Acu-Rite Control System MILLPWRG2 User Manual

							ACU-RITE MILLPWRG2 21
9.1 Geometry Calculator
Overview ............................................................................................................. 210
Accessing the geometry calculator...................................................................... 210
Geometry calculator layout ............................................................................. 211
Geometry listing.............................................................................................. 211
Geometry graphic ........................................................................................... 211
9.2 Geometry User Interface
Adding geometry features to listing .................................................................... 212
GeoPoint ......................................................................................................... 212
GeoLine........................................................................................................... 212
GeoArc ............................................................................................................ 212
Finding geometry solutions ................................................................................. 212
Managing geometry results ................................................................................. 214
Returning features to the part program ............................................................... 215
Geometry calculator functions ............................................................................. 215
Clear calculator ............................................................................................... 215
Loading and saving calculator contents .......................................................... 215
Loading the part program into the geometry calculator .................................. 215
Program example................................................................................................. 216
Locating points B and C .................................................................................. 216
Creating the program ........................................................................................... 216
Step 1.............................................................................................................. 216
Step 2.............................................................................................................. 217
Step 3.............................................................................................................. 218
Finding the points of tangency........................................................................ 219
Returning the line coordinate .......................................................................... 219
Returning the arc feature ................................................................................ 220
Finishing the program ..................................................................................... 220
9.3   RPM calculator
RPM functions ..................................................................................................... 221
Using the RPM calculator ............................................................................... 221
RPM dialogue.................................................................................................. 221 
						

							22   
10.1 Setup
Overview ............................................................................................................. 224
Setup .............................................................................................................. 224
Job setup ........................................................................................................ 224
Installation setup............................................................................................. 224
Tool table ........................................................................................................ 224
Message log ................................................................................................... 224
Job setup ............................................................................................................. 225
Job setup ........................................................................................................ 225
Scale factor ..................................................................................................... 226
Feed rate ........................................................................................................ 227
Display ........................................................................................................... 227
Job clock - parts counter................................................................................. 228
Probing............................................................................................................ 228
Tool table ............................................................................................................. 229
Message log ........................................................................................................ 229
Service files ......................................................................................................... 230
11.1 Auxiliary Machine Interface (AMI)
Machine Functions Menu .................................................................................... 232
12.1 Updating System Software
Software update .................................................................................................. 234
Procedure for updating the software ................................................................... 234
13.1 MILLPWRG2 Off-Line Software
Off-line simulator ................................................................................................. 236
System requirements .......................................................................................... 236
Installation............................................................................................................ 237
Operation ............................................................................................................. 237
On screen keypad ................................................................................................ 238
Keyboard shortcuts .............................................................................................. 238
Updating .............................................................................................................. 240 
						

							Introduction 
						

							241 Introduction
1.1 MILLPWR
G21.1  MILLPWRG2
The ACU-RITE MILLPWRG2 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. 
Basic editing of g-code programs is also possible.  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. 
						

							ACU-RITE MILLPWRG2 25
1.1 MILLPWR
G2Powering up
Turn the power switch On [1], (to the I position) on the MILLPWRG2 
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.
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.
The MILLPWRG2 console does not disconnect the power 
supply to the spindle motor. It can only be disconnected 
by turning off the main power supply. 
It is strongly recommended that the MILLPWRG2 
performs the Find Home feature at start up, prior to any 
other action taken. 
If the MILLPWRG2 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.  
						

							261 Introduction
1.1 MILLPWR
G2E-STOP and shutdown
The E-STOP is used for emergency program shut down by turning off 
the servo motors.
When the E-STOP button is pressed, the servo motors 
are stopped, and the quill can be raised.It does not 
shut down the spindle motor.
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 power down the 
control, so that the main switch can be turned off. 
Wait for the indication that it is OK to turn power off.
Press the Restart soft key to reboot the control, 
shutting down and subsequently starting back up.
Press the Cancel soft key to cancel and exit the shut 
down procedure.
The E-STOP 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.
Always shutdown the MILLPWRG2 before turning power 
off to the machine. Refer to the builders instructions for 
for additional information on turning power off. 
						

							ACU-RITE MILLPWRG2 27
1.1 MILLPWR
G2Emergency 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. 
						

							281 Introduction
1.1 MILLPWR
G2Find 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.
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.
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.
Before finding home with a 2 axes system, the quill must 
be fully raised first.
Finding home applies to the X, Y, Z, and W axes.
Not finding home before moving the table will risk 
exceeding the tables 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.
The Find Home soft key is not available if there is an error, 
and the front panel LED indicator is flashing. 
The error must be corrected, and then cleared from the 
message log. Then homing is allowed. 
Refer to Chapter 10 Message log on page 229 for 
information on opening the 
message log and clearing 
errors. 
						

							ACU-RITE MILLPWRG2 29
1.1 MILLPWR
G2Disengage Z axis feature
MILLPWRG2 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 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]. 
						

							301 Introduction
1.1 MILLPWR
G2Writing programs
Overview
The MILLPWRG2  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.