Page 1 User’s Manual MILLPWR 5/2016...
Page 2: Keys On Console
Numerical keys Controls of the MILLPWR Function Keys on console ZERO key. Motion control keys Function ONE key. GO key (e.g. run a program). TWO key. STOP key (duel function: press once to pause, press twice to stop a program). THREE key.
Page 3: Move Table And Navigation Keys
MINUS key. Peripherals supported: MULTIPLIER key  USB memory devices; e.g. a memory stick.  Networking, USB pointing devices; e.g. a mouse, USB DIVIDE key. keyboard. Potentiometer for feed rate override Feed rate override ACU-RITE MILLPWR...
Page 5: Manual Information
Refer to another Manual! This symbol indicates that information required is located elsewhere (i.e. Machines Owner Manual). Advice! This symbol indicates that an Advice tip is being provided. Important, and/or additional information about the function described. ACU-RITE MILLPWR...
Page 6: Fonts Used In This Manual
HEIDENHAIN CORPORATION is continuously striving to improve. Please help HEIDENHAIN CORPORATION by sending your request to the following e-mail address: sales@heidenhain.com Visit www.ACU-RITE.com for latest version of this manual. Model, software and features This manual describes functions and features provided by MILLPWR as of the following NC software number.
Page 7: New Functions Of Software
 Step Form Validation has been added; see page 102.  Radial Slot Cycle has been added; see Chapter 8.1.  Parameter for reduced feedrate on full pocket cuts has been added to Job Setup; see Chapter 10.1. ACU-RITE MILLPWR...
Page 8: Changed Functions Of Software
Changed functions of software 751005-01-01  Blend/Chamfer information input (see page 164) has been redefined.  Preset Moves information input (see page 49) has been redefined.  Display:Peck\Pass (see page 227) has a note added that the limit of pecks or passes is 9999. 751005-01-02 ...
Page 9 Shutdown / Restart procedure has changed (see page 26).  VIEW hard key description has been updated; see Chapter 5.1.  Aux step now allows user specified continuity; see page 205.  The Contour step is now part of the Position/Milling soft key; see page 161. ACU-RITE MILLPWR...
Page 11: Millpwr G2 Access Code
Press the Install Setup soft key, and enter the access code. Attention! To prevent setup parameters from being changed, remove this page from the manual after initial system setup. Retain this information in a safe place for future use. ACU-RITE MILLPWR...
Page 13: Table Of Contents
Changed functions of software ................8 751005-01-01 ...................... 8 751005-01-02 ...................... 8 751005-01-03 ...................... 8 751005-01-04 ...................... 8 751005-02-00 ...................... 8 751005-03-00 ...................... 9 751005-04-00 ...................... 9 MILLPWR Access Code Access code ......................11 Access to machine parameter operations ............. 11 ACU-RITE MILLPWR...
Page 14 1.1 MILLPWR ACU-RITE conversational and G-code format ............24 Powering up......................25 E-STOP and shutdown................... 26 Find home......................28 Disengage Z axis feature ..................29 Disengaging the Z axis drive: ................29 Re-engaging the Z axis drive................29 Writing programs ....................30 Overview ......................
Page 15 Electronic edge finder .................... 57 Skewing ......................... 58 Milling function keys ....................59 DRO operations ..................... 60 Rectangle milling....................60 Rectangle milling example ................60 Circle milling...................... 61 Circle milling example ..................61 DRO mill cycles ..................... 62 ACU-RITE MILLPWR...
Page 16 3.2 Calculator Accessing the calculator ..................63 Using the calculator to insert data ..............63 Trig functions ......................64 Trig functions ....................65 4.1 Tool Table Overview ....................... 68 Tool compensation required data ................68 Tool numbers / tool names ..................69 Locating the tool table ...................
Page 17 Entering milling steps ..................99 Adding/inserting milling steps................. 100 Editing or deleting a milling step..............100 Program errors ....................101 Program edited ....................101 Step Form Validation..................102 Running a Program ....................103 Skewing a part ....................103 ACU-RITE MILLPWR...
Page 18 Establishing a datum.................... 105 Overview ......................105 Steps to establish the datum ................106 X axis datum ....................107 Y axis datum ....................107 Z axis datum ....................107 Retract Z ......................108 Using an electronic edge finder ..............108 Setting the datum on an edge ................
Page 19 Changing to a tool of unknown length in a program ........160 Position/Milling ....................161 Position / Drill ....................161 Line ......................... 162 Arc........................163 Blend/chamfer....................164 Contour ......................167 Rectangular milling functions................169 Rectangle pocket .................... 169 Rectangle frame....................171 Rectangle face ....................173 Rectangle slot ....................175 ACU-RITE MILLPWR...
Page 20 Circular milling functions..................177 Circle pocket ....................177 Circle frame ....................179 Circle ring ......................181 Circle helix ...................... 183 Radial slot ....................... 184 Hole patterns ....................... 185 Row of holes....................185 Hole frame and array ..................187 Bolt circle patterns ..................189 8.2 Additional Milling Functions Step functions soft key..................
Page 21 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 ACU-RITE MILLPWR...
Page 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.................
Page 23 Introduction...
Page 24: Millpwr G2
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.
Page 25: Powering Up
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...
Page 26: E-Stop And Shutdown
E-STOP and shutdown The E-STOP is used for emergency program shut down by turning off the servo motors. 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. ...
Page 27 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...
Page 28: Find Home
When finding home, the MILLPWR will use (on machines equipped with ACU-RITE glass scales), the Position-Trac™ distance-encrypted reference mark line pattern. This line pattern allows MILLPWR accurately find home and re-establish workpiece zero from any position.
Page 29: Disengage Z Axis Feature
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...
Page 30: Writing Programs
Writing programs Overview The MILLPWR 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).
Page 31: Operating In 2 Axes And 3 Axes Modes
If the W axis is moved, use the DRO’S ABS display value to correctly position the Z axis. The INC display is corrected for any W motion at the start of the next step. Position / Drill steps and hole pattern steps are correct for any W motion. ACU-RITE MILLPWR...
Page 32: Program Steps On 2 Axis Systems
Program steps on 2 axis systems  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. ...
Page 33: 1.3 Console
1.3 Console Operating console The ACU-RITE MILLPWR 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 43 for mapping information of the start up screen.
Page 34: Screen Navigation
Screen navigation  The MILLPWR 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.
Page 35: Dialogues And Drop Down Menus
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. Three axis specific fields are not displayed when in two axis mode. ACU-RITE MILLPWR...
Page 36: General Operating Guidelines
General operating guidelines General operating guidelines for the MILLPWR  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].
Page 37: Operating Modes
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...
Page 38: Popup Menus
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.
Page 39: Keyboard
 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...
Page 40: Editing Keys
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. ...
Page 41: Context Sensitive Help
 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...
Page 42: Console Keypad
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. Axis keys, use to select the required axis. Numeric keys, use to enter numeric data.
Page 43: 1.4 Operating Mode Screens
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...
Page 44: Program Display Screen
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.
Page 45 Machining Fundamentals...
Page 46: 2.1 Conventions
2.1 Conventions Axis conventions Count direction When programming a part using MILLPWR , table movement and tool movement are determined by the use of positive or negative numbers. MILLPWR has been factory set with the following positive and negative count directions for the X, Y and Z-axes: X axis ...
Page 47: Absolute And Incremental Work Piece Positions
Absolute coordinates of hole 4 X = 10 mm Y = 10 mm Hole 5, with respect to 4 Hole 6, with respect to 5 X = 20 mm X = 20 mm Y = 10 mm Y = 10 mm ACU-RITE MILLPWR...
Page 48: Setting The Datum
Setting the datum Overview Datum is the workpiece zero or absolute zero, and is a point of reference that the MILLPWR bases all of the part's coordinates from. A datum must be established for every job. Datum's location may be indicated on the print;...
Page 49: 2.2 Manual Machine Positioning
ARROW keys (for X and Y) or the soft keys for Z. One jog increment is moved per ARROW key press. Continuous moves  To manually position the machine using continuous movement, press the Move Table soft key. Make sure none of the incremental Jog keys are highlighted. ACU-RITE MILLPWR...
Page 50: Adjusting The Feedrate
 Press the appropriate ARROW key (or soft key) to move the table in the direction required for the axis move. The table will move at the currently active jogging speed. The table will move until the ARROW key is released. Adjusting the feedrate The Feedrate Override potentiometer can be used to override the currently active feedrate or rapid rate for machine moves.
Page 51 DRO Mode and Calculator...
Page 52: 3.1 Dro Manual Data Input
3.1 DRO Manual Data Input Overview The MILLPWR is in either DRO mode or PGM mode. DRO mode allows data input for short one step machining operations. Manual operation, single step operation, and single commands can be entered. DRO mode also allows the running of programs;...
Page 53: Dro Screen
This window displays program steps if a program is loaded. If no program is loaded, then this window is blank. When a function has been selected (e.g. Pocket), its dialogue box would be displayed in this window. ACU-RITE MILLPWR...
Page 54: Status Bar Display
Status Bar display Status Bar Description Display Program This field indicates the program state: Stop when State program is not running, Run when program is running, or Pause when program is paused for operator. Feed This field indicates the current feedrate of the table or quill.
Page 55: Move Table
Each milling function will either open its own dialogue or allow selection of choices from a soft key popup. These milling function keys are described in more detail later in this chapter. Single cycle milling functions allow use of internal incremental reference. ACU-RITE MILLPWR...
Page 56: Zeroing An Axis
Zeroing an axis Pressing the Zero X, Zero Y, or Zero Z soft keys will zero the incremental position for those axes. A datum must be set to establish the point from which all absolute dimensions are based. Teach position Whenever X, Y or Z coordinates are being entered, the Teach Position soft key will appear, enabling MILLPWR to be in teach mode and to...
Page 57: Electronic Edge Finder
(1in/min) until the electronic edge finder touches the workpiece. When the electronic edge finder touches the part’s surface, the coordinate will appear in the field. The electronic edge finder is active whenever an entry field is highlighted. ACU-RITE MILLPWR...
Page 58: Skewing
Skewing The skew function automatically compensates for the offset angle of the part when it is not perfectly parallel with either the X or Y axis.  Press the DRO/PGM key to place the MILLPWR in DRO mode.  Press the ABS/INCR key to place the MILLPWR in ABS mode.
Page 59: Milling Function Keys
ARC opens the MILL ARC dialogue where information can be entered to mill an arc. BLEND opens the BLEND dialogue while in PGM mode where information can be entered to mill an arc, blending two surfaces together. Also used for chamfer. ACU-RITE MILLPWR...
Page 60: Dro Operations
DRO operations The following explains a few of the machining operations that are available. This example is providing an overview to the operator of the MILLPWR capabilities. The RECT, or CIRCLE keys as an example access popup menus to further refine the type of milling to be completed. Selecting the type of milling operation required will open the dialogue for that type of milling operation.
Page 61: Circle Milling
(e.g. pocket, frame, ring, or helix)  Select Pocket from the popup menu. The popup menu disappears, and the Circle Pocket dialogue is displayed.  Enter the data to mill the pocket.  Press GO to run the circle pocket. ACU-RITE MILLPWR...
Page 62: Dro Mill Cycles
DRO mill cycles The one step milling function are grouped in Four categories as shown in these groups.  Drill Cycles  Position  Row of Holes  Rectangular Frame  Rectangular Array  Bolt Circle  Rectangular Pocket Cycles ...
Page 63: 3.2 Calculator
 Then press the 2 key. This will also appear in the field as part of the calculation steps.  Then press the ENTER key, and the result will be entered into the dialogue field. ACU-RITE MILLPWR...
Page 64: Trig Functions
Trig functions The Trig function calculator can be accessed at any time, during most operations.  To access the calculator’s Trig functions, press the CALC key.  Then press the Trig soft key, and select the function to be used. The following Trig calculator soft keys are available: Soft key Description...
Page 65: Trig Functions
To exit the calculator press the CALC key a second time or press CANCEL. Trig functions When calculating the Sine, Cosine, or Tangent of an angle, enter the angle first (in decimal degrees), then press the function soft key. ACU-RITE MILLPWR...
Page 66 3 DRO Mode and Calculator...
Page 67: Tool Table
Tool Table...
Page 68: Overview
4.1 Tool Table Overview When the MILLPWR runs a program step that activates a tool, it only activates the diameter, and length values on that row of the Tool Table. The tool number, or tool type are not activated in dialogues that have these fields.
Page 69: Tool Numbers / Tool Names
The Tool Table should not have any tool length for a tool that is not repeatable. Locating the tool table The Tool Table is accessed from the DRO setup screen.  To activate the tool table, press the SETUP key.  Then press the Tool Table soft key. ACU-RITE MILLPWR...
Page 70: Tool Table
Tool table Editing the tool table When the tool table is open, a new tool can be added, or an existing tool can be edited by changing the existing information for that tool. It is necessary to first select the unit of measurement before entering values into the tool table.
Page 71: Editing An Existing Tool
Diameter Compensation value for the tool diameter D. Length Compensation value for tool length L. Type Tool type: A popup menu appears where you can select the type of tool being used. Plunge Angle Angle of plunge cut. ACU-RITE MILLPWR...
Page 72: 4.2 Tool Data
4.2 Tool Data Tool-length offsets Tool-length offset is the distance from Z0 Machine Home to the tip of the tool at the part Z0 (the surface of the work). Tool-length offsets allow each tool used in the part program to be referenced to the part surface.
Page 73: Diameter Offset In Tool Table
On machines equipped with collet-type tool holders, it is impractical to use the Tool Table to store tool-length offsets. You can set tool-length offset at tool change. Tool Table diameters are still required for compensated moves and when using cycles that have built-in compensation. ACU-RITE MILLPWR...
Page 74: Tool Radius Offset
Tool radius offset Tool radius offset is available with the MILLPWR . The tool center moves in the working plane along the programmed path or to the programmed coordinates. When programming a part profile, the path of the tool is a half of a diameter away from the depth of the cut. Offset the tool to the right-hand or left-hand of the cutting edge.
Page 75: Machining With Radius Offset
The tool center moves along the contour at a distance equal to the radius. “Right” or “left” are to be understood as based on the direction of tool movement along the work piece contour as viewed from behind a moving tool. ACU-RITE MILLPWR...
Page 76: Radius Offset: Machining Corners
Radius offset: machining corners  Outside corners: A programmed path around the outside corners on a transitional arc should have the feed rate at the outside corners reduced to relieve machining stress. Typical for any great changes of direction.  Inside corners: The operator must program the MILLPWR for the intersection of...
Page 77 Program Overview...
Page 78: 5.1 Programming Introduction
5.1 Programming Introduction Program display mode If the console has the Calculator active while in DRO mode, exit from Calc by pressing the Calc key, returning the MILLPWR to DRO mode. Program Functions can not be accessed when the Calculator is active in DRO mode. ...
Page 79: Program Function Screen
Shows the type of programs being displayed (e.g. MILLPWR or G-Code programs to be displayed; or DXF files). 10 Displays the current program loaded. 11 The Folders Tree can be used when connected to a network, USB memory devices, or folder management. ACU-RITE MILLPWR...
Page 80: Program Drawing View
The MILLPWR can save programs to a USB device, or to network drive (e. g. a PC) as well as to the MILLPWR User folder. The internal memory of the MILLPWR is organized into a folder structure. The default folder is the User folder. Programs can be stored in the User folder.
Page 81: Program Screen Display
Soft keys that have a small arrow in the lower right hand corner indicates that additional soft keys are available when the key is selected. Soft keys that have up arrow in the top left hand corner indicates that a popup menu is available when selected. ACU-RITE MILLPWR...
Page 82: Program Mode Soft Keys
Program mode soft keys When the DRO/PGM key is selected from DRO mode, the MILLPWR screen changes to PGM mode, and the program default screen is displayed. When the MILLPWR is set to program mode, types of milling functions specific to the hard key selected become available as soft keys.
Page 83: Program Functions
The Folder View soft key opens the folder tree window to access all folders, and sub folders. Use the Change Window soft key to navigate to the available windows. Press the Exit soft key to return to the Program Function screen. ACU-RITE MILLPWR...
Page 84  Pressing the Select soft key feature opens a popup menu that provides these three choices:  The Select feature will select one or more programs. Highlight each program to be selected, and choose Select for each program highlighted.  The Select All feature will select all programs in the folder.
Page 85 Plus is only available if Minus has been used. The MILLPWR will save 20 history steps. The 21st history step will replace the 1st history step. Edits to a program that have not been saved are lost. ACU-RITE MILLPWR...
Page 86: View Hard Key
View hard key Once a program is opened, first select how the part should be displayed in the graphics window. Pressing the VIEW key opens the display dialogue for View Setup to set the viewing graphic options of the program. Pressing the View key again, or pressing the CANCEL key will turn the VIEW key display off.
Page 87 ½X: Simulates the program at half the programmed feed rate. Machining a part in PGM mode will show the soft keys to easily select between 2D Line, 3D Line and 3D Solid without having to open the View Setup dialogue. ACU-RITE MILLPWR...
Page 88: Step Functions Soft Keys
Step functions soft keys The Step Functions soft key provides access to the following soft keys for assistance with programing steps, and modifying or arranging the programs steps. Soft key Function The Explode soft key will explode a program step e.g.
Page 89: Program Steps Soft Keys
Repeat, Rotate, or Mirror The Other Steps soft key opens a popup menu to further define the type of milling operation e.g. Engrave Line, Engrave Arc, Comment, Auxiliary Function, Dwell, or Reference Point. ACU-RITE MILLPWR...
Page 90: Clear Program Soft Key
Clear program soft key This soft key provides a quick method to clear the current loaded program. It does not provide an option to save before exiting. Its function is meant to quickly clear a program (e.g. once it has been run and is no longer needed), so that a new program can be loaded, or a blank program is available, or return to DRO mode without having a program loaded.
Page 91: Run Options Soft Keys
The Look Ahead soft key will detect when programmed features with an offset are too small for the current tool radius and adjusts the path as needed. The Exit soft key will exit the Run Options function and return to the previous display. ACU-RITE MILLPWR...
Page 92: Program Saving
Program saving When you create programs with the MILLPWR , they can be saved within MILLPWR 's User folder, on a USB device, or a network location. MILLPWR will retain a program in memory so it is not lost in the case of a power failure.
Page 93: 5.2 Program Mode Functions
Prior to removing the USB memory device, check that the activity indicator light on the USB drive is not active or blinking. This will ensure that all commanded disk operations have completed, and that it is now safe to remove the drive. ACU-RITE MILLPWR...
Page 94: 5.3 Creating Programs Overview
5.3 Creating Programs Overview New part program The following briefly describes how a new program is created. See "Fundamentals for Creating a Program" on page 99 for more complete information.  Press the DRO/PGM key from DRO mode to enter PGM mode. ...
Page 95 Programming...
Page 96: 6.1 Conversational Programming
6.1 Conversational Programming Programming considerations “From” and “To” points  Lines and arcs are defined by their From point (the point where they begin) and To point (the point where they end). Depth of cut When programming the depth of cut, MILLPWR will prompt for the Begin and End locations for the Z axis.
Page 97: Tool Offset
MILLPWR will use the quill’s previous retract position. A two axes system also requires the Z depth, and Z retract position. The operator will be prompted to manually move to a depth, or retract position. ACU-RITE MILLPWR...
Page 98: Absolute Vs. Incremental Dimensions
Absolute vs. incremental dimensions MILLPWR allows both absolute and incremental dimensions to be entered. A dimension measured from the point you defined as datum is an absolute dimension. A dimension measured from any other point is an incremental dimension. See "Absolute and incremental work piece positions"...
Page 99: Fundamentals For Creating A Program
As steps are added to the list, each will immediately be drawn on the screen so that it can be displayed graphically, showing the part machining in progress. MillPwr G2 allows a maximum of 9999 program steps. Entering milling steps ...
Page 100: Adding/Inserting Milling Steps
Adding/inserting milling steps  A new program step number automatically appears following the last step entered, and the new step is highlighted.  If the cursor was moved for any reason, use the ARROW keys to highlight the new step, then select the milling function to be added. ...
Page 101: Program Errors
 When a program that has been edited, but not saved, then it will revert back to the last saved version when closed. The program will not display an asterisk the next time it is loaded. ACU-RITE MILLPWR...
Page 102: Step Form Validation
Step Form Validation  Once a step has been programed in the program dialogue and the USE key has been pressed, if further data is required, that field will display a red x.  Once a step has been programed in the program dialogue and the USE key has been pressed, if the data in any field has been entered incorrectly, that field will display a yellow warning symbol.
Page 103: Running A Program
A work piece that has a rough edge should have multiple points entered along the straightest edge to more accurately calculate the skew angle. ACU-RITE MILLPWR...
Page 104 Setting the skew angle with an electronic edge finder: Press the Datum softkey to open the DATUM dialogue. Highlight the Angle field.  Press the Probe soft key. Touch off on two or more points along any single straight edge of your part.
Page 105: Establishing A Datum
The following example will illustrate touching off the edge of a work piece using a tool, but an edge finder can also be used in place of the tool. Either item will accomplish the same result. ACU-RITE MILLPWR...
Page 106: Steps To Establish The Datum
Steps to establish the datum Where and how you establish the datum will vary from job to job. The following step, by step process is a common method of establishing a datum. Being familiar with the basics, the same principles will apply for other parts, making adjustments to the procedure as needed when setting the datum.
Page 107: Axis Datum
When changing the state of W axis coupling (knee coupled to quill) to enable or disable it, this can result in invalid Z axis datum points. After changing the coupling state, always re-establish any Z axis datum points to ensure correct positioning. ACU-RITE MILLPWR...
Page 108: Retract Z
Retract Z  Now either enter the Z axis retract position (the position that the quill should return to between steps) which is the location above the top surface of your part.  Or press the CLEAR key to clear the value. If no value is set, the quill will retract to the upper travel limit between steps.
Page 109: Setting The Datum On An Edge
 To set the edge to a specific value, add or subtract an offset to the datum coordinate. For example, to have X = 3.0; press the +(PLUS), 3, and ENTER hard keys. ACU-RITE MILLPWR...
Page 110: Setting The Datum At The Centerline
Setting the datum at the centerline The position of the centerline is determined by probing two edges, either in the X or Y direction.  Press the Probe soft key.  Press the Centerline soft key. The message Move to first edge appears in the message bar.
Page 111: Test The Datum Setting
The readout screen should be at 0.0000, confirming the datum is accurate and programming can now begin.  The value of 0.0000 in the Z axis display may vary slightly depending on how the tool tip contacts the top surface of the part on the corner edge. ACU-RITE MILLPWR...
Page 112: Testing A Millpwr G2 Program
Testing a MILLPWR program Before machining a part, test the program for things like correct tool path, count direction, feed rate, and sequence of operations. MILLPWR provides several run-time choices to assist doing this. Always verify a program when it was loaded, or edited. Whenever a program is about to run, check that the handles are recessed.
Page 113: Single Step
This can be started at the beginning, or midway of a path. The dry run speed is defined in Job Setup. Press the GO key to begin. ACU-RITE MILLPWR...
Page 114: Machining Your Part
Machining your part Before running a program step, check the Status bar (located along the top of the MILLPWR screen) to ensure that the tool identified by MILLPWR matches the tool in the spindle. If there’s no tool identified, or if it’s incorrect, start with a Set Tool step that accurately identifies the tool that is to be used.
Page 115: Potentiometer For Feedrate Override
100% of the programmed feed rates. If the feed rate percentage is 50%, actual feed rates will run at half of the programmed feed rates. Adjustment of the feed rate with the potentiometer can be done at any time, even while the table or quill is moving. ACU-RITE MILLPWR...
Page 116: Manually Positioning The Quill
Manually positioning the quill Programs that do not include a Begin depth will require the operator to manually position the Z axis during machining. The same is true when the Z axis has been disengaged during setup. If an End depth is programmed, when it is time to manually position the Z axis, a preset value will be displayed in the Z axis display.
Page 117: Folders
To expand a folder use the RIGHT ARROW key. To collapse an expanded folder, use the LEFT ARROW key.  Highlight the folder where the new sub-folder is to be placed, and press the Create Folder soft key. ACU-RITE MILLPWR...
Page 118: Naming A New Folder
Naming a new folder  Using the on screen Keyboard, enter the name of the new folder. If the keyboard is not automatically displayed, press the Keyboard soft key.  Once the new folder’s name has been entered, press the Save/ Create soft key to create the new folder.
Page 119: Naming A Program
Press the Function soft key, and select Delete from the popup menu.  Press the Yes soft key to erase the program, or the No soft key to cancel. Once a program is deleted it cannot be recovered. ACU-RITE MILLPWR...
Page 120: Loading A Millpwr G2 (Mpt) Program
Loading a MILLPWR (MPT) program The Load soft key allows you to open programs in the folder listing. The steps below explain how to load a program from MILLPWR User folder, a USB device, or from a network location. Program extensions: MILLPWR programs have a .mpt extension.
Page 121: Importing A Dxf Drawing
The program will then appear on the display. Test the program before machining to ensure that the program steps and tool path do what is expected. The program can be edited and steps rearranged as needed. ACU-RITE MILLPWR...
Page 122: G-Code Programs
G-code programs G-code editing capabilities G-code programs have basic editing capabilities. The value of an existing g-code address can be changed. There are no soft keys available for editing, all navigation is done using the ARROW keys. Use UP and DOWN ARROW keys to move the cursor to the line that needs to be edited.
Page 123: Loading A G-Code Program
Verify the program in the CAD/CAM system that generated the program. MILLPWR will draw the program when Loaded. Finally, lower the knee and dry run the program to verify that the tool path, feeds and speeds are correct. ACU-RITE MILLPWR...
Page 124: Starting Or Stopping A G-Code Program
Using the tool table Each "T" block refers to the corresponding number in the Tool Table. For example, T1 will cause MILLPWR to retrieve the tool length offset from tool 1 of the Tool Table. MILLPWR will then offset the spindle by this amount.
Page 125: G-Code And M-Code Definitions
G20 † Set Program Units (INCH) Same functions as G70 and G71. These commands set the unit of measure. The setting applies to current and subsequent blocks. The default is G20 (INCH). G21 † Set Program Units (MM) ACU-RITE MILLPWR...
Page 126 G-code Description Comment MILLPWR does not have a method for establishing a “home” position. If one or more coordinates are specified in the block, the table/ Return to Home Reference quill will rapid to that location. Program execution will continue with the next program block.
Page 127 It feeds from the begin depth to Z depth, and then feeds back to the G85 † Boring Bidirectional Cycle retract height. G85 Z(zDepth) R(zBegin) P(zRetract) D(dwell) F(feedrate) Required: Z(zDepth) R(zBegin) ACU-RITE MILLPWR...
Page 128 G-code Description Comment This is the chip-breaker peck-drilling cycle, generally used to : Peck-drill medium to deep holes. The cycle feeds from the begin depth to the first peck depth in Z, rapid retracts the chip-break increment (W), feeds to the next calculated peck depth (initial peck less J), and continues this sequence until it reaches a U depth, or until final hole depth is reached.
Page 129: M-Code Definition
If the hardware is not present, the operator is prompted to turn the coolant on (mist), on (flood), or off. M9 † Coolant Off MILLPWR does not support control of a pallet changer. This code has Program End w/ Pallet Shuttle the same effect as M2. ACU-RITE MILLPWR...
Page 130 M-Code Description Comment Enable Speed/Feed Override It is not possible to disable feed rate override on MILLPWR . These commands are ignored. Disable Speed/Feed Override MILLPWR does not support control of a pallet changer. This code has Program Stop w/ Pallet Shuttle the same effect as M0.
Page 131 The coordinates represent the destination for the G0, G1, G2, or G3 Y † Y Axis Coordinate command currently in effect. They use the current units (G20/21 or G70/ 71) and offset mode (G90 or G91). Z † Z Axis Coordinate ACU-RITE MILLPWR...
Page 132: Additional G-Code Conventions For Millpwr G2
Additional G-code conventions for MILLPWR The following lists some of the expectations and limitations of programs ran in MILLPWR  Blocks may contain multiple commands and are executed with the following precedence: Messages Tool Change Spindle Control Coolant Control Dwell Motion Stop ...
Page 133: Backing Up A Program
Repeat to select the Folder Contents window. While copying, moving, or deleting a large number of files a dialog will appear to display the progress. At this time a cancel key will be available to cancel the operation. ACU-RITE MILLPWR...
Page 134: Program Errors
 Use the ARROW keys to highlight the program to be copied, then press the Select soft key.  A popup menu will open where either the highlighted program can be selected, or all programs in the folder can be selected. Highlight Select, or Select All, then press the ENTER key.
Page 135: Demonstration Program
Demonstration Program...
Page 136: Overview
7.1 Demonstration Program Overview The following steps and key stroke sequences will guide you through creating a demonstration program based upon information from the part drawing shown. All dimensions are in inches. This will help introduce you to MILLPWR and familiarize you with how it operates.
Page 137: Begin Programming
Enter 0.00 in the Y To field. Enter 1.00 in the Z To field.  Press the USE key. The programming of the part can now begin. Refer to chapter 8 "Selecting a tool" on page 155 for more information about Tool Position. ACU-RITE MILLPWR...
Page 138: Programming A Line
Programming a line For this example, the part will begin at the upper left hand corner, and cut in a clockwise (CW) direction.  Press the LINE key. The cursor will default to the From X1 field in the Mill Line dialogue. Using the numerical keypad, enter the following information: ...
Page 139: Programming An Arc
Enter the program name in the popup keyboard using the ARROW keys. Name the program DemonstrationProgram.MPT. See "Saving a program" on page 118 in the previous chapter for more information.  Press the Save / Create soft key. Next, the lower horizontal line will be programmed. ACU-RITE MILLPWR...
Page 140: Programming The Connecting Line
Programming the connecting Line  Step 001 is now highlighted. ARROW DOWN to the last blank step number (004) to highlight that step. The next step to program is the line that starts at the bottom of the arc.  Press the LINE key.
Page 141: Programming The Lower Vertical Line
Using the numerical keypad, enter the following information:  In the To: X2 field enter -3.0, and ARROW DOWN.  In the To: Y2 field enter -.838, and ARROW DOWN.  Press the USE key. Next, the lower angled line will be added. ACU-RITE MILLPWR...
Page 142: Programming The Lower Angle Line
Programming the lower angle Line Next, the line that angles in to the part from the lower vertical line will be added.  Press the LINE key. MILLPWR has again assumed that it will continue from where it left off, and all fields are filled in except for the To: fields. The cursor is also located here, in the first field.
Page 143: Programming The Upper Angle Line
Press the Save / Discard soft key.  Select Save from the popup menu to save the program, or select discard to delete the most recent changes since the last save. Next, a blend will be added to the two angled lines. ACU-RITE MILLPWR...
Page 144: Programming A Blend
Programming a blend In this step, a BLEND will be inserted between program steps 6 and 7.  ARROW UP one step to highlight program step 7.  Press the BLEND key.  In the Type field be sure that Blend is selected. ...
Page 145: Closing The Contour
The continuous line along the program steps has now changed to a closed rectangle. This represents that the contour is now closed. This happens when the To point of the last step is the same as the From point of the first step. ACU-RITE MILLPWR...
Page 146: Tool Change For The Bolt Hole Pattern
Tool Change for the bolt hole pattern Begin first by changing the tool.  Press the TOOL key. The tool form will open with the cursor in the Size: Diameter field.  Enter 0.25 in the Size: Diameter field using the numeric keypad. ...
Page 147: Programming The Bolt Circle
If a counter-clockwise direction was applied to the hole pattern, the second hole of our five hole pattern will be between 12 o’clock and 1 o’clock. The holes continue around the circle as shown below. ACU-RITE MILLPWR...
Page 148: Tool Change For The Rectangular Pocket
Tool change for the rectangular pocket Begin by changing the tool.  Press the TOOL key.  In the Set Tool dialogue enter 0.125 in the Size: Diameter field.  ARROW DOWN to highlight the Tool Type field.  With the Tool Type field highlighted, press the Tool Types soft key to open the Tool Type drop down menu.
Page 149: Programming The Rectangular Pocket
 ARROW DOWN to highlight the Direction field, and select CW (Clock Wise) by pressing the CW soft key.  Press the USE key. The demonstration program is now complete.  Save the program, replacing the existing program. ACU-RITE MILLPWR...
Page 150: Testing The Program
Testing the program  Whenever a new program has been created, it should always be tested first. Run Options Two options are available: Dry Run will move the table and Quill but no material will be cut, and Single Step will run the program one step at a time, then pause until GO is pressed to proceed with the next step.
Page 151: Running The Program
Press the X = 0, Y = 0 and Z = 0 soft keys to establish the current tool position as datum.  Press the DOWN ARROW key.  Set the Z retract position 1” above the workpiece.  Press the USE key. ACU-RITE MILLPWR...
Page 152: Tool Changes
Tool changes Whenever you encounter a Set Tool step, MILLPWR will display the DRO screen and let you know which tool to load. If no tool diameter was programmed in the Tool Step, a prompt will be displayed to provide one. ...
Page 153: Milling And Drilling
Milling and Drilling...
Page 154: Overview
8.1 Milling and Drilling Overview Most of the program steps described in this section can be performed as one-step milling functions from the DRO screen or be included as steps in a program. Many of the dialogues are similar in the way that the data is entered.
Page 155: Selecting A Tool
Press the ENTER key to select the tool. In most dialogues that contain a drop down menu, there are soft keys available for choosing a selection. These examples will refer to the use of the soft keys when available. ACU-RITE MILLPWR...
Page 156 Importing Tool Settings from the Tool Table  Cursor to the Diameter field.  Press the Tool Table soft key to open the table.  Cursor to the tool to be used and press the USE key. The tool’s diameter, length, plunge angle, and type are transfered to the Set Tool dialogue.
Page 157 The programming of a part can now begin. Tool length offsets are discussed on the following pages. If the Tool Table is used to enter a tool, MILLPWR will fill in the Diameter and Length fields in PGM mode only. ACU-RITE MILLPWR...
Page 158: Repeatable Tool Length Offsets
Repeatable tool length offsets Programming a tool When a program is using the Tool Length function, there are two requirements that must be followed to ensure that the tip of all additional tools is actually where MILLPWR has calculated it to be. ...
Page 159: Changing To A Tool Of Unknown Length In Dro Mode
This tool length offset is only valid while the tool is mounted. Once this tool is removed, these steps must be repeated to re-establish the tool length when it is used again. ACU-RITE MILLPWR...
Page 160: Changing To A Tool Of Unknown Length In A Program
Changing to a tool of unknown length in a program When running a program, it is possible to switch between tools of known length, to using a tool that has a non-repeatable length. When the tool which has a non-repeatable length is mounted, it’s length will be established in the same manner as above in DRO mode.
Page 161: Position/Milling
It feeds from the begin depth to Z depth, and then feeds back to the retract height. Position: Data can be entered to move the table to a position in the X & Y direction. Z moves are done manually. ACU-RITE MILLPWR...
Page 162: Line
 Enter the Z axis feed rate. The default Feed IPM rate provided must be adjusted according to the current machining operation. This field will automatically use the last entered feed rate in the program  If you want the tool to retract enter either the number of retracts or the distance between each retract.
Page 163: Arc
CCW soft key for a counter-clockwise direction.  ARROW DOWN and highlight the Offset field. Using the soft keys, select the tool offset— Left, Center, Right, Inside or Outside.  Enter the table’s Feed IPM. ACU-RITE MILLPWR...
Page 164: Blend/Chamfer
 If you need to enter a center coordinate, 3 point and/or sweep angle press the More soft key:  Center field:  Enter the center coordinate’s position for the X and Y axes.  Pointfield:  Enter your 3 coordinate’s position for the X axis (X3) and Y axis (Y3).
Page 165 Enter the blend's radius.  Press the Close Contour soft key to blend the end of a contour with the beginning. The step numbers in the To and From fields will automatically change.  Press the USE key. ACU-RITE MILLPWR...
Page 166 Chamfer A Chamfer is done in the same way, but with less steps. In the Size field enter the length of the chamfer. A chamfer is a bevel or line that’s inserted between two lines to relieve sharp angles or corners on a part. A chamfer can be inserted between two intersecting lines whose steps are adjacent in the program step.
Page 167: Contour
Select either Forward or Reverse for the direction of the finish pass. With Forward selected, the finish pass is made in the same direction as previous passes. With Reverse selected, the finish pass is made in the opposite direction.  Press the USE key. ACU-RITE MILLPWR...
Page 168 Tool path description:  The tool path follows the profile of the contour steps.  The Z step size is determined by the system and will not exceed the specified distance or number of passes.  The tool retracts to the active datum's retract position between Z passes.
Page 169: Rectangular Milling Functions
If programming by center and size, enter the Center X and Y axes coordinates.  You can tilt a rectangular pocket by identifying a tilt angle. Highlight the Angle field and enter an angle measured from the X axis. ACU-RITE MILLPWR...
Page 170 Finish Finish allows you to leave some excess material that will be removed during the finish cut reducing tool marks. The finish cut will automatically arc on and arc off.  Enter the amount of material to be removed during the finish cut in the Cut field.
Page 171: Rectangle Frame
Enter either the number of passes or the distance between each pass. Pass refers to the cuts that are used to machine the frame to its End depth. Which choice is shown in the dialogue was selected in Job Setup.  Enter the Z axis Feed Rate. ACU-RITE MILLPWR...
Page 172  Add a corner blend radius or a chamfer to the corners of the rectangular frame.  For Direction, press either the CW soft key for a clockwise cutting direction or the CCW soft key for a counter-clockwise cutting direction. ...
Page 173: Rectangle Face
You can tilt the face by identifying a tilt angle. Highlight the Angle field and enter an angle measured from the X axis.  Enter a stepover percentage (how much the tool to is to overlap on each pass) for the Finish pass. ACU-RITE MILLPWR...
Page 174 Tool path description:  Machining of the face begins near the first corner.  The tool plunges at the Z feed rate.  The tool makes back and forth passes in the XY plane along the defined length of the face. Tool motion extends beyond the ends of the rectangle by an amount equal to the tool radius.
Page 175: Rectangle Slot
CCW soft key for a counter-clockwise cutting direction.  Enter the Slot Width. The slot length will automatically be calculated.  ARROW DOWN or press the More soft key and enter the table’s feed rate.  Enter the Center X and Y axes coordinates. ACU-RITE MILLPWR...
Page 176  The Tool fields will automatically be filled in with the current tool loaded. If a different tool is to be used, enter a Set Tool step prior to this program step.  You can tilt a rectangular slot by identifying a tilt angle. Highlight the Angle field and enter an angle measured from the X axis.
Page 177: Circular Milling Functions
CCW soft key for a counter-clockwise cutting direction.  The Tool fields will automatically be filled in with the current tool loaded.  Enter the Z axis Feed Rate. The last feed rate used previously in the program will be displayed. ACU-RITE MILLPWR...
Page 178  ARROW DOWN or press the More soft key.  The Finish fields will assume the same as the previous finish fields in the program if it exists. Otherwise this data must be added if required, or leave it blank if not required. ...
Page 179: Circle Frame
 Select the Offset from the drop down menu, or the soft keys Left, Center, Right, Inside, Outside.  Enter the Z axis Feed Rate. The last feed rate used previously in the program will be displayed. ACU-RITE MILLPWR...
Page 180  ARROW DOWN or press the More soft key.  The Finish and Feed fields will assume the same as the previous finish fields in the program if it exists. Otherwise this data must be added if required, or leave it blank if not required. ...
Page 181: Circle Ring
CCW soft key for a counter-clockwise cutting direction.  The Tool fields will automatically be filled in with the current tool loaded.  Enter the Z axis Feed rate. The last Feed rate used previously in the program will be displayed. ACU-RITE MILLPWR...
Page 182  ARROW DOWN or press the More soft key.  The Finish and Feed fields will assume the same as the previous finish fields in the program if it exists. Otherwise this data must be added if required, or leave it blank if not required. ...
Page 183: Circle Helix
(3 o’clock position is 0 degrees; 12 o’clock position is 90 degrees).  Press the USE key. If the tool size and type listed in the Tool field are incorrect, change the tool settings before running your program. ACU-RITE MILLPWR...
Page 184: Radial Slot
Radial slot A radial slot can be defined one way:  By the center, radius, start angle, and sweep angle. To program a radial slot:  From the PGM screen, press the CIRCLE key to access the Circle popup Menu. ...
Page 185: Hole Patterns
To program a row of holes: MILLPWR includes several built-in routines that let you program hole patterns quickly and easily  From the PGM screen, press the HOLES key to access the HOLES popup Menu. ACU-RITE MILLPWR...
Page 186 Entering data:  Select the Row of Holes from the popup menu.  In the From field, enter the X and Y axes coordinates for the center of the first hole and ARROW DOWN to the next field.  Now either: Enter the X and Y axes coordinates for the center of the last hole in the To field;...
Page 187: Hole Frame And Array
You’ll also be prompted for Peck and Tool Retract values. Peck lets you break chips and reduce chip buildup during drilling operations. Tool Retract allows you to program MILLPWR to raise the tool at regular intervals. ACU-RITE MILLPWR...
Page 188 Entering data:  From the PGM screen, press the HOLES key to access the HOLES popup Menu.  Select the Rectangle Array from the popup Menu.  Enter the 1st Corner X1 and Y1 axes coordinates.  Now enter either the Size of the array or the 2 Corner coordinates.
Page 189: Bolt Circle Patterns
The Tool Retract and Tool Dwell fields are optional.  The Tool field enters the current tool selected as reference information. To use a different tool, that tool has to be entered as the current tool.  Press the USE key. ACU-RITE MILLPWR...
Page 190: 8.2 Additional Milling Functions
8.2 Additional Milling Functions Step functions soft key Additional functions are available from the PGM screen by pressing the Step Functions soft key. Explode  When in PGM mode there are certain functions that can be exploded. Pressing the Explode soft key will explode a program step into several, more detailed steps.
Page 191: Reverse Step
From PGM mode, highlight any step within the continuous tool path that you want to reverse.  Press the Step Functions soft key.  Press the Reverse Path soft key. The original steps are replaced with steps in the reverse order. ACU-RITE MILLPWR...
Page 192: Change Steps
Change steps The Change Steps feature gives you the ability to change or edit the depth, offset and feed rate of several steps simultaneously.  You can use this feature from anywhere within your program and does not require the specific step to be highlighted. To Change Steps: ...
Page 193: Delete Steps
 Press either the Move Or Copy soft key. Make sure the desired location is selected in the program or, use Paste Location to select where to move or copy the steps.  Press the USE key. ACU-RITE MILLPWR...
Page 194: Custom Pockets
Custom pockets A custom pocket step must immediately follow a closed contour. You can create a custom pocket from any closed contour. A closed contour is any shape consisting of lines, arcs, and/or blends (or chamfer), where the last step ends at the same point where the first step begins.
Page 195: Island
The CW/CCW direction of roughing passes is determined by the direction of the profile formed by the custom pocket.  The XY step size is determined by the system and will not exceed the specified percentage of the tool diameter. ACU-RITE MILLPWR...
Page 196  The percentage must be 50% or less. This is required to make sure that all material is removed.  The pocket is machined at the feed rate programmed in the custom pocket step. When the tool makes a cut greater than the step over, the full cut override is applied to the feed.
Page 197: Advanced Custom Pocket Machining
Press the Custom Pocket soft key.  Select Pilot Drill in the popup menu.  Enter either the number of pecks or the distance between each peck.  Enter the Z axis feed rate.  Press the USE key. ACU-RITE MILLPWR...
Page 198: Rough Milling
Rough Milling It is possible to rough mill a custom pocket with multiple tools, starting with a larger tool to remove large amounts of material quickly followed by smaller tools to remove material inaccessible to the previous tool. Each subsequent tool change and rough mill cycle only removes the material left by the previous coarse tool.
Page 199: Bottom Finishing
Enter the Z axis feed rate.  Enter the table's finish feed rate.  For Direction, press either the CW or CCW soft key. The direction is applied specifically to the bottom finish operation.  Press the USE key. ACU-RITE MILLPWR...
Page 200: Side Finishing
Side Finishing The Side finish step removes material from the side wall of the custom pocket. It is possible to program multiple tool change and side finish steps Side Finish steps are programmed after the Bottom Finish step. To program a side finishing operation: ...
Page 201: Repeat, Rotate
Enter the X and Y axes coordinates for the Center point of rotation.  Enter the Z offset.  Enter the angle for each rotation in the Angle field.  Enter the number of times required to rotate the original steps.  Press the USE key. ACU-RITE MILLPWR...
Page 202: Mirror
Footer note for Repeat and Rotate When running a program at the point of executing a Repeat or Rotate, the footer in the program list view will display the line number, step type, and iteration of the step. Mirror  The steps being mirrored must precede the Mirror step.
Page 203: Engrave Line
 Select the Modifier as either the Normal or Mirrored soft key. Normal is readable from left to right; Mirrored will make the engraving appear backwards.  Enter the table’s feed rate.  Press the USE key. ACU-RITE MILLPWR...
Page 204: Engrave Arc
Engrave arc All ASCII characters within the range of x032 - x126 are allowed, which includes Uppercase, Lowercase, Numbers, and Punctuation.  From the PGM screen, press the Program Steps soft key.  Then press the Other Steps soft key. ...
Page 205: Comment Step
AMI. Select from the Off, On, and Pulsed soft keys for each. When Pulsed is selected, another field allows the duration of the pulse length to be entered in seconds. Enter the required time. The range is 0.1 to 999.9. ACU-RITE MILLPWR...
Page 206 Position Description The AMI output contacts will switch to an energized state. The AMI output contacts will switch to their default states. The AMI output contacts will switch to an energized PULSED state for the length of time that is defined. Display The AMI allows the operator to pause the step User...
Page 207: Dwell
Other Steps soft key.  Press the Reference Point in the popup Menu.  Enter your reference point’s position for X, Y and Z.  Press the USE key. The reference point will show graphically at the programmed location. ACU-RITE MILLPWR...
Page 208 8 Milling and Drilling...
Page 209 Geometry/RPM Calculator...
Page 210: 9.1 Geometry Calculator
9.1 Geometry Calculator Overview The MILLPWR geometry calculator is used to construct Point/Line/ Arc entities which can then be transferred to the part program. MILLPWR built-in calculator is capable of handling everything from simple arithmetic to complex trigonometry, geometry, and RPM calculations.
Page 211: Geometry Calculator Layout
(0,0). A ruler is also shown.  Highlight features:  Focus feature – Blue  Selected features – White  New features – Green  Normal features – Yellow  A GeoPoint is displayed as a crosshair (×). ACU-RITE MILLPWR...
Page 212: 9.2 Geometry User Interface
9.2 Geometry User Interface Adding geometry features to listing Geometry steps are limited to GeoPoints, GeoLines, and GeoArcs. A new step is added by pressing the POINT, LINE, or ARC key. As with a part program, the new step is added before the currently highlighted geo step GeoPoint ...
Page 213 2 Arcs Intersection points. Lines tangent to arcs; shortest line Given a radius, all arcs tangent to between arcs. both arcs. ACU-RITE MILLPWR...
Page 214: Managing Geometry Results
Some operations require entry of additional information (distance, angle, or radius). If needed, the user is prompted to enter a value by displaying a dialogue with fields that require additional data. If the field is left blank, the data is calculated automatically.
Page 215: Returning Features To The Part Program
 Hole patterns are converted to a series of GeoPoints.  Rectangle and circle steps are converted to profile GeoLines and GeoArcs  All other steps (tool, replication, engrave, etc.) are not supported ACU-RITE MILLPWR...
Page 216: Program Example
Program example In some cases, a part drawing may not provide all of the dimensions needed to program the part. In the following illustration the coordinates of points B and C, where the arc is tangent to the sides, are unknown. The coordinates will have to be identified before lines A-B and A-C and the arc that extends from point B to point C can be programmed.
Page 217: Step 2
From Y1 field.  Enter 0 in the To X2 field, and 0 in the Y2 field.  Press the USE key to enter the data into the program. The Geometry Calculator screen should now have these two lines displayed. ACU-RITE MILLPWR...
Page 218: Step 3
Step 3 Finding the arc that’s tangent to the two lines.  Highlight 001 GeoLine and press the Select Feature soft key. The ARROW indicates that the feature has been selected.  Next, highlight 002 GeoLine and press the Select Feature soft key.
Page 219: Finding The Points Of Tangency
Highlight the GeoPoint representing point B (step 004). Press the Return Feature soft key. The program screen will return, and point B’s coordinates will appear in the To field.  Press the USE key to accept the line into the part program. ACU-RITE MILLPWR...
Page 220: Returning The Arc Feature
Returning the arc feature  Press the CALC key.  Press the Geometry soft key.  Highlight the GeoArc (step 003). Press the Return Feature soft key. The program screen will return and automatically add an arc step to your program and place the arc's information into the dialogue.
Page 221: 9.3 Rpm Calculator
Inch and MM.  Enter the surface speed for the material and cutter type in the Surface Speed field.  MILLPWR will calculate the RPM.  Press the CANCEL key to return to the program. ACU-RITE MILLPWR...
Page 222 9 Geometry/RPM Calculator...
Page 223: Setup
Setup...
Page 224: Overview
10.1 Setup Overview The MILLPWR has a set of parameters that can be setup as default values. Some of these values can be over-ridden per the program step dialogue, while others remain in affect until changed in the Job Setup dialogue.
Page 225: Job Setup
This defines the step over amount for milling pockets as either a percentage of the tool’s diameter or as a distance.  For Angles: The setting can either be in Degrees or DMS.  For Res. Inch and Res. MM: Select the desired display resolution for the DRO display. ACU-RITE MILLPWR...
Page 226: Scale Factor
 Manual Z: Defines the action the DRO takes when a running program encounters a manual Z operation. The default is Switch to Inc which switches the DRO to INC mode. The alternative is Do Nothing which performs no action, leaving the DRO in whatever mode the user has it in.
Page 227: Feed Rate
Job Setup.  Highlight the Graphics field and set to either On to always show the field graphic assistant in a step form or set to Automatic for displaying additional fields when available in place of the graphic assistant. ACU-RITE MILLPWR...
Page 228: Job Clock - Parts Counter
Job clock - parts counter The parts counter appears on the status bar when in DRO mode, or running a program. This is useful to track how many times the current program has run and therefore how many parts have been completed. Here, setting the parts counter, stopping or starting the Job Clock are setup.
Page 229: Tool Table
Pressing the Delete soft key will only exit the dialogue if there was only one error message.  To exit the Message Log, press the Exit soft key. A quick method for clearing all messages in the log is to press the “0” on the numeric keypad. ACU-RITE MILLPWR...
Page 230: Service Files
Service files Occasionally, it may be necessary to provide HEIDENHAIN Corporation with diagnostic files to document or troubleshoot a problem with the machine or user experience. These are known as Service Files.  The service files are created by pressing the Log Files soft key and then pressing the Service Files soft key (accept the default name and press the OK soft key).
Page 231: Auxiliary Machine Interface (Ami)
Auxiliary Machine Interface (AMI)
Page 232: Machine Functions Menu
11.1 Auxiliary Machine Interface (AMI) Machine Functions Menu The MILLPWR software can be configured to access the Machine Functions menu. This menu includes a set of soft keys that provide manual access, and control of some features specific to AMI The machine tool builder enables the soft keys when the AMI configured.
Page 233 Software Update...
Page 234: Software Update
12.1 Updating System Software Software update If desired as a precautionary method, a backup of the control's internal drive can be made prior to updating the system software, by using the included USB Recovery Drive (1127022-xx). Please refer to the manual included with the drive for the backup procedure.
Page 235 Off-Line Software...
Page 236: Millpwr G2 Off-Line Software
13.1 MILLPWR Off-Line Software Off-line simulator The off-line software provides a convenient way to write part ® programs and simulate machine behavior using a standard Windows computer. Features and functionality are virtually identical to that of the MILLPWR control itself. System requirements ...
Page 237: Installation
Start menu. Normal shutdown procedure should be used unless the force quit method is absolutely required. Programs created in the off-line software can be copied to the CNC, and (with the correct setup) run on your machine. ACU-RITE MILLPWR...
Page 238: On Screen Keypad
Likewise, if necessary, the keypad application can be manually started using the "Launch Keypad" shortcut located in the Windows® Start Menu, under All Programs - ACU-RITE - MillPWR Off-Line. Keyboard shortcuts The keys on the MILLPWR keypad can be simulated using the key combinations described below.
Page 239 Alt + Enter (Configuration menu) Alt + K (Calculator) F12 (Plus/Minus Toggle) F12 (Plus/Minus Toggle) Esc (Cancel) Del (Clear) Alt + Enter (Use) Enter (Enter) Alt + J (Press once: Pause / Press Twice: Stop) Alt + S (Go) ACU-RITE MILLPWR...
Page 240: Updating
Soft keys Shortcut Numeric, and ARROW keys: The ARROW keys on a standard PC keyboard will simulate the console ARROW keys, and the number keys will simulate the console number keys (using number lock). When number lock is turned off, the ARROW keys on the number keys (2, 4, 8, 6) will simulate the console ARROW keys.
Page 241 NC software number 6 Editing the tool table 70 Sin 64 New functions of software 7 Electronic Edge Finder 57 Square 64 Numerical keys 2 Error Log 229 Square Root 64 E-STOP and Shutdown 26 Tan 64 E-Stop button 26 ACU-RITE MILLPWR...
Page 242 Clear Program 82 Program Functions 82 Teach Position 56 Change Window 83 Tool Table 68 Exit 83 Tool Table Structure 71 Folder View 83 Tool-Length Offsets 72 Function 83 Load 83 USB Access 93 Program Type 83 Save 83 Writing Programs Overview 30 Select 83 Program Steps 82 Circle 89...
Page 244 HEIDENHAIN CORPORATION 333 East State Parkway Schaumburg, IL 60173-5337 USA +1 (847) 490-1191 +1 (847) 490-3931 E-Mail: info@heidenhain.com www.heidenhain.com 1034384-2E · Ver 14 · Printed in USA...

ACU-RITE MILLPWR G2 User Manual

Manual Information

MILLPWR Access Code

MILLPWR G2 Access Code

Millpwr G2

Operating in 2 Axes and 3 Axes Modes

1.3 Console

1.4 Operating Mode Screens

1.5 Accessories

2.1 Conventions

2.2 Manual Machine Positioning

3.1 DRO Manual Data Input

3.2 Calculator

Tool Table

4.2 Tool Data

5.1 Programming Introduction

5.2 Program Mode Functions

5.3 Creating Programs Overview

6.1 Conversational Programming

Folders

Demonstration Program

Milling and Drilling

8.2 Additional Milling Functions

9.1 Geometry Calculator

9.2 Geometry User Interface

Quick Links

Need help?

Questions and answers

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Summary of Contents for ACU-RITE MILLPWR G2