.
General Wiring Procedure The steps below explain the general procedure for wiring any device to the connections on the AMI. Refer to Figure 1 (page 4) for the location of each AMI and Emergency Stop (E-Stop) input and output connection. Also refer to the AMI System Overview section for common applications and descriptions of each connection. All wiring should be performed by a qualified electrician. • Check that the MILLPWR system is powered down and disconnected from its power source.
Fig. 10 Fig.
Connecting to a Power Source The AMI’s electrical specifications determine which power source should be used. If the AMI is set to run at 115V, it can easily be incorporated into the MILLPWR servo motor power loop. AMIs that are set up for 230V must be connected directly into an existing electrical circuit using a cable with wires that are 24 -16AWG(max.). Carefully follow the instructions for the type of AMI you are installing. All wiring should be performed by a qualified electrician.
• After all of the inputs/outputs have been properly wired, power up the MILLPWR system. 230V AMI systems (via the J16 connector): • Check the MILLPWR system is powered down and disconnected from its power source. Check that there is no power to the AMI. • Remove the cover from the AMI. • Insert a 0.17” to 0.47” diameter cable (with 24-16 AWG maximum wires) through the liquid tight strain relief that’s nearest the power connector. All wiring should be performed by a qualified electrician.
J16 Connectors Fig.
AMI Operation Programming Auxiliary Output Devices Wired to J18 (Aux 1-4) Devices that are connected to pins 1 through 12 of the AMI’s J18 output connector can be controlled from within any MILLPWR part program. Simply insert an auxiliary function step at each point in the program where you want the appropriate device to turn on, off or pulse. When MILLPWR reaches an auxiliary function step, an Operator Intervention Message (OIM) will appear. The OIM will display the status for each device.
• Press the MORE STEPS softkey two more times. • Press the AUXILIARY FUNCTIONS softkey. • Highlight the auxiliary relay(s) that you want to program. (The “AUX” numbers in each field correspond with the number on the AMI.) Select from the OFF, ON, and PULSED softkeys for each. ON The AMI output contacts will switch to an energized state. OFF The AMI output contacts will switch to their default (de-energized) states.
G-code Programs When using a G-code program that requires coolant commands, certain outputs are configured to specific commands (M7, M8, M9). The following rules apply while running G-code programs: 1) M7 command turns on the Aux 1 as the coolant flood relay. 2) M8 command turns on Aux 2 as the coolant mist relay. 3) M9 turns off both Auxs 1 and 2. 4) Only one output, Aux 1 or Aux 2, is permitted to be on at a time. 5) These outputs will be turned On and Off as defined in the G-code program.
Using the In-Position Relay • Press the SETUP key. • From the Installation Setup menu, cursor down to the AMI Outputs field and press the ENTER key. • Along the bottom of the screen the OFF, ON and PULSED softkeys will also appear. If ON is selected, the output will be asserted when the desired X/Y position is reached and will remain on until the X and Y positions have moved out of position. If PULSED is selected, the desired pulse time must be entered in seconds.
Motor Assembly Monitor When the motor assembly monitor is enabled, it shows the real-time operating status of each axis and the AMI on the DRO screen. Use it to verify the status of all AMI inputs and outputs. Top Bar (Power Status) INC Displays the table’s incremental position (its position relative to incremental zero). ABS Displays the table’s absolute position (its position relative to datum).
Guards Closed Safety feature that will alter the activity of certain program functions when they are open. Oil Not Low Safety feature that will, under certain conditions, stop program functions when the lubrication pump supply reaches a certain minimum level of oil. No Go Key Provides a switch input that can be used in place of the operator pressing the GO key or the remote Stop/Go switch.
AMI Troubleshooting Guide This troubleshooting guide is arranged in three columns—Symptom, Probable Cause and Recommended Corrective Action. Begin by locating the symptom and probable cause that best matches the problem you are experiencing, then follow the directions for each corrective action. If the suggestions herein do not solve the problem, contact ACU-RITE for repair and/or replacement procedures.
Recommended Corrective Action Symptom Probable Cause No operation or improper operation (cont’d) F3 fuse is loose Check that the F3 fuse is securely in place. F3 fuse is blown Replace the F3 fuse with one that’s appropriate for the AMI operation (refer to Electrical Specifications). Improper wiring Ensure stripped end of the wire is adequately crimped by the terminal on the board (vs. insulation being crimped).
32 Recommended Corrective Action Symptom Probable Cause Emergency stop message is constantly displayed on MILLPWR operator console. No External E-Stop is wired to the J4 connector, or it may be done so incorrectly. This input must be configured. Either connect an external emergency stop switch to J4, or use a wire jumper to defeat it. Machine guards and low oil messages are reversed Improper wiring Check the wiring to the AMI’s J2 connector.
Symptom Probable Cause Table limit switches do not work (cont’d) Improper wiring (cont’d) Recommended Corrective Action Ensure that all of the table limit switches are normally closed and wired in series. If more than one table limit switch exists, verify that they are “normally closed” and wired in series. "External E-Stop" and "Table Limits" messages are reversed Incorrect wiring Verify that the proper wires are connected to pins 5 and 6 on the J4 connector (refer to Emergency Stop Inputs).
34 Recommended Corrective Action Symptom Probable Cause No response to oil or guards switches (cont’d) Improper wiring (cont’d) Ensure that all of the wires are secure beneath the screw(s) on the J2 connector. Disconnect power to MILLPWR and the AMI. Completely loosen each screw on the connector. One by one, reinsert each wire into the connector, under the body of the screw. Tightening each screw as you do so. Output devices not responding/not responding properly AMI is not receiving power.
Recommended Corrective Action Symptom Probable Cause Output devices not responding/not responding properly (cont’d) Improper wiring Compare the wiring to the "normally closed" and "normally open" contacts for that connector, as described in the manual. Rewire as needed. One or more wires not secure in the J2 connector Each wire must be secured under the corresponding screw. Disconnect power to MILLPWR and the AMI. Completely loosen each screw on the connector.
Electrical Specifications The installation location must be able to support the AMI operating and electrical requirements listed below. Characteristic Specification Operating conditions 0° to 40° C (32° to 104° F) 25% to 85% relative humidity (non-condensing) Storage conditions -20° to 60° C (-4° to 140° F) 25% to 95% relative humidity (non-condensing) Input requirements: 36 Voltage 115VAC ±10% 230VAC ±10% Frequency 47-63Hz Current 124mA (max.) @ 115VAC 62mA (max.
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