CONGRATULATIONS! You have just purchased MILLPWR by ACU-RITE, a versatile and flexible 2-axis Control/ 3-axis Readout system that effectively combines powerful features and functionality with ease of use at an affordable price. MILLPWR satisfies the needs of the milling market where manual and automated operation are both useful and needed.
MILLPWR System Setup Access Code An access code must be entered before the system setup parameters can be set or changed. This prevents inadvertently resetting parameters. IMPORTANT The access code is 8891 Refer to section 7, “System Setup.” IMPORTANT Supervisors may wish to remove this page from the MILLPWR manual after initially setting up the system parameters. Keep it in a safe place for future use.
TABLE OF CONTENTS Section 1. Introduction System Overview........................................................................... 1-1 Machine Layout ................................................................... 1-1 Keypad Layout .................................................................... 1-3 Screen Layout ...................................................................... 1-4 Saving, Backing Up, and Creating Directories For Programs......................................................
TABLE OF CONTENTS Continuous Milling ................................................................ 3-3 Creating a Program ....................................................................... 3-4 The View Key ..................................................................... 3-6 Running a Program ........................................................................ 3-6 Setting the Datum ................................................................. 3-6 Testing Your Program ....................
TABLE OF CONTENTS Programming the Bolt Circle ............................................... 4-13 Programming the Pocket .................................................... 4-15 Saving Your Program ......................................................... 4-17 Testing Your Program ........................................................ 4-17 Running the Program .......................................................... 4-18 Tool Changes .....................................................................
TABLE OF CONTENTS Custom Pocket .................................................................. 5-17 Engrave ............................................................................. 5-18 Explode ............................................................................. 5-20 Section 6. Calculator Four Function Arithmetic ............................................................... 6-1 Trig and Math Functions ................................................................
TABLE OF CONTENTS Section 8. Remote Storage Equipment ..................................................................................... 8-1 Choosing a Serial Cable ................................................................ 8-1 Connecting MILLPWR to Your PC ............................................... 8-2 Installing the Remote Storage Program ...........................................
TABLE OF CONTENTS Setting the PC’s COM Port and BAUD Rates ............................... 8-4 Common Error Messages .............................................................. 8-5 Section 9. Troubleshooting Guide Introduction .................................................................................. 9-1 Using the Table ............................................................................. 9-1 Table ...........................................................................................
TABLE OF CONTENTS 387900-167 Software Version 1.
INTRODUCTION MILLPWR INTRODUCTION System Overview Machine Layout Operation Manual Page 1-1
INTRODUCTION MILLPWR Front View of Operator Console TOOL RECT CIRCLE HOLES POS LINE ARC BLEND INFO SET UP Floppy diskette inside ! VIEW ABS INC PGM 7 8 9 / DRO 4 5 6 X CANCEL 1 2 3 - USE . 0 +/- + Keypad Emergency TABLE STOP TABLE STOP Softkeys CALC DEL ENTER STOP GO FEED + FEED - Rear of Operator Console Side of Controller Cabinet Contrast and brightness knobs--adjust them for best picture Main power switch. Use this to turn MILLPWR on and off.
INTRODUCTION MILLPWR Keypad Layout Milling Functions Main Function Keys INFO These let you set up the MILLPWR, get information about what you are doing, switch between program (PGM) and DRO, and “USE” the milling functions as steps in a program. TOOL RECT CIRCLE HOLES POS LINE ARC BLEND With these keys, you define the operations you want MILLPWR to perform. These operations end up as “steps” in a program, or you can run just one of them at any time.
INTRODUCTION MILLPWR The cursor keys help you navigate around the screen while you are using MILLPWR.
INTRODUCTION MILLPWR Screen Layout The MILLPWR display screen is divided into four sections. SERVO OFF FEED 0 100% TOOL: SCALE 1.0000 INCH 1 2 3 ZERO X ZERO Y ZERO Z DATUM MOVE TABLE 4 Status bar - displays the servo motor status (on/off), feed rate, current tool, scale, and inch/mm display view. 2 Information screen - displays information for the job being performed. • Used as a readout, the screen will display the current location for each axis.
INTRODUCTION MILLPWR Saving, Backing Up, and Creating Directories for Programs If you're writing a long program, don't wait until the end to save your work. Frequent saving reduces the risk of losing work due to a power interruption. When you begin to create programs for your MILLPWR to run, you can save your programs in any of three places—on MILLPWR ’s internal hard disk drive, on a 3 ½” floppy disk, or on your PC’s hard disk drive.
INTRODUCTION MILLPWR Conventions Axis Conventions Cartesian Coordinates When programming a part using MILLPWR , table movement and tool motion are determined by the use of positive or negative numbers. MILLPWR has been factory set with the following positive and negative directions for X, Y, and Z: X-axis: the table will move to the left, with tool motion to the right, for positive positions. Y-axis: the table will move toward you while tool motion is away from you for positive positions.
INTRODUCTION MILLPWR Absolute / Incremental Dimensions you enter from the print can be either absolute or incremental. Absolute dimensions are measured from the datum which is the workpiece zero. Incremental dimensions are measured from one point to another. Holes A and B are dimensioned as absolute, but hole C is dimensioned incrementally from A. +Y When entering these dimensions in the MILLPWR , we would say: 4 B C Hole A: X = 2.000 ABS Hole B: X = 4.000 ABS Hole C: X = 3.625 INC from hole A 1.
INTRODUCTION MILLPWR Notice that if you don’t use incremental coordinates, Point 2 will be incorrect because it will be measured from the datum instead of from Point 1.
INTRODUCTION MILLPWR BLANK PAGE Page 1-10 Operation Manual
DRO MILLPWR DRO FUNCTIONS Start-Up Power Up • Make sure the power switch on the back of the Operator’s Console is on. • Turn the on/off switch on the side of the controller cabinet ON. After the program has loaded, the following screen will appear: SERVO OFF FEED 0 100% TOOL: X Y Z ZERO DRO stands for “digital readout”. X ZERO Y SCALE INC 0.0000 INC 0.0000 INC 0.0000 ZERO Z 1.0000 INCH 0.0000 0.0000 0.0000 DATUM ABS ABS ABS MOVE TABLE This is called the “DRO” screen.
DRO MILLPWR Finding Home The ACU-RITE’s ENC150 precision glass scales included with your MILLPWR system are different from standard ENC150 glass scales because they have only one reference mark. The reference mark will be located between five and eight inches from the centerline of your scale. The reference mark will most likely be found in the positive count direction for both the X and Y axes; however, it may be found in the negative count direction depending upon how the scale(s) are mounted.
DRO MILLPWR DRO Functions Reset an Axis Pressing the ZERO X, ZERO Y, or ZERO Z softkey will zero the incremental position of that axis. You can’t change to metric if you have an “inch” program active, and vice versa. Inch - Metric To change the measurement system between inches and metric units, press the SETUP key to get the INCH and MM softkeys. Select the system you want, and press USE NEW SETTINGS. Move Table This function lets you move the table rapidly using the arrow keys.
DRO MILLPWR The table moves in the direction of the arrows. You can move in both X and Y at the same time. MOVE TABLE AWAY FROM YOU It’s a REALLY good idea to fold in the handcrank handles before moving the table! MOVE TABLE LEFT While the MOVE TABLE softkey is pressed, the servo motors are on. Press it again to turn them off. MOVE TABLE RIGHT MOVE TABLE TOWARDS YOU Establishing a Datum A datum is a reference point that you establish as the workpiece zero. You need to set a datum for each job.
DRO MILLPWR If you can’t position the tool center right at the datum, you’ll need to enter a value for each axis. The value to use is the absolute position of the tool center from the new datum. For one axis at a time, position the tool to a known location, such as the edge of the workpiece. Without moving the tool, enter the desired location of the tool center and press ENTER. Then move to position the next axis. When all are entered, press USE.
DRO MILLPWR One Time Milling Functions Any of the milling functions, except BLEND, can be used “one time” without creating a program. Press the desired milling function key, fill in the information, and press GO. The information for each function will be remembered for the next time you use it. Each function is described in the Program Steps section. For many of the milling functions, such as a pocket, you will need to set the proper tool diameter. You can use the TOOL key as a one-time function to do this.
PROGRAMMING MILLPWR PROGRAMMING Programming Considerations Depth of Cut Since the vertical Z-axis is not controlled by a servo motor, you must make changes to the depth of cut manually. You don’t have to program the depth, but if you do, MILLPWR will preset the programmed value into the DRO for you. Then, when it’s time, MILLPWR will show you the DRO and ask you to set the depth. If you are not programming depth, leave it set to 0.
PROGRAMMING MILLPWR “From” and “To” Points FROM TO MILLPWR lines and arcs are defined by both FROM and TO points. MILLPWR will automatically go to the start point before it asks you to set the depth. FROM X1 Y1 ABS ABS TO X2 Y2 ABS ABS Datum Selection The datum is the point where all absolute dimensions are measured from. You must look at the blueprint of the part and decide what to use as a datum.
PROGRAMMING MILLPWR If we use point A as our datum, many of the given dimensions are incremental because they are measured from the incremental reference point F and not from the datum. 7.123 X D Y A 0.00 ABS 0.00 ABS B 3.421 INC F 0.00 ABS 4.893 3.421 C 3.603 Point E 1.011 3.421 INC F 3.603 INC F D -4.893 INC F 3.603 INC F E 0.00 ABS 1.011 INC F F 7.123 ABS 3.936 ABS F 2.96 DIA THRU HOLE 3.
PROGRAMMING MILLPWR Creating a Program Press the PGM key, and the following program screen appears. SERVO OFF FEED 0 100% TOOL: SCALE 1.0000 INCH CURRENT PROGRAM END OF 0 PROGRAM FUNCTIONS CLEAR PROGRAM MORE STEPS EXPLODE RUN OPTIONS You create a program by creating a list of milling steps to be performed. As you add to your list, each step will be drawn immediately on the screen so you can see a picture of your part in progress.
PROGRAMMING MILLPWR describing the step into the form. • After entering all the data for a step, press the USE key to accept the data. This updates the picture and moves down for the next step. SERVO OFF FEED 0 100% TOOL: SCALE 1.0000 INCH CURRENT PROGRAM 001 SET TOOL 002 MILL ARC END OF 2 PROGRAM FUNCTIONS CLEAR PROGRAM EXPLODE MORE STEPS RUN OPTIONS • To change a step, use the arrow keys to move to the step and press USE or ENTER.
PROGRAMMING MILLPWR The View Key If you need to see more detail of the picture, press the VIEW key. This brings up the following softkeys: ZOOM IN ZOOM OUT RESTORE The ZOOM IN softkey magnifies the picture, and the arrow keys move the picture up, down, left, and right. The ZOOM OUT softkey will de-magnify the picture, and the RESTORE softkey brings back the original view. Press VIEW again (or CANCEL) to see the normal programming softkeys.
PROGRAMMING MILLPWR Testing Your Program Before you run your program, you might want to test it for things like tool path, directions, feed rates, and sequence of operations. MILLPWR provides several runtime options to assist you. In the program screen, press RUN OPTIONS to display the following softkeys. SINGLE STEP DRY RUN GRAPHICS ONLY MANUAL POSITIONING DISABLE LOOK AHEAD RUN OPTIONS Press any key to activate the option; press it again to release it.
PROGRAMMING MILLPWR Pressing the GO Key To run a program, with or without any of the run options, move to step 1 and press GO. Most MILLPWR program steps will cause the tool to move rapidly to the start point of the step. You then set the tool to the proper depth, press GO, and MILLPWR performs the action required for the step.
PROGRAMMING MILLPWR The remote button acts as STOP if you are going and as GO if you are stopped. During any rapid or feed move, you may press the STOP key or the emergency TABLE STOP button to disengage the power feed for any reason. This will stop the table motion but will not stop the rotating cutting tool unless your machine has been specifically wired to do so. If you press the emergency TABLE STOP button, the program stops running immediately.
PROGRAMMING MILLPWR If you have programmed a Z depth, when it is time for you to position the Z axis, MILLPWR will preset the depth value into the DRO Z-axis, and the following Z- axis prompt will appear: ! ATTENTION Z AXIS SET TO 0.000 PRESS "GO" Move the quill until the absolute Z display is zero. If you wish, you can set MILLPWR to the incremental travel display view (see System Setup). In this view, every move will start at 0.000 and end at the programmed value.
PROGRAMMING MILLPWR Program Functions Accessing the Load, Save, Delete, and Backup Options MILLPWR offers you several versatile features for loading, saving, deleting, and backing up information. Plus, built-in organizational tools make it easy to categorize—and later retrieve—the programs you’ve stored. To access these features, press the PROGRAM FUNCTIONS softkey. SERVO OFF FEED 0 100% TOOL: SCALE 1.
PROGRAMMING MILLPWR Saving a Program You can save your programs in any of three places—on MILLPWR ’s internal hard disk drive, on a 3 ½” floppy disk, or on your PC’s hard disk drive. It is always a good idea to save your programs for later reference and as a preventative measure against accidental loss due to a power failure. As a rule of thumb, save your programs often to avoid losing valuable information.
PROGRAMMING MILLPWR Note: If you make any changes, make sure that you save the program again.
PROGRAMMING MILLPWR Directories One of the best ways to keep programs organized is to save them in directories. Directories are like file folders—they should be clearly labeled and contain closely related projects. They can be used to categorize programs by job, operator, customer, or any other method you prefer. • Press the PROGRAM FUNCTIONS softkey, then press the DIRECTORY softkey. SELECT A DIRECTORY FUNCTION.
PROGRAMMING MILLPWR subdirectory under JULY1998, layer another one under that, one under that and so on. How many directories you create and how you layer them is up to you. Follow the steps below to create directories for your own programs. • After you have selected the PROGRAM FUNCTIONS and DIRECTORY options, press the SELECT DIRECTORY softkey. SERVO OFF FEED 0 100% CURRENT PROGRAM TOOL: SCALE 1.
PROGRAMMING MILLPWR • Highlight the folder you want to put your new directory in. (In our example, we highlighted “MILLPWR,” then created a subdirectory “COMPANY1.”) • Press the SELECT DIRECTORY softkey again to verify your choice. The “Directory” screen will disappear. • Now press the DIRECTORY softkey. • Select the CREATE DIRECTORY softkey. You will be asked to name the directory. • Name the directory using the numeric keys on the operator console or by selecting letters from the ALPHABET option.
PROGRAMMING MILLPWR Selecting a Directory The SELECT DIRECTORY softkey allows you to open any of the established directories on MILLPWR ’s internal hard disk drive, on a 3 ½” floppy disk, or on your PC’s hard disk drive—whichever one you’ve chosen. You will use this feature anytime you save or load a program. • After you have selected the PROGRAM FUNCTIONS and DIRECTORY options, press the SELECT DIRECTORY softkey. The last directory that was opened will appear.
PROGRAMMING MILLPWR subdirectories you have created should appear under the “Directory” heading. On your PC: Press the REMOTE STORAGE softkey. “REMTSTOR” and any subdirectories you have created should appear under the “Directory” heading. • Using the arrow keys, highlight the directory you want to open. (If the list is long, use the PAGE UP/PAGE DOWN softkeys to scroll through the list more quickly.) • Press the SELECT DIRECTORY softkey again. The “Directory” list will disappear.
PROGRAMMING MILLPWR Deleting a Directory Note: MILLPWR will not delete directories that contain programs. You must delete each program stored within the directory before continuing. Refer to the Deleting a Program section. To delete an empty directory: • After you have selected the PROGRAM FUNCTIONS and DIRECTORY options, press the DELETE DIRECTORY softkey. • Identify where the directory you want to delete is located.
PROGRAMMING MILLPWR Other Program Functions Naming a Program Before you save a program, MILLPWR requires that you name it. • If you have accidentally selected the wrong letter or number, simply press the DEL key and rename the program. PLATE 12 If you want to use alpha characters, press the ALPHABET softkey. An alphabet will appear just below the “Program Name” area. • • Using the arrow keys, you can scroll from one letter to the next. Press the ENTER key to make a selection.
PROGRAMMING MILLPWR Deleting a Program You can remove any program that has already been saved. To delete a program, follow these steps: • Select the directory that contains the program you want to delete. (Refer to the Selecting a Directory section.) • After you return to the “Current Program” screen, press the DELETE softkey. SELECT A PROGRAM FUNCTION. LOAD SAVE DELETE BACKUP DIRECTORY • Using the arrow keys, highlight the program you want to delete. • Press the ENTER key.
PROGRAMMING MILLPWR Backing Up a Program The BACKUP softkey gives you the opportunity to make backup copies of programs that you have already saved on MILLPWR ’s internal hard disk drive. Remember, you should keep backup copies on hand in case a program is accidentally deleted, your hard disk drive fails, or you are unable to recover the original files for any other reason. It’s best to save and clear the final version of a running program before creating a backup copy.
PROGRAMMING MILLPWR Now press the BACKUP PROGRAMS softkey. MILLPWR will highlight the program(s) and save a backup copy 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 one. Choose the “Yes” softkey to continue or the “No” softkey to cancel the operation. • Operation Manual After the backup copies are made, the programs list will disappear.
PROGRAMMING MILLPWR Loading a Program The LOAD softkey allows you to open programs that have already been saved. The steps below tell you how to retrieve a program from MILLPWR ’s internal hard disk drive, a 3 ½” floppy disk, or your PC’s hard disk drive. IMPORTANT! Save and clear any running programs before continuing. Otherwise, your work will be lost when another program is loaded. From MILLPWR ’s internal hard disk drive: • After you have selected the PROGRAM FUNCTIONS option, press the LOAD softkey.
PROGRAMMING MILLPWR In the sample screen on the previous page, the MILLPWR directory contains four numeric (i.e., program.mpt) programs. You can retrieve any text programs (i.e., program.txt) you have saved by pressing the TEXT FORMAT softkey. If the program is saved in the MILLPWR directory: • “MILLPWR” should appear at the top of the left column. If it doesn’t, check that the USE FLOPPY and REMOTE STORAGE softkeys are not selected.
PROGRAMMING MILLPWR SERVO OFF FEED 0 100% CURRENT PROGRAM TOOL: SCALE 1.0000 INCH DIRECTORY MILLPWR COMPANY1 COMPANY2 COMPANY3 2 OF 4 SELECT A WORKING DIRECTORY. SELECT DIRECTORY PAGE UP PAGE DOWN USE FLOPPY REMOTE STORAGE • Using the arrow keys, highlight the directory that contains the program you want to load. • Press the SELECT DIRECTORY softkey again. The “Directory” screen will disappear. Now that you’ve opened the appropriate directory, you can load your program.
PROGRAMMING MILLPWR • Insert the 3 ½” floppy disk containing the file you want to load into the floppy disk drive (located in the upper left-hand corner of the MILLPWR operator console). • Press the USE FLOPPY softkey. The A: directory and any programs it contains should appear. Note: If your program is saved as a text file, select the TEXT FORMAT softkey. Operation Manual • Using the arrow keys, highlight the program you want to load. • Press the LOAD softkey.
PROGRAMMING MILLPWR From your PC: • Save and clear any running programs before continuing. (Refer to the note at the beginning of the Loading a Program section.) • After you have selected the PROGRAM FUNCTIONS option, press the LOAD softkey. • Press the REMOTE STORAGE softkey. A “Programs” directory and any programs it contains should appear. If the REMOTE STORAGE softkey does not appear, then it is likely that MILLPWR and the PC have not been properly set up.
PROGRAMMING MILLPWR BLANK PAGE Operation Manual Page 3-29
DEMONSTRATION MILLPWR A DEMONSTRATION PROGRAM The following steps and key stroke sequences will guide you through creating a program to machine the part illustrated below: 3.00 .750 .750R .838 .250R 1.75 .838 1.5 0R POCKET .500 X 2.000 .250 DEEP .125R CORNERS .250 DIA THRU TYP (5) Selecting the Datum Although there is no clear “zero point” on this drawing, we’re going to use the center of the bolt hole pattern as our datum.
DEMONSTRATION MILLPWR Selecting A Tool A logical first step for most programs is to choose the tool that you want to start with. Let’s use a ¼" FLAT END MILL. TOOL Press the TOOL key. SERVO OFF FEED 0 CURRENT PROGRAM 001 100% TOOL: SCALE SET TOOL SET TOOL 1.0000 INCH 001 TOOL INCH TYPE 1 OF 1 INCH TOOL LIBRARY MM Enter .25 followed by the enter key. . You can select a tool from the Tool Library if you like. Press the TOOL TYPES softkey. 2 5 ENTER TOOL 0.
DEMONSTRATION MILLPWR Milling the Workpiece Contour 3.00 This part could be started at several different places. We'll start at the bottom of the semi-circle on the right end of the workpiece, and we’ll cut in a counterclockwise (CCW) direction. 1.5 0R ARC Press the ARC key. SERVO OFF FEED 0 CURRENT PROGRAM 001 SET TOOL 002 X MILL ARC 100% TOOL: SCALE MILL ARC 1.0000 INCH 002 FROM X1 ABS Y1 ABS TO X2 ABS Y2 ABS DEPTH Z ABS RADIUS DIRECTION CCW TOOL 0.
DEMONSTRATION MILLPWR TO: X2 = 0 Y2 = 1.5 DEPTH: Z = -.25 RADIUS: 1.5 DIRECTION: CCW +/- 0 ENTER 1 . 5 ENTER . 2 5 ENTER 1 . 5 ENTER CCW Since we are starting the arc on the bottom and moving around to the top, we picked CCW for the direction. The tool specifications will be filled in automatically based on the previously selected tool. Now move to OFFSET and select RIGHT or OUTSIDE from the softkey choices.
DEMONSTRATION MILLPWR Finally, move to FEED and enter the FEED RATE you would like to use. To FEED MILLPWR has been factory set with a feed rate of 10 IPM. 1 0 ENTER USE SERVO OFF FEED 0 100% TOOL: SCALE 1.
DEMONSTRATION MILLPWR 3.00 Next, we will enter the 3" line which starts at the top of the arc and The FROM point of this line is automatically set to the end of goes left. the arc programmed before. 1.5 0R SERVO OFF FEED 0 100% 001 SET TOOL 002 MILL ARC TOOL: SCALE MILL LINE CURRENT PROGRAM INCH 1.0000 003 FROM 003 X MILL LINE X1 0.000 ABS Y1 1.500 ABS TO X2 ABS Y2 ABS DEPTH Z 0.2500 ABS TOOL 0.
DEMONSTRATION MILLPWR Operation Manual Page 4-7
DEMONSTRATION MILLPWR 3.00 Press the LINE key to add another line.The FROM dimensions, DEPTH dimension, and TOOL specifications will carry forward from the previous line. .838 LINE Press the LINE key. Enter the following TO dimensions: TO: Notice that you don’t have to use the ENTER key after the last value – just press USE. X2 = -3.0 ABS Y2 = 0.838 ABS SERVO OFF FEED 0 100% . TOOL: SCALE 8 1.
DEMONSTRATION MILLPWR Now we will program the two diagonal lines. Notice that in the xaxis the end of the first diagonal line is .750 from the beginning of the line. FROM (X1, Y1) This means we can use incremental dimensioning. 3.00 .750 .838 We say that “X2 is .750 incremental from X1.” TO (X2, Y2) .75 LINE Press the LINE key. In the TO point, enter X2 = .750 Then press the ABS/INC key.
DEMONSTRATION MILLPWR LINE Press the LINE key again for the second diagonal line: X2 = -3.000 ABS Y2 = -0.838 ABS . +/- SERVO OFF FEED 0 100% TOOL: SCALE 8 1.
DEMONSTRATION MILLPWR We can see that lines 005 and 006 should be connected with an arc. We’ll go back and insert a BLEND step between them. Using the up arrow key, select the last step, 006 MILL LINE. To Step 006 BLEND Press the BLEND key. SERVO OFF We could just as easily have put the BLEND step in right after we did LINE 005. The BLEND step would then show up in the listing, but it would not show in the graphics until we put in the second line.
DEMONSTRATION MILLPWR 3.00 Notice how the last two lines are now “blended” together with a radius. 1.5 0R Press the down arrow key to move to the end of the program to continue entering more steps. To End of Program LINE Press the LINE key. In the TO point enter: X2 = -3.0 ABS +/- Y2 = -1.5 ABS SERVO OFF FEED 0 100% TOOL: SCALE 1 1.0000 +/- 3 ENTER .
DEMONSTRATION MILLPWR LINE Press the LINE key. In the TO point enter: Second line TO: X2 = 0 ABS +/- Y2 = -1.5 ABS SERVO OFF FEED 0 100% TOOL: SCALE 1 1.0000 . 0 ENTER 5 USE INCH CURRENT PROGRAM Notice how the marks to the right of the step numbers have changed to indicate that the contour is now closed.
DEMONSTRATION MILLPWR Programming the Bolt Circle TOOL First, we want to change the tool to a drill. Press the TOOL key and enter the data for a 0.250" drill. . 2 5 ENTER TOOL TYPES Select DRILL and press ENTER. Press USE to complete the SET TOOL step. To DRILL ENTER USE Now, press the HOLES key to see a series of hole pattern choices. Choose the BOLT CIRCLE softkey.
DEMONSTRATION MILLPWR The CENTER and DIRECTION are carried forward from the previous arc. All we need to do is change the radius and enter the number of holes. CENTER: 0.0 0.0 DEPTH: THRU RADIUS: 0.75 DIRECTION: CCW HOLES: 5 The value of ”THRU” for the depth is entered by a softkey. We could choose not to program a depth, since we can easily tell when we drill through the part. To RADIUS . 7 5 ENTER To HOLES 5 When all dimensions are entered, press USE to view the graphics screen.
DEMONSTRATION MILLPWR Programming the Pocket TOOL First we program the tool that we’ll use for the pocket. Press TOOL and enter the data for a 0.125" diameter flat end mill. . 1 2 5 ENTER TOOL TYPES To FLAT END MILL ENTER USE RECT Press the RECT (rectangle) key, then select the softkey for POCKET . SERVO OFF FEED 0 CURRENT PROGRAM 001 SET TOOL 002 MILL ARC 003 MILL LINE 004 MILL LINE 005 MILL LINE 006 BLEND 100% TOOL: SCALE POCKET 1.
DEMONSTRATION MILLPWR Enter the following dimensions for the rectangular pocket: CENTER: +/- X = -1.75 Some of these dimensions are already here so we can down arrow past them. 1 . 7 5 ENTER Y = 0.0 To Size SIZE: X = 0.5 . Y = 2.0 DEPTH: 5 ENTER 2 ENTER Z = -0.25 To Corner Radius CORNER BLEND RADIUS: .125 DIRECTION: . 1 2 5 CCW Press the USE key. USE As with previous tool changes, the tool specifications will be automatically entered from the 010 SET TOOL step.
DEMONSTRATION MILLPWR Saving Your Program The sample part is now completely programmed. Press the softkey labeled PROGRAM FUNCTIONS. PROGRAM FUNCTIONS Press the SAVE softkey. SAVE Name your program by pressing the numeric keys or by selecting the ALPHABET softkey, highlighting a letter, then pressing the ENTER key. You may select up to eight characters, mixing numbers and letters if you wish. After you’ve selected a name, press the USE key to save the program.
DEMONSTRATION MILLPWR Operation Manual Page 4-19
DEMONSTRATION MILLPWR Running the Program The first step in running a new program is to set the datum point on the workpiece. Remember that we chose the center of the bolt circle as the datum. • Mount the workpiece in a vise. • Press DRO and use the MOVE TABLE function to position the quill over the workpiece where you think the bolt circle center might be. DRO MOVE TABLE Move the table to the workpiece datum. • Release the MOVE TABLE function. • Press the DATUM softkey.
DEMONSTRATION MILLPWR If the part falls entirely within the workpiece, you can now actually cut the part. • Press RUN OPTIONS , then deselect the DRY RUN softkey to turn off dry run. Now when you press the GO key, you can follow the instructions MILLPWR gives you and make the part.
DEMONSTRATION MILLPWR Tool Changes You may wish to consider using a POS step before a tool step to allow room for changing the tool. Whenever MILLPWR encounters a SET TOOL step, it shows you the DRO and tells you which tool to load. • Use the MOVE TABLE function to clear the workpiece. • Load the required tool. • Using the move table function, position the tool over a surface of known depth. MOVE TABLE Load tool. Use move table function to position the tool.
DEMONSTRATION MILLPWR Answer YES and the screen will be cleared for another program.
PROGRAM STEPS MILLPWR PROGRAM STEPS Simple Milling & Drilling Set Tool TOOL This step causes MILLPWR to suspend the program and ask you to change the cutting tool. SET TOOL 001 TOOL INCH TYPE You have several options for filling in this step: Tool Types and the Tool Library are opened with softkeys. • Leave it blank; just press USE to insert an “empty” tool step in the program. When you run the program, MILLPWR will ask you what tool diameter to use. • Type in a DIAMETER.
PROGRAM STEPS MILLPWR Mill Line LINE This function moves rapidly to the starting point and mills a line to the end point at the programmed feed rate. FROM and TO are the beginning and ending points of the line. TOOL OFFSET is set with softkeys LEFT, CENTER, or RIGHT. FEED must be programmed or it will default to the last MILL LINE 001 FROM X1 Y1 ABS ABS TO X2 Y2 ABS ABS DEPTH Z 0.0000 ABS TOOL feedrate used or from the value entered in setup.
PROGRAM STEPS MILLPWR Blend BLEND A blend is a circular fillet (connecting radius) which connects two lines, two arcs, or a line and an arc. Just give the RADIUS of the blend, and MILLPWR will calculate the exact tangent points for you. BLEND 001 STEPS FROM TO RADIUS The STEPS are filled in automatically; the FROM step is the one before the blend, and the TO step is the one after the blend. You can program the blend right after the FROM step, before you have entered the TO step.
PROGRAM STEPS MILLPWR Rectangular Milling Functions MILLPWR has several “canned cycles” to let you program pockets, frames, and slots with a single step. There is also a step to let you face off a workpiece. RECT Pressing the RECT key on the front panel will display these softkeys. POCKET FRAME FACE SLOT Pocket A pocket is defined by its CENTER point and its SIZE . You can specify a CORNER RADIUS.
PROGRAM STEPS MILLPWR Rectangular Frame A frame step takes one cut in a rectangular shape. The frame is defined by its CENTER and SIZE . As with a pocket, you can have rounded corners, and the DIRECTION determines the milling type.
PROGRAM STEPS MILLPWR Face This step provides a quick way to face off a workpiece. Enter the CENTER location and the SIZE of the area to be faced. MILLPWR will start at the lower left of the area and zigzag upwards. The MORE softkey brings up fields to let you TILT the face rectangle, and to change the tool STEPOVER. FACE 001 CENTER X Y ABS ABS SIZE IN X IN Y DEPTH Z 0.
PROGRAM STEPS MILLPWR Slot For a slot, enter the CENTER of each arc and the SLOT WIDTH . You can enter the SLOT LENGTH and ANGLE instead of the 2ND ARC CENTER. The MORE softkey displays fields which let you specify the ANGLE of the slot (it rotates about the FIRST ARC CENTER) and enter a FINISH CUT. SLOT 001 FIRST ARC CENTER X1 ABS Y1 ABS SECOND ARC CENTER X2 ABS Y2 ABS DEPTH Z 0.
PROGRAM STEPS MILLPWR Circular Milling Functions MILLPWR CIRCLE has several “canned cycles” to let you program pockets, frames, and rings with a single step. Pressing the CIRCLE key on the front panel will display these softkeys. POCKET FRAME RING Circular Pocket CIRCLE POCKET Enter the CENTER and RADIUS of the pocket. The DIRECTION will determine whether you are climb or conventional milling. The MORE key brings up the FINISH CUT option.
PROGRAM STEPS MILLPWR Circular Frame The INSIDE and OUTSIDE softkeys can help you with the Tool Offset. Enter the frame’s CENTER and RADIUS . The DIRECTION, coupled with the TOOL OFFSET, will determine whether you are climb or conventional milling, and whether you are cutting an inside or outside frame. The MORE softkey brings up fields to let you enter a FINISH cut. CIRCLE FRAME 001 CENTER X Y DEPTH Z ABS ABS 0.
PROGRAM STEPS MILLPWR Ring A ring is actually a circular pocket with a circular island in the center. Enter the CENTER position, the radius of the pocket (OUTSIDE RADIUS ), and the radius of the island (INSIDE RADIUS ). The DIRECTION of cut on the inside radius will determine whether you are climb milling or conventional milling. MILLPWR will reverse the tool movement direction on the outside radius so the milling direction stays the same. RING 001 CENTER X Y DEPTH Z ABS ABS 0.
PROGRAM STEPS MILLPWR Hole Patterns HOLES MILLPWR has several “canned cycles” to let you program patterns of holes. Pressing the HOLES key on the front panel will display these softkeys. ROW FRAME ARRAY BOLT CIRCLE ROW OF HOLES Row of Holes The FROM point is the center of the first hole, and the TO point is the center of the last hole. Enter the number of holes in the HOLES field. Instead of the TO point, you can enter the HOLE SPACING and ANGLE .
PROGRAM STEPS MILLPWR Hole Frame and Hole Array The frame and the array hole patterns need the same information. Arrays have holes in the middle of the rectangular pattern, while frames have holes only on the outside edge of the rectangle. HOLE FRAME CENTER X Y 001 ABS ABS SIZE Enter the rectangle’s CENTER and SIZE , and the number of HOLES in each direction. The MORE softkey brings up fields to let you TILT the frame or to enter the hole-to-hole SPACING.
PROGRAM STEPS MILLPWR Bolt Circle Enter the CENTER and the RADIUS of the bolt circle, and the number of HOLES you want. The MORE softkey brings up the START ANGLE and END ANGLE entry fields, which let you do partial circles. The number of holes you entered will be spaced evenly between the angles. The DIRECTION field is useful if you have a clamp or fixture that you need to avoid.
PROGRAM STEPS MILLPWR More Steps MORE STEPS Additional steps are available that extend the capabilities of your MILLPWR . Select the MORE STEPS softkey to see a menu of the following extended functions: CUSTOM POCKET REPEAT ROTATE MIRROR ENGRAVE REFERENCE POINT Repeat Using this step you can repeat whole parts, or sections of parts, horizontally, vertically, or both.
PROGRAM STEPS MILLPWR Rotate Just as you can repeat sections of a program, you can also rotate sections. ROTATE Enter the CENTER of rotation and the ANGLE of rotation. CENTER X Y Example: 001 002 003 004 005 STEP RANGE FIRST LAST ABS ABS ANGLE MILL LINE MILL LINE MILL LINE POSITION/DRILL REPEAT MORE To rotate the part twice at 30° each, fill in the ROTATE form like this: ROTATE STEP RANGE FIRST LAST CENTER X Y 005 001 004 1.000 0.
PROGRAM STEPS MILLPWR Mirror You can make a mirror image of any section of your program using this step. Enter the RANGE of steps you want to mirror, and the end points of the “mirror line,” called the axis of reflection. The axis does not have to be vertical or horizontal; you can use any line.
PROGRAM STEPS MILLPWR Custom Pocket You can create a pocket from any closed contour. A closed contour is any shape made of lines, arcs, and/or blends, where the last step ends at the start point of the first step. 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 in the closed contour.
PROGRAM STEPS MILLPWR Engrave You can engrave part numbers and other text into a part using this feature. The ENGRAVE feature has two parts. First, specify the characteristics of the text, such as where it goes and how large it is. Then you need to select the actual text characters (alpha or numeric) that you want to engrave. The text that you specify will occupy a rectangular area called a text block.
PROGRAM STEPS MILLPWR The second part is to enter the text characters. Press the EDIT TEXT softkey to see the ENGRAVE TEXT EDITOR. This is the “insertion point”, where the next character will go. This area will hold the contents of the text block. The screen is divided into the TEXT BLOCK area and the CHARACTERS area. The TEXT BLOCK area is where you see the text that you will engrave. The CHARACTERS area contains all the different characters that are available in the font you have selected.
PROGRAM STEPS MILLPWR Explode Any repetitive type of step causes MILLPWR to create copies of one or more simpler steps. For example, the ROTATE step below creates 2 copies of the contour-with-hole shape, yet it only takes one step. Similarly, a single BOLT CIRCLE step causes MILLPWR to drill several holes. Strictly speaking, EXPLODE is not a step, but it can create steps.
CALCULATOR MILLPWR CALCULATOR Four Function Arithmetic + - X / The four arithmetic keys, , are available when you are in any numeric entry field, such as X, Y, CENTER, or RADIUS . Just use these keys as you would any calculator. 2 KEY + 2 RESULT 5 2+ ENTER 5 7 The keys will act on a number that is already in the field. For example, if you move to a radius field which already has a value of 3.125, and you want to double it, just press: X 2 ENTER to get 6.250.
CALCULATOR MILLPWR SHIFT SHIFT COS SIN TAN SQR ROOT ARC COS ARC SIN ARC TAN SQR ( ) X Typically, a result is calculated by entering a number and then selecting the appropriate math function. For example, to enter a RADIUS whose value is the square root of 2, press the 2 key, the CALC key and then select the SQR ROOT softkey. A value of 1.4142 (the square root of 2) will be displayed.
CALCULATOR MILLPWR The parentheses softkeys can be used to group certain calculations within an arithmetic statement. For example, 2 + 1 / 16 gives two and one-sixteenth, but (2 + 1) / 16 gives three-sixteenths. The parentheses are not always displayed during the key stroke sequence, but they are remembered by the MILLPWR as it calculates the correct answer.
CALCULATOR MILLPWR Geometry Calculator Why We Need a Geometry Calculator Occasionally, a drawing will not have enough information to program a part in the usual way. .62 5 An example is the illustration below. The part is uniquely defined by the given information. However, the coordinates of points C and D, where the arc is tangent to the sides, are unknown. These coordinates are needed to define lines 002 and 004, as well as the FROM and TO points of the arc.
CALCULATOR MILLPWR Working with the Geometry Calculator To open the geometry calculator, referred to as GeoCalc, press the CALC key. If you are not in a numeric field, the GeoCalc screen appears. If you are in a numeric field and the trig calculator softkeys appear, press the CALC key again to get the GeoCalc screen. SERVO OFF FEED 0 100% TOOL: SCALE 1.
CALCULATOR MILLPWR The kinds of “interesting” things that GeoCalc finds depend on the features you select and whether you ask for a point, line, or arc. The table below lists all of the points, lines, and arcs found by the GeoCalc.
CALCULATOR MILLPWR Example Problem We’ll use the example below to demonstrate how to use GeoCalc. Strategy We can program the line from A to B directly. Then we’ll use GeoCalc. .62 5 Our strategy will be: D C 70° 70° A • Enter the line from A to D. • Enter the line from B to C. • Select the two lines, and use the FIND ARC function. • Get points C and D, the endpoints of the arc. Then, transfer them into the program from GeoCalc. B 2.
CALCULATOR MILLPWR Entering the Lines Press the CALC key on the front display panel to enter the GeoCalc screen. Press the LINE key and construct the line from A to D. Although we will mill this line in the other direction (towards the datum), in the GeoCalc, a line is just a line, and its direction doesn’t matter. Here’s how we do it: “From the datum” means we can use absolute dimensioning. • We know the start point: X = 0, Y = 0. • We know the angle of the line from the datum is 70°.
CALCULATOR MILLPWR “From its own start point” means we can’t use absolute dimensioning. We need to use “incremental”. Next, we’ll put in the other side line. This line starts at X = 2, Y = 0, and goes out from its own start point at a 110° angle. Again, since we know the angle, we can use polar coordinates. But because the angle (and the length) will be measured from point B, not from the datum, we need to use incremental dimensioning, not absolute. • • R2 A2 70° 110° +X 2.
CALCULATOR MILLPWR Finding the Arc The white highlighting lets you know which line you’re pointing to. First, move to 001 GEOLINE and press the SELECT FEATURE key. Repeat for 002 GEOLINE . Notice that an arrow appears to signify that the lines have been selected. Also, the message line above the softkeys tells you which features are selected. Press the FIND ARC softkey. A field for the arc radius will be displayed in the message bar. Enter 0.625, press USE, and GeoCalc displays all possible 0.
CALCULATOR MILLPWR Highlight the arc that forms the top of the part. Press the KEEP ONE softkey, and GeoCalc makes that arc number 003. Then press the CLEAR RESULTS softkey to erase the remaining arcs. SERVO OFF FEED 0 100% TOOL: SCALE 1.
CALCULATOR MILLPWR Finding the Points of Tangency Keep in mind that the ultimate goal is to have GeoCalc determine the points of tangency between the lines and the arc. Since the FIND ARC function calculates the arcs which are tangent to the two selected lines, the ends of the arcs are the points we need. We just have to select the arc and have GeoCalc find the end points. • Select 001 GEOLINE and press the SELECT FEATURE softkey. This will de-select the line. • Move down to 002 GEOLINE and de-select it.
CALCULATOR MILLPWR Returning Features GeoCalc will return features to the part program by pressing the RETURN FEATURE key. We will now program the second line, the arc, and the last line. Press CANCEL to return to the program. Make sure you are after the first MILL LINE step. • Press LINE to get a new MILL LINE form. The FROM point is automatically set to point B. SERVO OFF FEED 0 100% TOOL: SCALE 1.0000 INCH CURRENT PROGRAM 001 SET TOOL 002 MILL LINE D .
CALCULATOR MILLPWR • Press CALC to get to GeoCalc. • Highlight the arc. • Press the RETURN FEATURE softkey. MILLPWR automatically adds an arc step to the program and places the arc’s information into the form. • Press USE to put the arc into the program. • Press the LINE key. The end of the line is at the datum, so enter X2 = 0, Y2 = 0 in the TO point, and press USE to keep the line. The program is now complete.
SETUP MILLPWR SETUP SETUP Pressing the SETUP key displays information about the system that you can adjust. This is the OPERATOR SETUP list. SERVO OFF FEED 0 100% TOOL: SCALE 1.0000 INCH OPERATOR SETUP TOOL LIBRARY SCALE FACTOR DISPLAY OPTIONS TOUCH PROBE FEED RATE SETTINGS SYSTEM SETUP 1 OF 6 INCH MM USE NEW SETTINGS CANCEL CHANGES Select the item you wish to change and press ENTER. After you have made any desired changes to the settings, press the USE NEW SETTINGS softkey to activate them.
SETUP MILLPWR Operator Setup Tool Library Put your most commonly used tools first! A list of tools is available to you for convenient selection during programming and/or operation of the MILLPWR . There are 99 “slots” in the Tool Library. You can organize tools any way you wish. One way is to keep all your flat end mills together in a group, all drills in a group, and so on. Another way is to group them by size. Move to TOOL LIBRARY , and press ENTER. SERVO OFF FEED 0 100% TOOL: SCALE 1.
SETUP MILLPWR Scale Factor The scale factor can be set to scale the workpiece up or down from the programmed size. All programmed dimensions will be multiplied by this scale factor when the program is run. The numbers in your program are not changed. A scale factor of 1.000 causes the MILLPWR to use programmed dimensions exactly. Values greater than 1 cause the MILLPWR to make parts larger than the programmed dimensions; values less than 1 to make parts smaller. Operation Manual SCALE FACTOR SCALE 1.
SETUP MILLPWR Display Options Select DISPLAY OPTIONS and press ENTER. For each of the settings, a series of softkeys gives you the available options. lets you show angles as decimal degrees, radians, or degrees-minutes-seconds (DMS) ANGLES INC DISPLAY will let you see INCREMENTAL TRAVEL or DISTANCE TO GO in the DRO incremental display. Incremental travel is the distance from the start of the line to the tool; it reads 0 at the start. This is equivalent to “zero and go” operation.
SETUP MILLPWR Touch Probe The diameter of the probe or edge finder, used for finding the workpiece edge during datum setting, is set by selecting TOUCH PROBE and entering the diameter. Feed Rate Settings Here you can change the settings for various speeds and feeds. is the size of the percent step used when you press the FEED+ and FEED- keys. FEED RATE SETTINGS STEP OVERRIDE % STEP OVERRIDE % 5 MAX OVERRIDE % 150 MAX % is the most you can override the programmed feed rate with the FEED+ key.
SETUP MILLPWR System Setup When you select SYSTEM SETUP from the OPERATOR SETUP list, you are asked for a passcode. The passcode is defined on page 2 of this manual. Enter it to bring up the following list of settings. SERVO OFF FEED 0 100% TOOL: SCALE 1.
SETUP MILLPWR Error Compensation If the milling machine shows signs of wear, actual part dimensions may differ from programmed dimensions. A correction factor can be entered for the axis that is not holding accurate dimensions. SERVO OFF FEED 0 100% SYSTEM SETUP TOOL: SCALE 1.0000 INCH ERROR COMPENSATION X: STANDARD LENGTH (INCH) 0.0000 PROTECTION ERROR COMPENSATION ENCODER DIRECTION X: COMPENSATION PPM 0 SERIAL PORT Y: STANDARD LENGTH (INCH) 0.
SETUP MILLPWR Encoder Direction If you don’t like the plus and minus directions that MILLPWR has chosen for you, you can change them. This might happen if you prefer to have the quill-down direction be positive, or if the X-axis scale is mounted to the front of the table instead of to the back. Changing an axis from POSITIVE to NEGATIVE changes the count direction. Use the softkeys to make the changes.
SETUP MILLPWR Serial Port After you have created a part program, you can store it any of three ways: on MILLPWR ’s internal hard disk drive, on a 3 ½” floppy disk, or on the hard disk drive of your PC using MILLPWR ’s serial port. Storing programs on your PC is often a good idea, because doing so frees up MILLPWR ’s hard disk drive space, allowing MILLPWR to perform faster. Before you save a program on your PC using MILLPWR ’s serial port, you’ll need to configure the parameters for the serial port.
SETUP MILLPWR • Using the arrow keys, highlight the BAUD rate. • Define the BAUD rate by using the HIGHER and LOWER softkeys. The BAUD rate you select must match the BAUD rate of your PC. If you are unsure which BAUD rate to select, start with 2400. You can adjust it later on if you need to. • Page 7-10 SERIAL PORT FUNCTION REMOTE STORAGE BAUD RATE 2400 When you are finished, press the USE NEW SETTINGS softkey.
REMOTE STORAGE MILLPWR REMOTE STORAGE When you create programs using MILLPWR , you can save them on the hard disk drive of your PC using the remote storage feature. The remote storage feature enables you to free up MILLPWR ’s internal hard disk drive space. Plus, your PC is the ideal place to back up important files and organize them in one convenient location.
REMOTE STORAGE MILLPWR Connecting MILLPWR to Your PC Before you can save programs remotely, you need to connect MILLPWR to your PC. ! CAUTION To avoid the possibility of electrical shock, power down both MILLPWR and your PC before connecting the serial cable. • Connect one end of the cable into the serial port located on the side of MILLPWR ’s controller cabinet. Connect the opposite end of the cable into an available COM port on the back of your PC.
REMOTE STORAGE MILLPWR Installing the Remote Storage Program You can install the Remote Storage program on your PC using either Microsoft® Windows® 95 or DOS® operating systems. Choose the system you will use, then follow the applicable steps below. For Windows 95: 1. Boot 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.
REMOTE STORAGE MILLPWR Setting the PC’s COM Port and BAUD Rates After the Remote Storage software has been loaded, the following screen will appear on your PC: Communications Baud Rate Port Selected READY COM: 1 COMMAND 01-01-99 14:00:43 BAUD: 2400 TIME PROGRAM DIRECTORY 0 of 0 Keyboard Command Softkeys ACU-RITE Remote Storage Utility v1.0.0 COM PORT (F1) BAUD (F2) QUIT (F5) Now you need to identify your COM port and set the BAUD rate.
REMOTE STORAGE MILLPWR Common Error Messages If the communication lines between MILLPWR and your PC are disrupted, an error message will appear on the MILLPWR screen. Settings that do not match and a faulty serial cable connection are the most common problems and are easiest to correct. Error Cause Solution BAUD rate error MILLPWR and PC BAUD rate settings do not match. Change one of the settings so that MILLPWR and the PC BAUD rates are the same.
REMOTE STORAGE MILLPWR Error Cause Solution No response from PC (cont’d) The selected COM port a) Change the PC’s COM port is disabled. setting and connect the serial cable into the appropriate port; ORb) Exit the remote storage program on your PC, then refer to your Microsoft® Windows® operating system’s and PC operator’s manuals for instructions on how to enable a COM port.
TROUBLESHOOTING GUIDE MILLPWR Troubleshooting Guide Introduction: This Troubleshooting Guide is intended to assist you with diagnosing problems should you experience any difficulties with your MILLPWR. Using the Table: This MILLPWR Troubleshooting Guide is arranged in three columns entitled: Symptom, Problem and Recommendation. The Symptoms are listed in the order of most common, easiest to check, and least expensive to correct.
TROUBLESHOOTING GUIDE MILLPWR Symptom Operator Console Displays a Blank Screen Problem Recommendation Brightness/Contrast Intensity is Too Low. Adjust Brightness/Contrast knob located on the back of the operator’s console. No Power Check that the power switch located on the back of the operator console is on. Ensure that the power cord between the operator console and the controller cabinet is properly connected.
TROUBLESHOOTING GUIDE MILLPWR Symptom Operator Console Keyboard Does Not Function Problem MILLPWR System Needs to be Reset Recommendation Turn the system off. Wait at least one minute. Then turn the system back on. Should the above recommendation not correct the problem, contact your ACU-RITE MILLPWR representative for repair or replacement procedures. System Powers Up But Motor(s) Will Not Move Table Emergency Table Stop Button is Activated Release the Emergency Table Stop Button.
TROUBLESHOOTING GUIDE MILLPWR Symptom System Powers Up But Motor(s) Will Not Move Table (cont.) Problem Temperature Recommendation Check that the fan is operating. Check that the controller cabinet filter is not blocked. The filter may need to be replaced. Check that the door Louver filter is not blocked. The filter may have to be replaced. If the fan and filter are operational, leave the controller cabinet door open for approximately 10 minutes with the power on.
TROUBLESHOOTING GUIDE MILLPWR Symptom Table Run Away (cont.) Problem Recommendation X and/or Y Axis Linear Encoders Stopped Counting (cont.) Should the linear encoder count in certain areas only, contact your ACU-RITE MILLPWR representative Should the above recommendation not correct the problem, contact your ACU-RITE MILLPWR representative for repair or replacement procedures.
TROUBLESHOOTING GUIDE MILLPWR Symptom System Not Repeating or Circles Out of Round (Cont.) Problem Machine Tool Related Problems (Cont.) Recommendation Tram the head. Lower the quill full travel with a sturdy tool in 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 manufacturers’ specifications between the spindle and the spindle bearing and between the quill and the bore.
TROUBLESHOOTING GUIDE MILLPWR Symptom Poor Finish Problem Recommendation Dull Tool Replace the tool. Incorrect Feeds and/or Speeds Ensure that the correct feeds and/ or speeds are being used and/or programmed. Gibs Out of Adjustment Refer to the machine tool manual. Worn Spindle Bearings Lower the quill full travel with a sturdy tool in the spindle. Set up a dial indicator to check movement of the spindle; then move the tool side-to-side.
TROUBLESHOOTING GUIDE MILLPWR BLANK PAGE Page 9-8 Operation Manual
