Introduction
2
1.1 MILLPWR
G2
The ACU-RITE MILLPWR
G2
control is a workshop-oriented contouring control that enables you to program conventional machining operations right at the machine in an easy-to-use conversational programming language. It is designed for milling and drilling machine tools, with up to 3 axes.
MILLPWR
G2
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
G2
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.
The MILLPWR
G2
has many powerful features that will improve your productivity. The screen layout is clearly arranged in such a way that the functions are easy to access, fast and user friendly.
MILLPWR
G2
is a closed-looped system with positioning feedback provided by ACU-RITE precision glass scales (1µm/0.00005" resolution). MILLPWR
G2
also includes Position-Trac™, an advanced, unique feature that enables you to easily, quickly and accurately re-establish work piece zero after shutting down, or power loss.
ACU-RITE conversational, and G-code format
The ACU-RITE conversational programming format is a method of writing programs; g-code (ISO) programming can be used, and run, but can not be edited. Preview graphics in the editor illustrate the individual machining steps for programming the contour as well as the corresponding tool path generated. A production drawing does not need to be dimensioned for NC programming, the MILLPWR
G2
can be programmed using the dimensions directly from the production drawing. The programming format is the same as used in previous
MILLPWR products. Always verify old programs before machining with MILLPWR
G2
.
1 Introduction
Powering Up
The MILLPWR
G2
console does not disconnect the power supply to the spindle motor. It can only be disconnected by turning off the main power supply.
Turn the power switch On [1], (to the I position) on the MILLPWR
G2 console which is located on the back of the unit.
Follow the builder’s instructions to turn off the machine.
The start up screen with 3 soft keys will be displayed; Shut Down,
Find Home
, and Cancel. After pressing either the Find Home, or
Cancel
soft key, the default DRO screen will be displayed.
It is strongly recommended that the MILLPWR
G2 performs the Find Home feature at start up, prior to any other action taken.
If a program was loaded when the MILLPWR
G2
was shut down, that same program will be reloaded when the unit is powered up again.
If the MILLPWR
G2
did not perform the Find Home feature at start up, press the Datum soft key from the default DRO screen to display the Home soft key. Press the Home soft key then the Find Home soft key will be displayed.
ACU-RITE MILLPWR
G2
3
E-STOP and Shutdown
The E-STOP is used for emergency program shut down by turning off the servo motors. It does not shut down the spindle motor. The spindle motor must always be manually stopped using the spindle switch to stop the motor, and the cutting tool.
When the E-STOP button is pressed, the servo motors are stopped, and the quill can be raised.
When the STOP key is pressed once, the servo motors pause, but are still active. All axes are locked, and can not be moved.
The program can now either continue by pressing the
GO
key, or stopped by pressing the STOP key a second time.
If the STOP key is pressed a second time canceling the program, the spindle motor must be stopped, and the tool raised before moving any of the remaining axes.
Shutting down the MILLPWR
G2
system is done by using the Shutdown soft key.
Press the Shutdown soft key to shut down the
MILLPWR
G2
system. This soft key is available in both
DRO
and PGM mode.
Confirm the shut down by pressing the Yes soft key.
Press the No soft key to cancel and exit the shut down procedure.
Always shutdown the MILLPWR
G2
before turning power off to the machine. Refer to the builder's instructions for for additional information on turning power off.
4
1 Introduction
Emergency Stop (E-STOP)
Press E-STOP to take all axes servos offline. This ends all machine movement, and allows the quill to be raised to move the tool out of the way.
To reset the E-STOP, turn the rotary switch clockwise in the direction of the arrows. The switch pops outward, and is reset.
Resetting E-STOP does not reactivate the servos.
Activating/Resetting the Servos
For safety reasons, the mill powers up with the servomotors disengaged. While the servos are disengaged the mill axes cannot move under servo power. The axes can be manually positioned if necessary.
Reset the servos as follows:
If a limit switch disengaged the servos, manually reposition the machine inside its normal range of travel.
If a miscount occurs, press the Find Home soft key to reset the servos and return all axes to their home position.
ACU-RITE MILLPWR
G2
5
Find Home
You should find home before a program is run, or immediately after startup.
During start up, the Find Home soft key is provided on the start up screen soft key area.
If the find home step is not performed at initial start up, it can be initiated at any time during operation. Press the Datum soft key, then press the Home soft key, and then press the Find Home soft key.
A 3 axes system will move the table and quill. They will automatically move a few inches along the Z, Y, and then X to find home. If a W axis exists (i.e. coupling knee to quill) then the control will prompt you to move the W manually to home it.
A 2 axes system will move the table. The table will automatically move a few inches along the Y, and then X to find home. Then the control will prompt you to move the Z quill manually to home it. If a
W axis exists (i.e. coupling knee to quill) then the control will prompt you to move the W manually also to home it.
Before finding home with a 2 axes system, the quill must be fully raised first.
When finding home, the MILLPWR
G2
will use (on machines equipped with ACU-RITE glass scales), the Position-Trac™ distance-encrypted reference mark line pattern. This line pattern allows MILLPWR
G2
to accurately find home and re-establish workpiece zero from any position.
Finding home applies to the X, Y, Z, and W axes.
Position-Trac will accurately re-establish workpiece zero after power loss, or shut down. After home has been found, the tool’s position
(relative to the most recent datum set) will be displayed.
Not finding home before moving the table will risk exceeding the table's travel limits, and possible damage to the machine, and the MILLPWR
G2
system.
Programs will not be allowed to run if the homing process does not complete successfully.
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1 Introduction
Disengage Z Axis feature
MILLPWR
G2
provides the flexibility to switch between 2 axes and
3 axes operation.
Disengaging the Z axis drive:
Leave the Z BEGIN field blank when programming a step, or a one time milling operation.
Raise the quill, then loosen the quick release knob [1] on the front of the the Z axis drive system.
When a program step, or milling operation is then performed, the operator is prompted to manually position the quill.
Re-engaging the Z axis drive
Raise the quill handle to seat the ball screw into the nut block (e.g. this would be similar to hitting a dead stop).
Tighten the quick release knob [1].
ACU-RITE MILLPWR
G2
7
Writing Programs
Overview
The MILLPWR
G2
allows many features to be used without having to write a program. For operations that repeat, or complex machining it is best to write a program. Before writing a program, determine the work-holding device and the location of Part Zero (the point to which all movement is referenced). Since absolute positions are defined from Part Zero, try to select a location that directly corresponds to dimensions provided on the part print, such as the lower left corner of the work. Then you can develop a program. The following is a general approach to programming:
First, select the unit of measurement (Inch/MM) using the MM key.
This will place the DRO in the required unit of measure, and all dialogues will use the selection. If the selection is changed after data has been entered, the MILLPWR
G2 will convert the data to the new unit of measure.
The first step in a program selects the tool that is to be used. It’s size can be entered in either Inch or MM regardless of the unit of measure selected in the DRO. The Tool dialogue provides fields for data input for the tool position. This is a tool change position, a location away from the work area where the axes can return for safe tool changing. TOOL POSITION will use the unit of measure that has been selected for the DRO.
The remaining steps in the program describe the required moves, single cycles, and Tool changes to complete the machining.
The next to the last step in the program returns the axes to the Tool change position and ends the program.
After writing a program, verify it. Run it to troubleshoot for errors.
Verify that all programmed moves are safe, and accurate to the part print dimensions.
Setup the work piece into the intended holding device.
First run the program in Single-Step Mode to verify that both the program and the setting of Tool Offsets are correct. Single-Step
Mode allows you to run the program step-by-step. Make any necessary corrections. Once verified, the program can be run in
Auto Mode.
When the finished program is ready for production, back it up on a
USB memory device.
If there is an interruption to the power supply, the program is not lost. The program is periodically saved. Verify that the most recent steps (prior to the power failure) are in the program. The fixture zero location is also remembered.
8
1 Introduction
1.2 Operating in 2 Axes and 3 Axes
Modes
Overview
The MILLPWR
G2
is capable of running a 2 axes machine (manual Z) or a 3 axes machine with the Z being switched to manual as needed. This
User's Manual covers 2 axes and 3 axes operation. This section provides some general guidelines. In 2 axes mode, all Z moves must be made manually.
When running a program, the system will pause and provide a prompt whenever a Z move is required.
The incremental DRO display will show the distance to the Z axis target position.
Press the ABS/INCR key to toggle between absolute and incremental display modes.
In incremental mode, a bar graph is displayed below each axis position. A small blue indicator moves toward the center of the bar as the incremental position approaches 0. When at 0, the blue indicator will be centered.
After moving the Z axis to the programmed position, press the GO key to continue running the program.
Program Steps in 2 Axis Mode
When running a program step in 2 axis mode, not all information in the program step is used. Values may be programmed for Z Pass, Z Peck, and Tool Retract, but they will not be used when running in 2 axis mode.
When prompted to set Z, the incremental display will show the distance to the Z end depth.
After drilling to depth, raise the quill and press the GO key to continue running the program.
For pocket steps, raise the quill and press GO when prompted.
If an additional pass is needed for a step, press STOP to end the program and run the step again.
It may also be necessary to repeat a set of steps for each pass in a program.
ACU-RITE MILLPWR
G2
9
Selecting 2 Axis Mode on 3 Axis Systems
To run a program in 2 axis mode, disengage the quill assembly before pressing the GO key.
A prompt will appear indicating that the quill is disengaged.
If this is intentional, press GO and the program will run in 2 axis mode.
To program a specific step to run in 2 axis mode:
Select POSITION for the Z operation type (drill steps).
For pockets, clear the Z begin depth field.
When the step is run, the Z axis servo motor will be turned off to allow manual movement.
Follow all manual Z motion prompts. See "Tool Table" on page 44 for a complete description about using the Tool
Table.
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1 Introduction
1.3 Console
Operating Console
The ACU-RITE MILLPWR
G2
Console has a 12.1-inch Flat-Panel Color
Screen Display. The following list of items are located on the front panel.
See "DRO display screen" on page 21 for mapping information of the
start up screen.
See "Console Keypad" on page 20 for a full description of the console
keypad layout. The individual keys are fully described on page ii of the inside front cover.
The following features are located on the front panel of the console:
1
Color flat panel screen display.
2
Emergency “E” Stop
3
Soft keys
4
Power On indicator light / Error indicator light
5
Potentiometer for feed rate override
6
Go, Pause/Stop, Navigation keys, and Move Table keys
7
Axis keys
8
Console keypad
9
USB Port
See "Calculator" on page 18 for a full description of the calculator
keypad.
Rear Panel
The ACU-RITE MILLPWR
G2
DRO rear panel has the following list of items located on the panel.
1
Power switch
2
Power connector
3
Servo Power connector
4
Earth (ground) terminal
5
Ethernet port
6
USB port
7
KT 130 Edge Finder
8
Pendant (Remote switch)
9
RS-232-C connector
10 Auxiliary Machine Interface (AMI); for future expansion.
11 Servo connector (X, Y, and Z)
12 Grounding Edger Finder
13 Encoder Inputs (W and Z axis)
ACU-RITE MILLPWR
G2
11
Screen Navigation
The MILLPWR
G2
display layout changes between DRO Mode and
PGM
(Program) Mode by pressing the DRO/PGM key. The following illustrates the differences between the two screen modes.
DRO Mode display
In general, the display changes as different functions are activated.
Soft keys in the lower display area change per the function selected.
Soft keys perform their associated function by pressing the key directly below it. Basic procedures and features remain the same regardless of which mode is selected. For a complete description of
the display areas see "DRO Screen" on page 31.
1
Status Bar display for Servo Motor Status, Feed rate, Tool,
Datum, Scale, Skew, (Inch/MM), Estimated Time, Part Clock,
Parts (run), Job Clock, and Time of Day. See "Status Bar Display" on page 32.
2
Axes Display (current position).
3
Operator Intervention Message line (OIM).
4
Soft keys display area.
5
Dialogue box display area for milling functions.
PGM Mode display
When PGM mode is selected, the display changes from DRO mode to display program functions and graphics. Soft keys change to programming functions. All soft keys are run by pressing the
corresponding hard key located directly below it. See "Status Bar
Display" on page 32 for complete descriptions.
1
Status Bar display for Servo Motor Status, Estimated Time, Tool,
Datum, Scale, Skew, (Inch/MM).
See "Status Bar Display" on page 32.
2
Display window of graph simulation.
3
Operator Intervention Message (OIM).
4
Soft keys display area.
5
Program name.
6
Program steps.
12
1 Introduction
Dialogues, and Drop Down Menus
This manual provides complete information where specific examples of actions are being explained.
As a general overview of the dialogues provided by the MILLPWR
G2
, several fields are likely to be provided for input. To navigate a dialogue, use the ARROW keys to select the desired field. After entering the data into a field, press either the ENTER key, or the UP or DOWN ARROW keys to move to the next field. Exiting a field with one of these key methods will retain the entered data in that field.
When the required data has been entered, press the USE key to accept the data entered for use in that specific function.
Most dialogues contain Drop Down menus. Specific milling functions may require additional information. The choices available are provided in a drop down menu. In most cases, they are also provided as soft keys. The choices can be selected from either location.
Operator Prompts
For actions that require immediate input to continue the operation an operator prompt will be displayed by the MILLPWR
G2
in the message bar. The required data can be entered with the numerical keypad, and in some instances using the alphanumeric on screen keyboard.
Cursor
The MILLPWR
G2
uses a highlighted cursor to mark a field for selection or editing. In some instances, the cursor will default to a field without highlighting the field. Use the ARROWS keys to move the cursor. The UP, and DOWN ARROWS move the cursor through the fields available. The
RIGHT
ARROW will open a field that contains more choices, or subfolders in the folder tree. The LEFT ARROW will close the menu, or subfolders.
The cursor will also change from a highlighted bar to a text cursor when a field selected is having data entered.
ACU-RITE MILLPWR
G2
13
General Operating Guidelines
General operating guidelines for the MILLPWR
G2
.
Additional operation soft keys are located in the soft key area along with task selection, and dialogue. The soft keys change in relation to the task being performed.
Selection of a particular soft key that requires additional information may open a popup menu [1].
A soft key may open a dialogue menu that requires input necessary to continue with the operation selected.
The status bar in the top of the display is constant, and reflects only what has been selected for the current program.
Use the Context Sensitive Help (INFO key) feature when assistance is desired. This is an intuitive feature that aids the user by going directly to the section in the manual in relation to the feature, or key that has been selected to obtain assistance with.
14
1 Introduction
Operating Modes
The MILLPWR
G2
has two main operating modes: DRO, and PGM
(Program). These are accessed from the front panel hard key. This is a toggle key.
DRO
mode shows the current position of each axis relative to current datum. In DRO mode, manual machining, and Single Cycles can be performed. Tool selection, units, along with most setup features can be accessed.
Program mode PGM, displays the list of program steps and part-view graphics. New programs can be created as well as editing existing programs.
Programs, new or existing, can be saved, deleted, or copied using program functions.
A USB pointing device e.g. mouse, trackball, etc. may also be used.
If a pointing device is being used, the action of clicking on a soft key button is the same as pressing the corresponding soft key. A USB keyboard can also be used for data entry and cursor control.
ACU-RITE MILLPWR
G2
15
Popup Menus
Within the soft keys, additional features may be available in program mode. A soft key that has a down arrow in the lower right hand corner indicates that additional soft keys are available for that feature.
As an example, pressing the Program Steps soft key (in PGM mode) opens another set of soft keys available for this function. Then you will notice an up arrow on most of the soft keys. This indicates a popup menu will open when that key is pressed.
Soft keys for PGM provide access to edit existing programs, or create a new program. Sub menus provide dialogue for machining operations such as milling a line, an arc, engraving, drilling and creating pockets.
Pressing the required operation step soft key will open a popup menu to further define the machining operation required.
A selection for a popup can occur in one of two ways:
Use the shortcut number to the left of the feature; for example, pressing 9 on the numeric keypad will select the Circle Ring dialogue.
Or use the Up and Down arrow keys to highlight the feature to be used, then press ENTER.
When the type of machining operation has been selected, the corresponding dialogue opens so that the required data can be entered.
A dialogue in DRO mode will retain the previous data entered making it possible to re-run the previous operation without having to re-enter all the data.
At anytime when entering data into a dialogue the calculator can be accessed by pressing the CALC key.
Soft keys for CALC provide access to additional math functions such as trig functions.
When a dialogue is activated, it is not possible to change to another dialogue. The current dialogue must be exited by pressing USE to save the data in the dialogue or pressing
CANCEL
to discard the data.
16
1 Introduction
Keyboard
An on screen QWERTY keyboard will automatically popup when you enter a field that requires text information input.
The keyboard becomes visible (popup) when text, and numerical information is required for an action (e.g. saving a program, or entering text for engraving).
Use the ARROW keys for navigation of the cursor to go to the desired character and press ENTER to select the character.
When the information has been entered using the keyboard, press the Save soft key. The keyboard will disappear from the screen. The keyboard will also be removed from the screen when the CANCEL key is pressed.
When using a USB keyboard, the on screen keyboard can be disabled by pressing the Keyboard soft key. The on screen keyboard will remain disabled untill it is enabled by pressing the Keyboard soft key again. When the console goes through a power cycle, the key board will retain its setting prior to the power cycle.
Special Characters
The keyboard also provides a “Special Characters” display which is accessed by the “(#*\!...” key.
Arrow over to the “(#*\!...” key to highlight the key, and press the the ENTER key.
Navigational Soft keys
The following navigational soft keys are always available on the keyboard.
The “Up Arrow” key switches the keyboard from upper to lower case letter mode, or from lower to upper case letter mode depending on the current keyboard mode.
The “Abc” key switches the keyboard from the special character key mode to the alpha numeric key mode.
The “(#*\!...” key switches the keyboard from the alpha numeric key mode to the special character key mode.
ACU-RITE MILLPWR
G2
17
Editing Keys
The following keys are available for editing text on the keyboard.
The Copy key will copy the highlighted text in the text field.
The Paste key will paste to the text field text that was previously highlighted, and copied.
The Clear key will remove all text in the text field.
The back space key will delete text in the text field one character at a time.
Calculator
Numeric Keypad
The numeric keypad on the front of the console resembles a standard calculator with keys for numbers 0 through 9, four math function symbols (+, -, x, and ÷), a decimal point, and a positive/negative sign
(+/-).
The calculator is accessible from nearly any screen or field. Press the CALC key to access the “stand-alone” calculator. The math function soft keys are displayed in the soft key area. Calculations can be entered directly into a highlighted field.
Using the calculator in an entry field in a dialogue requires the operator to press the ENTER key to run the calculation.
To move to the next field using the ENTER key requires the operator to press ENTER a second time.
Anytime data is entered into an entry field in a dialogue and the value is changed using the +/- key, the operator is required to press the ENTER key to use the value change.
Moving to the next field using the ENTER key requires the operator to press ENTER a second time.
18
1 Introduction
Context Sensitive Help
The MILLPWR
G2
uses an intuitive method to aid the user when assistance is required. When assistance is needed with a feature, the
User Manual can be displayed directly at the point which describes the feature.
To use this help, in this example, the console is in PGM mode, and a
Linear Engraving cycle is being programed. It is desired to see descriptions of the cycle parameters, and the cycle itself. The following steps describe the actions needed to take.
Using Context Sensitive Help
Press the INFO key to open the on screen User
Manual.
This will display a new window containing the section in the User
Manual, opened directly to the description of the desired feature.
This is the active window when Context Sensitive Help is activated.
To activate the Contents View on the left side of the display, press the Contents View soft key. This allows the user to see all available topics from the User Manual. The Forward and Back soft keys will navigate the users previous history. The Previous Topic and
Next Topic
soft keys will select the previous and next topic in the manual contents (shown in the Contents View on the left hand side).
These soft keys allow the user to select other sections of the User
Manual while in Context Sensitive Help. Using these keys will navigate the User Manual even if the Contents View is hidden.
The following describes the action, and use of the soft keys:
The Back soft key navigates one page back per key press to a previous page that was viewed from the history. History is not cleared when the Help Screen is exited.
The Forward soft key navigates one page forward per key press from the viewed pages in history.
The Previous Topic soft key navigates one Topic up in the contents window per key press.
The Next Topic soft key navigates one Topic Down in the contents window per key press.
The Contents View soft key is a toggle key to show/ hide the contents view on the left hand side of the display.
To close, press the Exit soft key.
ACU-RITE MILLPWR
G2
19
Console Keypad
The following keys are located on the console keypad. There is also a quick reference guide located at the beginning of this manual on page ii of the inside front cover.
1
Axis keys, use to select the required axis.
2
Numeric keys, use to enter numeric data.
3
CANCEL
key, use to cancel current action.
4
CLEAR
key, use to clear selections such as values entered in a field.
5
ARROW
keys, use to navigate around the screen, and highlight dialogue fields. Also used to move the table axes.
6
STOP
key, use to pause, or stop a program that is running, or a machine operation.
7
GO
key, use to start, or resume a program.
8
USE
key, use to complete an operation, i.e. data values entered in a dialogue.
9
ENTER
key, use to activate selections, and entries.
10 +/- key, use to toggle key for “Plus/Minus” data entry.
11 CALC key, opens the fully functional calculator.
12 Function keys, select appropriate key for quick access to the
function and data entry.
13 Milling function keys. Selection of appropriate key provides direct
access to the milling function dialogue.
20
1 Introduction
1.4 Operating Mode Screens
Display navigation
The DRO mode is the default start up mode, and PGM mode can be selected from the front panel key after start up. A condensed description of these has been provided here on how to navigate, and become familiar with the information that is being provided.
Complete descriptions, and details of these are provided later in this
manual, see "DRO Screen" on page 31.
DRO display screen
The MILLPWR
G2
display screen provides the information required to monitor the machine, it’s movement, programming, and more.
The default screen, or home screen, displays two main windows, and soft keys in the soft key display area. When the console is first turned
on, the unit defaults to this screen. See "Screen Navigation" on page
12.
The DRO screen displays information per the current operation. DRO mode allows the use of the milling function keys, or can be used as a
DRO in manual machining operations.
The system Shutdown soft key is located here as well as in PGM mode.
ACU-RITE MILLPWR
G2
21
Program Display Screen
From the DRO mode, press the DRO/PGM key, and the display changes to program mode showing the currently selected or loaded program.
When Programing a job, the display activates a graphic view of the program. While the program is running, the operation that is being performed is graphically shown as well. The VIEW key provides features to configure the graphic area.
For more information, see "Program Function Screen" on page 55.
1.5 Accessories
Electronic Edge Finder
The Electronic Edge Finder KT 3D enables the ability to teach positions, find the center point of a circle, or locate datum (work piece zero) by touching off on the part. Advantage of an electronic edge finder is that it instantly senses when contact is made with the point
(even if the axis over traveled).
22
1 Introduction
