ACU-RITE MILLPWR G2 User manual

Technical Manual
ACU-RITE
®
MILLPWR
G2

3
Table of Contents
1 Update Information
1.1 General Information ............................................................................13
2Introduction
2.1 Meaning of the Symbols Used in this Manual ....................................15
2.2 Proper Operation.................................................................................15
2.3 Trained Personnel ...............................................................................15
2.4 Grounding, and Connections...............................................................15
2.5 General Information ............................................................................16
2.6 Overview of Components...................................................................17
2.6.1 MILLPWRG2 Control ..............................................................17
2.6.2 Keys on visual display unit .....................................................18
Power control keys...........................................................18
Data Entry keys ................................................................18
Function keys ...................................................................18
Numerical keys.................................................................19
Axis Keys..........................................................................19
Soft Keys ..........................................................................19
2.6.3 Navigation keys......................................................................20
2.6.4 Calculator Function keys........................................................20
2.6.5 Potentiometer for feed rate ...................................................20
2.6.6 Milling Function keys .............................................................21
2.6.7 Peripherals Supported:...........................................................21
2.6.8 Touch Probe Systems............................................................22
2.6.9 Documentation ......................................................................24
2.7 Brief Description .................................................................................25
Accessories ......................................................................29
Software options ..............................................................29
2.8 Software..............................................................................................30
2.8.1 Designation of the Software..................................................30
Type..................................................................................30
2.8.2 PLC Software.........................................................................30
2.8.3 Enabling Software Options ....................................................30
Enabling software options................................................31
2.8.4 Updating Software.................................................................32
2.8.5 Procedure for updating the software.....................................33
2.8.6 Data Backup...........................................................................34
2.9 Software Releases..............................................................................34
2.9.1 NC Software 751 005-xx........................................................34
NC software
751 005-01........................................................................34
2.10 PC Software Utilities ..........................................................................35
2.10.1 Support ..................................................................................35
2.10.2 Management:.........................................................................39
2.11 Save Service Files ...............................................................................39

4 ACU-RITE Technical Manual MILLPWRG2
3 Mounting and Electrical Installation
3.1 General Information ............................................................................41
3.1.1 Safety Precautions.................................................................41
3.1.2 Degrees of Protection............................................................42
3.1.3 Electromagnetic Compatibility ...............................................42
Likely sources of interference ..........................................42
Protective measures.........................................................42
3.2 Environmental Conditions ...................................................................43
3.2.1 Storage and operating temperatures .....................................43
Limit values ......................................................................43
Limit value for temperature inside the console................43
Humidity during operation ................................................44
Storage temperatures.......................................................44
3.2.2 Heat generation and cooling ..................................................44
3.2.3 Installation elevation ..............................................................44
3.2.4 Mechanical Vibration..............................................................44
3.3 Console Back Panel.............................................................................45
3.4 Power Supply......................................................................................46
3.5 Buffer Battery......................................................................................47
3.6 Encoder Connections .........................................................................48
3.6.1 General Information ...............................................................48
3.7 Touch Probe Systems.........................................................................48
3.7.1 Triggering Touch Probe for Workpiece Measurement...........49
Touch probe connection...................................................49
3.8 Data Interfaces....................................................................................51
General information..........................................................51
3.8.1 Ethernet interface RJ45 connection ......................................52
3.8.2 RS-232-C/V.24........................................................................53
Data Interface...................................................................53
3.8.3 USB Interface.........................................................................54
Front/Rear panel ...............................................................54
USB hub ...........................................................................54
3.9 Cable Specifications............................................................................55
3.10 Dimensions .........................................................................................56
3.10.1 MILLPWRG2...........................................................................56
3.10.2 Adapter Block for the Data Interface .....................................57
3.10.3 USB Hub ................................................................................58
3.10.4 Touch Probe Systems............................................................59
Adapter cable for TS.........................................................59
TS 220 ..............................................................................60
Adapter cable for TS 120/TS 220......................................60
SE 640 transmitter-receiver unit.......................................61
SE 540 transmitter-receiver unit.......................................62
TS 440 ..............................................................................63
TS 640 ..............................................................................63

5
4 Machine Parameters
4.1 General Information ............................................................................65
4.2 Managing Parameters.........................................................................67
4.2.1 Entering and Editing Machine Parameters.............................67
Icons in the object tree....................................................68
Displaying help texts........................................................70
Entering and editing parameters ......................................71
Limit values ......................................................................71
Copy/Paste value function in ConfigEditor .......................71
Deleting objects................................................................71
Inserting and copying objects...........................................71
Changing key names .......................................................72
Saving input values...........................................................72
Find function.....................................................................73
Finish editing ....................................................................75
4.2.2 Managing Configuration Files ................................................75
4.2.3 Sort File Content....................................................................75
4.2.4 Attribute Information..............................................................76
Access rights....................................................................76
Reaction to change...........................................................77
4.2.5 Update Rules .........................................................................77
4.2.6 Remove Syntax Error.............................................................78
4.2.7 Reset Update Version............................................................78
4.2.8 Backup of Parameters............................................................79
4.3 Allocation of Configuration Data .........................................................81
3-axis system ...................................................................82
Multiple variants ...............................................................82
4.4 Structure of a Parameter File ..............................................................83
Rules for entries ...............................................................83
4.5 Machine Parameter Subfiles...............................................................85
4.5.1 Syntax of MP Subfile .............................................................85
4.5.2 Activating MP Subfiles...........................................................85
Activation in the configuration editor................................85
Activation by the PLC .......................................................87
4.5.3 Displaying/Editing Data Records in the Configuration
Editor88
Basic data .........................................................................89
Loaded subfile(s) ..............................................................89
Temporary data.................................................................89
Effective data....................................................................89
Unload subfile...................................................................89
4.6 Read or Change Machine Parameters via a PLC Module ...................90
4.7 Overview of the Machine Parameters ................................................93
4.7.1 "System" group.......................................................................93
"Channels" group.............................................................181
"Axes" group ...................................................................201
KeySynonym...................................................................241
4.7.2 UserSetup Parameters.........................................................241

6 ACU-RITE Technical Manual MILLPWRG2
5 Configuring the Axes
5.1 Software Version...............................................................................245
5.2 Machine Structure.............................................................................246
5.2.1 Adapting the Control to the Machine Structure...................246
5.2.2 Definition of Axes ................................................................247
Defining the logical axes................................................247
Special kinematics axes.................................................249
5.3 Configuration of Machining Channels ...............................................250
5.3.1 Configuring a Machining Channel ........................................250
Type of NC channel ........................................................250
Axes of machining channel.............................................251
Kinematics of machining channel...................................251
Error behavior of machining channel ..............................252
5.3.2 Traversing the Reference Marks..........................................253
5.3.3 Moving to Restore Position .................................................254
5.4 Configuration of Axes........................................................................255
5.4.1 Axis Designations and Coordinates .....................................256
Properties of
the principal
axes X, Y, Z.....................................................................256
Algebraic signs
of the axes......................................................................256
Standard coordinates......................................................257
5.4.2 Programmable Axes.............................................................258
Index for SysRead and SysWrite....................................259
Axis without a separate drive motor...............................259
5.4.3 Physical Axes.......................................................................260
Activate axis ...................................................................261
Assigning parameter blocks ..........................................262
Virtual axis ......................................................................262
5.4.4 Kinematics Properties of Axes.............................................263
5.4.5 2 Axis System.....................................................................264
5.5 Encoders ...........................................................................................265
5.5.1 Type of Encoder...................................................................265
Signal period...................................................................267
5.5.2 Distance-Coded Reference Marks.......................................269
5.5.3 Encoder Connections...........................................................270
Position encoder input...................................................270
Position encoder signal..................................................271
5.5.4 Defining the Traverse Direction ...........................................273
5.5.5 Encoder Monitoring .............................................................274
Position encoder.............................................................274
5.6 Analog Axes ......................................................................................276
Analog output .................................................................276
Rapid traverse for analog axes .......................................277
5.7 Reading Axis Information..................................................................278
Reading the axis coordinates..........................................279
5.8 Traverse Ranges ...............................................................................280
5.9 Controlling Axes by PLC....................................................................281
Positioning of axes by PLC ............................................281

7
5.10 Axis Error Compensation ..................................................................284
5.10.1 Backlash Compensation.......................................................285
5.10.2 Linear Axis Error Compensation ..........................................287
5.10.3 Nonlinear Axis Error Compensation .....................................289
Compensation value tables ............................................291
Entering compensation values .......................................292
Importing data from calibration software: ......................293
Assigning the compensation value tables to the axes...293
Activate error compensation ..........................................294
5.10.4 Compensation of Thermal Expansion ..................................297
5.11 Machine Kinematics..........................................................................299
5.11.1 Configuration of the Machine Kinematics............................299
Configuration of the machine kinematics .......................299
5.12 Reference Marks...............................................................................308
5.12.1 Definition..............................................................................308
5.12.2 Traversing the Reference Marks..........................................309
Distance between the scale reference point and
the machine datum.........................................................309
Renewed traversing of the reference marks..................310
5.12.3 Defining the Process of Traversing the Reference
Marks311
Direction and velocity ....................................................312
Position encoder with distance-coded reference marks 313
Position encoder with one reference mark ....................314
Linear measurement through rotary encoder.................315
5.12.4 “Pass Over Reference Point” Mode of Operation ..............317
Reference end position ..................................................317
Machine datum...............................................................318
Positioning after reference mark traverse ......................318
5.13 The Control Loop...............................................................................319
5.13.1 Relation Between Jerk, Acceleration, Velocity and
Distance320
Acceleration and jerk .....................................................320
Distance..........................................................................321
5.13.2 Geometry Filter....................................................................322
5.13.3 Look-Ahead..........................................................................324
Contour smoothing.........................................................325
Path- specific limit values ..............................................326
Axis-specific limit values................................................329
Tolerance for corners and arcs .......................................331
5.13.4 Interpolator...........................................................................332
5.13.5 Filter before Position Control Loop ......................................333
Configuration of filters ...................................................333
Function of the filters before the position control loop ..335
5.13.6 Position Controller................................................................338
Feedback control ............................................................339
Feedback control with following error ...........................340
Interrelation of kvfactor, feed rate, and following error .341
Limiting of controller output ...........................................341
Feedback control with velocity feedforward ..................342
Rapid traverse and feed rate limitation...........................344
Feed rate values in PLC operands..................................344

8 ACU-RITE Technical Manual MILLPWRG2
5.13.7 Activating and Deactivating Position Control Loops ............346
Opening the position control loop..................................346
Clamping the axes..........................................................347
Actual-to-nominal value transfer.....................................348
5.13.8 Feed-Rate Enable.................................................................349
5.13.9 Controller Parameters for Manual Traverse.........................350
Filter before position control loop..................................350
5.13.10 Controller Parameters for Analog Axes................................351
General information........................................................351
Characteristic curve kink point (only for analog axes).....352
Acceleration feedforward control for analog axes..........353
Compensation of reversal peaks for analog axes...........353
Compensation of reversal peaks ....................................356
Analog offset ..................................................................358
Position loop resolution for analog axes.........................359
5.13.11 Switching Parameter Blocks................................................360
5.14 Monitoring Functions ........................................................................362
5.14.1 Monitoring the Drives ..........................................................362
Switching off monitoring functions globally ...................362
Switching off monitoring functions for individual axes...363
5.14.2 Position Monitoring..............................................................364
Clamped axes, hanging axes..........................................366
Difference between position at switch-on and
shutdown .......................................................................366
5.14.3 Movement Monitoring.........................................................367
5.14.4 Standstill Monitoring............................................................369
5.14.5 Positioning Window.............................................................370
Axes in position ..............................................................371
Axes in motion................................................................372
5.14.6 Temperature Monitoring......................................................373
Temperature of the MC.................................................373
Interrogate the values of the internal ADCs ...................373
5.14.7 Momentary Utilization of Drive Motors................................374
5.14.8 EMERGENCY STOP Monitoring ..........................................376
Flowcharts......................................................................377
5.15 Integrated Oscilloscope ....................................................................378
5.15.1 Fundamentals ......................................................................378
Overview of signals........................................................378
Sampling rate..................................................................379
5.15.2 Prepare Recording ...............................................................380
Setup for analog signals.................................................380
Setup for
digital signals ..................................................................383
5.15.3 Record Signals .....................................................................384
Starting and stopping the recording ...............................384
Trigger conditions...........................................................385
5.15.4 Analyze Recording ...............................................................386
Recording
completed.......................................................................386
Changing the display......................................................387
Analyze an individual analog signal ................................387
Influence the signal display............................................387
Second cursor.................................................................388

9
5.15.5 Saving and Loading Recordings...........................................388
5.15.6 Configure the Colors of the Oscilloscope Display................389
6 Machine Integration
6.1 Software Version...............................................................................393
6.2 Display and Operation.......................................................................394
6.2.1 Position and Status Display..................................................394
6.2.2 Unit of Measurement for Display and Operation .................395
6.2.3 Decimal Separator................................................................395
6.3 Switching the Control On/Off............................................................397
6.3.1 Powering Up the Control .....................................................397
Message for power interruption.....................................397
Customer-specific logo...................................................398
Starting the control with empty PLC partition ................399
6.3.2 Shutting Down the Control ..................................................400
6.3.3 System Language ................................................................405
6.3.4 Programming station mode..............................................407
6.4 Control Operation in the Operating Mode Group..............................409
Modes of operation ........................................................409
Start/stop of the machining channels.............................410
Reaction to errors...........................................................410
6.5 Control Operation in the Machining Channel ....................................411
6.5.1 Channel-Specific Settings ....................................................411
Arc End-Point Tolerance .................................................411
Retract tool at NC stop...................................................412
6.5.2 NC Program Run ..................................................................413
Starting an NC program .................................................413
Automatic NC program start...........................................414
Terminating the
NC program ....................................................................416
Interrupting an
NC program ....................................................................416
Moving the axes during program interruption ................418
NC program cancellation ................................................418
Block scan (start block search) .......................................419
Finding the NC program and block number....................419
Control in operation ........................................................419
M, S or T function in parallel with traverse motion.........420
6.5.3 Error Status..........................................................................421
6.5.4 Assignments in Manual Modes of Operation ......................422
6.6 Error Messages and Log Files...........................................................423
6.6.1 Error Log ..............................................................................423
Deleting errors................................................................424
6.6.2 Error Log File........................................................................426
Current and previous error
log file.............................................................................427
Filter................................................................................427
6.6.3 Keystroke Log File ...............................................................429
Current and previous keystroke log file..........................430
6.6.4 Saving Service Files .............................................................431
6.6.5 PLC Error Messages............................................................432

10 ACU-RITE Technical Manual MILLPWRG2
PET table (PLC Error Table) ............................................432
Error text file...................................................................433
Structure of the
PET table ........................................................................433
Structure of the error text file.........................................434
Entering data in
log files ...........................................................................439
6.7 Keystroke Simulation ........................................................................441
6.7.1 Control Keyboard .................................................................441
Codes for keystroke simulation......................................447
6.8 Override ............................................................................................449
6.8.1 Override Devices .................................................................449
6.8.2 Compensation for Potentiometers.......................................451
6.8.3 Override Functions...............................................................452
Speed override ...............................................................452
Feedrate override ...........................................................453
Rapid traverse override...................................................455
6.9 Incremental Jog Positioning..............................................................456
6.10 Operating Times and System Times.................................................458
6.10.1 Measuring Operating Times ................................................458
6.10.2 System Time........................................................................463
Accessing the System Date and Time Dialog ................463
Changing the System Date and Time.............................463
6.11 Touch Probe......................................................................................465
Selection of the touch probe ..........................................465
6.11.1 Using the Touch Probes.......................................................466
TS 440, TS 640 ...............................................................466
Maximum probing feed rate...........................................467
6.12 Diagnosis with the Online Monitor (OLM) ........................................469
6.12.1 Introduction..........................................................................469
Software structure..........................................................469
6.12.2 Operation of the OLM..........................................................470
Keyboard and display......................................................470
Starting and exiting the OLM .........................................470
6.12.3 Screen Layout......................................................................471
Variable Display ..............................................................471
Units ...............................................................................472
Status display .................................................................473
6.12.4 Selecting Axes and Channels...............................................474
6.12.5 Group of NC Axes................................................................474
Nominal commands of the PLC (Plc Nom Data).............474
IPO-internal variables (Ipo Act Data)...............................475
Internal working data of PLC-IPO
(Plc Ipo Data) ..................................................................478
Data from the IpoOffset module (Offset Data)...............481
Nominal status of the axes (Plc Nom State)...................483
Actual status 1 of the axes (Ipo Act State 1) ..................484
Actual status 2 of the axes (Ipo Act State 2) ..................486
Deleting the following error (Clear PeakLag)..................488
Deleting the reference point (Clear RefOk) ....................488

11
6.12.6 Group of NC Channels .........................................................489
Data of the interpolator module (Ipo Data) .....................489
Internal data of the offset interface (Offset Data) ..........492
Current status of the channel (Act State) .......................493
6.12.7 Hardware Group...................................................................494
Data of the static RAM (S-RAM).....................................494
Data of the analog outputs (Analog Output)...................494
Counter function blocks of the MILLPWRG2 (GAL Data)495
Hardware port states (HW ports) ...................................496
6.12.8 Auxiliary Group.....................................................................498
Enabling debug outputs (Get(Set DebugPrint)................498
Generating error messages (Set Error)...........................501
6.12.9 PLC Group............................................................................502
Displaying the values of the analog-to-digital converter .502
Plc trace..........................................................................504
PLC Trace on/off.............................................................504
Plc-Trace Save ................................................................504
6.12.10 Queue-Trace ........................................................................505
Activating a Q Trace .......................................................506
Deleting Trace information .............................................506
6.12.11 Frequent Causes of Error.....................................................507
Servo drive cannot be switched on ................................507
Servo drive does not move.............................................508
7 Data Interfaces
7.1 Introduction.......................................................................................509
7.2 The Ethernet Interface ......................................................................511
Ethernet interface RJ45 connection
(100BaseT)......................................................................511
7.3 Connecting to the Network...............................................................512
7.3.1 Configuring the Network Settings .......................................512
DHCP..............................................................................513
Static IP Address ............................................................514
7.3.2 Configuring Access to a Network Share..............................515
7.4 The USB 2.0 Interface.......................................................................517
Structure.........................................................................518
Functionality and signal designations .............................519
USB devices
on the control .................................................................519
7.5 The Serial Interface ...........................................................................520
7.5.1 RS-232-C/V.24 Interface.......................................................520
Hardware........................................................................520
Signal levels....................................................................521
Signal designations.........................................................522
Pin layout........................................................................522
7.6 Configuring the Serial Interface.........................................................523
7.6.1 Control Characters ...............................................................523
7.6.2 Configuration of Interfaces ..................................................524
Selecting a parameter block ...........................................524
Creating parameter blocks, configuring interface ports..526
Defining the LSV2 baud rate...........................................526

12 ACU-RITE Technical Manual MILLPWRG2
Data transfer rate
Baud rate ........................................................................527
Communications protocol...............................................528
Word length
Data bits .........................................................................528
Transmission reliability
Parity bit..........................................................................529
Synchronization:
Stop bits .........................................................................530
Data transfer check: Handshaking..................................530
Hardware handshaking...................................................531
Software handshaking....................................................532
Defining the
file system......................................................................533
Block Check Character (BCC) .........................................534
7.7 Serial Data Transmission Protocols...................................................535
7.7.1 Standard Communications Protocol.....................................535
General information........................................................535
Output selected file........................................................536
Download selected file ..................................................536
7.7.2 Communications Protocol with Block Check Character.......537
Header............................................................................537
Block Check Character (BCC) .........................................537
Handshaking...................................................................538
Report an error
to the control ..................................................................539
Request external directory .............................................539
Output selected file........................................................540
Output marked files........................................................540
Download
selected file ....................................................................540
7.7.3 LSV2 Transmission Protocol ................................................541
7.8 Saving and Downloading Files ..........................................................542

1.1 General Information 13
1 Update Information
1.1 General Information
Future updates to hardware and software are documented in this section.

14 ACU-RITE Technical Manual MILLPWRG2

2.4 Grounding, and Connections 15
2 Introduction
2.1 Meaning of the Symbols Used in this Manual
2.2 Proper Operation
The described components may only be installed and operated as described
in this manual. Commissioning, maintenance, inspection and operation are
only to be performed by trained personnel.
2.3 Trained Personnel
Trained personnel in the sense of this manual means persons who are familiar
with the installation, mounting, commissioning, and operation of the
HEIDENHAIN components. Furthermore, electrical engineering work on the
system may be carried out only by trained electrical engineering technicians or
persons trained specifically for the respective application. Basically, persons
who perform work on HEIDENHAIN components must meet the following
requirements:
They must have been trained or instructed in the standards of safety engi-
neering.
They must have appropriate safety equipment (clothing, measuring
systems).
They should be skilled in first-aid practice.
2.4 Grounding, and Connections
See Chapter 4 of the Installation Manual (I.D. 1034382-20) for wiring, and
connection diagrams.
Danger
Failure to comply with this information could result in most serious up to
fatal injuries or in substantial material damage.
Attention
Failure to comply with this information could result in injuries and
interruptions of operation up to material damage.
Note
Insights for operation as well as important information, for example about
standards and regulations as well as for better understanding of the
document.

16 ACU-RITE Technical Manual MILLPWRG2
2.5 General Information
The MILLPWRG2 is a compact contouring control with three (optionally two)
analog controlled axes designed for use with milling, drilling, and boring
machines.
The workshop-oriented programmability in ACU-RITE conversational format
makes the MILLPWRG2 the ideal choice for your drilling and milling
applications. Many canned cycles, programming features and expansion
capabilities are available for daily work with the MILLPWRG2.
The MILLPWRG2 is based on the HEIDENHAIN NCK software platform.
The compact main computer takes up very little space as it is housed directly
behind the 12.1" display. This provides a highly integrated assembly with
reduced wiring for high reliability, ease of installation and service.
Note
For more information on usage please refer to the user's manual
(Id. Nr. 1034384-20).

2.6 Overview of Components 17
2.6 Overview of Components
2.6.1 MILLPWRG2 Control
MILLPWRG2
Arm˜mount compact contouring
control with integrated main
computer, flat-panel LCD display
and integrated operating keys.
3 analog closed-loop axes
(1 VPP or EnDat).
Up-to 4 encoder inputs.
Analog nominal-value to servo
drives.
2x USB 2.0 ports.
1x RS-232C.
1GHz Celeron M Processor.
1GB DRAM.
12.1" XGA resolution TFT LCD.
Integrated keyboard.
Id. Nr. 654 461-xx
CFR memory card Id. Nr.
Compactflash memory card for MILLPWRG2,
contains MILLPWRG2 software, no export license
required.
654 255-xx

18 ACU-RITE Technical Manual MILLPWRG2
2.6.2 Keys on visual display unit
Power control keys
Data Entry keys
Function keys
Key Function
Go key (e.g. run a program).
Stop key (duel function: press once to
pause, press twice to stop a program).
Key Function
cancel key cancels operation, i.e. form.
clear key clears selections, i.e. values,
program step.
use key completes operation, i.e. data
form.
Enter key completes selection, i.e.
values, data entered.
Key Function
ABS/INCR key toggles between
Absolute or Incremental positioning.
DRO/PGM key toggles between the
DRO display or Program mode.
view key opens menu for setting part
graphic display parameters, i.e. type,
orientation.
INFO key opens on-screen manual.
MM key toggles between INCH or MM
mode.
SETUP key opens configuration menu.

2.6 Overview of Components 19
Numerical keys
Axis Keys
Soft Keys
Key Function
Zero key.
One key.
Two key.
Three key.
Four key.
Five key.
Six key.
Seven key.
Eight key.
Nine key.
Decimal key.
Plus / Minus key.
Key Function
Axis keys open the datum, or preset
form.
Key Function
Soft keys execute the key directly
above it in the bottom menu bar of the
display screen.

20 ACU-RITE Technical Manual MILLPWRG2
2.6.3 Navigation keys
2.6.4 Calculator Function keys
2.6.5 Potentiometer for feed rate
Key Function
Left arrow key to move cursor to the
left.
Right arrow key to move cursor to the
right.
up arrow key to move cursor up.
down arrow key to move cursor down.
Key Function
blank key opens the user defined
MILLing function data input form.
CALC key opens the trig calculator.
Plus key.
Minus key.
Multiplier key
divide key.
Feed rate