MILLPWR°&2 ACU-RITE Technical ManualTable of Contents 1 Update Information 1.1 General Information 13, 2 Introduction 2.1. Meaning of the Symbols Used in this Manuel... 15 2.2 Proper Operation 15 2.3 Trained Personnel 15 24 Grounding, and Connections. 15 2.5 General Information 2.6 Overview of Components 2.6.1 MILLPWR° Control..... 2.6.2 Keys on visuel display unit . : Power control keys. 18 Deta Entry keys ..... Function keys Numerical keys... Axis Keys Soft Keys... 2.6.3 Navigation keys.. 2.6.4 Calculator Function keys 2.6.5 Potentiometer for feed rate 2.6.6 Milling Function keys..... 2.6.7 Peripherals Supported: 2.6.8 Touch Probe Systems... 2.6.9 Documentation .. 2.7 Brief Description . Accessories... soo Software options, 29 28 Software. 30 2.8.1 Designation of the Software 30 Type. 2.8.2 PLC Software. 2.8.3. Enabling Software Options Enabling software options at 284 Updating Software 22 285 Procedure for updating the software 23 286 Data Backup. 24 29 Software Releases 24 2.9.1 NC Software 751 005-x« 24 NC software 751 005-01 24 2.10 PC Software Utilities 25 2.10.1. Support 25 2.102 Management 29 241 Save Service Files 2932 23 24 25 26 a7 38 29 2.10 Mounting and Electrical Installation General Information 3.1.1. Safety Precautions 3.1.2 Degrees of Protection 3.13 Electromagnetic Compatibility Likely sources of interference... Protective measures Environmental Conditions 3.2.1 Storage and operating temperatures Limit values...... ve Limit value for temperature inside the console Humidity during operation... Storage temperatures. 3.2.2 Heat generation and cooling 3.23 Installation elevation 3.2.4 Mechanical Vibration Console Back Panel Power Supply Buffer Battery Encoder Connections 3.6.1 General Information Touch Probe Systems 48 3.7.1. Triggering Touch Probe for Workpiece Measurement 49 Touch probe connection. Data Interfaces cess General information Ethernet interface RJ45 connection .. RS-232-C/V.24.... Data Interface 383 USB Interface. Front/Rear panel... USB hub) Cable Specifications 55 Dimensions 56 3.10.1 MILLPWRS? 56 2.10.2 Adapter Block for the Data Interface 57 2.103 USB Hub 3.10.4 Touch Probe Systems Adapter cable for TS... TS 220 Adapter cable for TS 120/TS 220...... SE 640 transmitter-receiver unit. SE 540 transmitter-receiver unit... Ts 440 TS 640 veeseneneten ACU-RITE Technical Manual MILLPWR°?an 42 43 44 45 46 a7 Machine Parameters General Information 65 Managing Parameters 67 4.2.1 Entering and Editing Machine Parameters. 67 Icons in the object tree... Displaying help texts. Entering and editing parameters .... Limit values Copy/Paste value function in ConfigEditor Deleting objects. Inserting and copying objects. Changing key names Saving input values. Find function Finish editing... : Managing Configuration Files .. Sort File Content... Attribute Information, ‘Access rights Reaction to change. Update RULES ncn Remove Syntax Error: Reset Update Version Backup of Parameters... val Allocation of Configuration Data .. S-axis system Multiple variants Structure of a Parameter File Rules for entries Machine Parameter Subfiles 4.5.1 Syntax of MP Subfile 4.5.2 Activating MP Subfiles Activation in the configuration editor... ‘Activation by the PLC 4.5.3 _Displaying/Editing Data Records in the Configuration Exitore8 Basic data Loaded subfila(s)... Temporary data. Effective deta Unload subfile Read or Change Machine Parameters via a PLC Module Overview of the Mechine Parameters 47.1 *System" group. “Channels” group.. "Axes" group KeySynonym. 4.7.2 UserSetup Parameters.64 62 63 64 55 56 87 58 59 Configuring the Axes Software Version 245 Machine Structure 246 5.2.1. Adapting the Control to the Machine Structure 246 5.22 Definition of Axes 287 Defining the logical axes - sone DAT Special kinematics axes. 249 Configuration of Machining Channels 250 53.1. Configuring a Machining Channel 250 ‘Type of NC channel... . .250 Axes of machining channel 251 Kinematics of machining channél... .251 Error behavior of machining channel 252 53.2 Traversing the Reference Marks. 253 53.3 Moving to Restore Position 254 Configuration of Axes 255 5.4.1. Axis Designations and Coordinates 256 Properties of the principal @x@5 X.Y, Zevon 256 Algebraic signs of the axes... enn 256 Standard coordinates. 257 5.4.2 Programmable Axes 258 Index for SysRead and SysWrite 259 Axis without a separate drive motor. 259 543 Physical Axes 260 Activate axis... . 261 Assigning parameter blocks 262 Virtual axis .. 262 5.44.4. Kinematics Properties of Axes 263 54.5 2 Axis System., 264 Encoders 265 55.1 Type of Encoder... . - ne 285 Signal period 267 5.5.2 Distance-Coded Reference Marks 269 55.3 Encoder Connections 270 Position encoder input : ennesernne2TO, Position encoder signal. a 5.5.4 Defining the Traverse Direction 273 5.5.5 Encoder Monitoring 274 Position encoder .n.n 274 Analog Axes 276 Analog outout. — 276 Rapid traverse for analog axes 217 Reading Axis Information 278 Reading the axis coordinates 279 Traverse Ranges 280 Controlling Axes by PLC. 281 Positioning of axes by PLC 281 ACU-RITE Technical Manual MILLPWR°?5.10 a 512 513 Axis Error Compensation 5.10.1 Backlash Compensation 5.10.2 Linear Axis Error Compensation 5.10.3. Nonlinear Axis Error Compensation Compensation value tables Entering compensation values Importing data from calibration software: . - Assigning the compensation value tables to the axes...293 Activate error compensation san 5.10.4 Compensation of Thermal Expansion Machine Kinematics... 5.11.1 Configuration of tne Machine Kinematics Configuration of the machine kinematics 299 Reference Marks. 208 5.12.1 Definition. 208 5.12.2 Traversing the Reference Marks. 309 Distance between the scale reference point and the machine datum, 209 Renewed traversing of the reference marks..... 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 wn. Linear measurement through rotary encoder 315 5.12.4 “Pass Over Reference Point” Mode of Operation 317 Reference end position ... Machine datum. Positioning after reference mark traverse The Control Loop... 5.13.1 Relation Betwean Jerk, Acceleration, Velocity and Distence320 Acceleration and jerk Distance... 5.13.2 Geometry Filter 5.13.3 Look-Ahead.. Contour smoothing Path- specific limit valves ... Axis-specific limit values: Tolerance for corners and arcs 5.13.4 Interpolator... - 5.13.5 Filter before Position Control Loop Configuration of filters Function of the filters before the position control loop ..335 5.13.6 Position Controller. Feedback control Feedback control with following error .. Interrelation of ky factor, feed rate, and following etror 341 Limiting of controller output . Feedback control with velocity feedforward 342 Rapid traverse and feed rate limitation.. Feed rate values in PLC operands5.14 5.15 5.13.7 Activating and Deactivating Position Control Loops 346 Opening the position control 10D... 346 Clamping the axes 347 Actual-to-nominal value transfer. 348 5.13.8 FeedRate Enable.. 349 5.13.9 Controller Parameters for Manuel 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 @x@8 353 Compensation of reversal peaks for analog axes 363 Compensation of reversal peaks 356 Analog offset 368 369 .360 Monitoring Functions. 362 5.14.1. Monitoring the Drives seven 362 Switching off monitoring functions globally 362 Switching off monitoring functions for individual axes....363, Position loop resolution for analog axes... 5.13.11 Switching Parameter Blocks... 5.14.2 Position Monitoring, ; - 364 Clamped axes, hanging axes 366 Difference between position at switch-on and shutdown 368 5.14.3 Movement Monitoring 367 5.14.4 Standstill Monitoring 369 5.14.5 Positioning Window 370 AXES iN POSITION worn . 371 Axes in motion, 372 5.14.6 Temperature Monitoring 373 Temperature of the MC.. 373 Intetragate the values of the internal ADCs 373, 5.14.7 Momentary Utilization of Drive Motors. 374 5.148 EMERGENCY STOP Monitoring 376 Flowcharts... 377 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 3¢4 Starting and stopping the recording ...... 384 Trigger conditions 385 5.15.4 Analyze Recording 386 Recording completed. 386 Changing the display... - eee 387 Analyze an individual analog ana 387 Influence the signal display... 387 Second cursor 388 ACU-RITE Technical Manual MILLPWR°?61 62 63 64 65 66 5.15.5 Saving and Loading Recordings 388 5.15.6 Configure the Colors of the Oscilloscope Display 389 Machine Integration Software Version... Display and Operation 6.2.1 Position and Status Display... 622 Unit of Measurement for Display and Operation. 6.2.3 Decimal Separator. Switching the Control On/Ofi.. 6.3.1 Powering Up the Control Message for power interruption 397 Customer-specitic logo... - Starting the control with empty PLC partition 399 63.2 Shutting Down the Control 400 63.3 System Language 405 63.4 Programming station mode 407 Control Operation in the Operating Mode Group 409 Modes of operation 409 Start/stop of the machining channels. seerneee AO Reaction to errors 410 Control Operation in the Machining Channel ait 65.1 Channel-Specific Settings Aro End-Point Tolerance... Retract tool at NC stop 65.2 NC Program Run Starting an NC program Automatic NC program start. 414 Terminating the NC program 416 Interrupting an NC program Moving the axes during program interruption... NC program cancellation Block scan (start block search)... Finding the NC program and block number. Control in operation... M, Sor T funetion in parallel with traverse motion.....420 653 Error Status 421 65.4 Assignments in Manual Modes of Operation 422 Error Messages and Log Files. 423 66.1 Error Log Deleting errors... 66.2 Error Log File... Current and previous error log file. Filter. 663 Keystroke Log File Current and previous keystroke log file seen ABO Saving Service Files . PLC Error Messages67 6s 69 6.10 611 612 PET table (PLC Error Table) 432 Error text file... 433 Structure of the PET table . eens 433 Structure of the error text fle 434 Entering data in log files 439 Keystroke Simulation 4a 67.1 Control Keyboard aa 447 449 449 451 452 452 Codes for keystroke simulation... Override .... . 681 Override Devices .. . .. 6.8.2 Compensetion for Potentiometers. 683 Override Functions... Speed override Feedrate override... - 453 Rapid traverse override 455 Incremental Jog Positioning 456 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 Touch Probe 465 Selection of the touch probe 465 6.11.1. Using the Touch Probes. 468 TS 440, TS 640 voneen enn 466 Maximum probing feed rate 467 Diagnosis with the Online Monitor (OLM) 469 6.12.1 Introduction 469 Softwere 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 4a Units arse seen - 472 Status display 473 6.12.4 Selecting Axes and Channels 47a 6.12.5 Group of NC Axes 474 Nominal commands of the PLC (Plo Nom Data) ...cn474 IPO -internal variables (Ipo Act Data) 475 Internal working data of PLC-IPO (Pic Ipo Data) 478 Deta from the IpoOffset module (Offset Data) ween 481 Nominal status of the axes (Pie Nom State) 483 Actual status 1 of the axes (loo 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) 498 10 ACU-RITE Technical Manual MILLPWR°?74 72 73 74 75 78 6.126 Group of NC Channels Deta of the interpolator module lo Data) Internal data of the offset interface (Offset Data) .......492 Current status of the channel (Act State) . 6.12.7 Hardware Group... Data of the static RAM ($-RAM) Deta of the analog outputs (Analog Outout). on 94 Counter function blocks of the MILLPWRE? (GAL Data)495 Hardware port states (HW ports) 6.12.8 Auxiliary Group... Enabling debug outputs (Gei(Set DebugPrint) 498, Generating error messages (Set Error). 6.129 PLC Group. Displaying the values of the analog-to-digital converter 502 Pic trace... PLC Trace onfott.. Pic-Trace Save... 6.12.10 Queue-Trace .. Activating a Q Trace Deleting Trace information .. 6.12.11 Frequent Causes of Error. - . Servo drive cannot be switched on 507 Servo drive does not move. Data Interfaces Introduction 509 The Ethernet Interface 611 Ethernet interface RU45 connection (100BaseN)... Connecting to the Network... 7.3.1 Configuring the Network Settings DHCP. Static IP Address... . 7.3.2. Configuring Access to @ Network Share. The USB 2.0 Interface. Structure. Functionality and signal designations 519 USB devices ‘on the control 519 The Serial Interface 520 7.5.1 RS-232-CNV.24 Interface. 520 Hardware - Signal levels Signal designetions. Pin layout. Configuring the Serial Interface 7.6.1 Control Characters 7.6.2 Configuration of Interfaces Selecting a paremeter block Creating parameter blocks, configuring interface ports. 526 Defining the LSV2 baud rate.Data transfer rate Baud rate venvene 527 Communications protocol. 528 Word length Data bits 528, Transmission reliability Parity bit, 529 ‘Synchronization: Stop bits Deta transfer check: Handshaking... Hardware handshaking Software handshaking... Defining the file system... . r Block Check Character (BCC). 534 7.7 Serial Data Transmission Protocols 535 7.7.1 Standard Communications Protocol 535 General information... Cutput selected file Download selected file. 7.7.2. Communications Protocol with Block Check Character. Header Block Check Character (BCC... Handshaking Report an error to the control Request extemal directory... Output selected file Output marked files... Download selected file. 7.7.3. LSV2 Transmission Protocol 7.8 Saving end Downloading Files ...... ACU-RITE Technical Manual MILLPWR°?1 Update Information 1.1 General Information Future updates to hardware and software are documented in this section. 1.1 General Information 134 ACU-RITE Technical Manual MILLPWR°?2 Introduction 2.1 Meaning of the Symbols Used in this Manual @® Danger Sy Feilure 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, 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, 2.4 Grounding, and Connections 152.5 General Information ‘The MILLPWR® 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 MILLPWR®? the ideal choice for your drilling and milling applications. Many canned cycles, programming features and expansion capabilities are available for daily work with the MILLPWRS?. The MILLPWR® 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 (ld, Nr, 1034384-20) 16 ACU-RITE Technical Manual MILLPWR?2.6 Overview of Components 2.6.1 MILLPWR® Control MILLPWR°? ‘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 AS-232¢. = 1GHz Celeron M Processor. = 1GB DRAM. = 12.1" XGA resolution TFT LCD. = Integrated keyboard. Id. Nr. 654 461-xx ‘Compactflash memory card for MILLPWR' contains MILLPWR® software, no export license required. 654 255-xx 2.6 Overview of Components 72.6.2 Keys on visual display unit Go key (e.g. run a program). Power control keys Stop key (duel function: press once to pause, press twice to stop a program). cancel key cancels operation, i.e. form. Bre Data Entry keys clear key clears selections, ie. values, program step, use key completes operation, ie. data form. Enter key completes selection, values, data entered, Function keys ABs. ABS/INCR key toggles between INcR Absolute or Incremental positioning, Ro DRO/PGM key toggles between the Pom DRO display or Program mode. view key opens menu for setting part view graphic display parameters, 1.9. type, orientation: rn INFO key opens on-screen manual MM key toggles between INCH or MM. mm mode fi nmi os SETUP key opens configuration menu. 18 ‘ACU-RITE Technical Manual MILLPWR°?Numerical keys. Ea Zero koy. One key. Two key. Three key. Four koy. Five key. Six key, Seven key. Eight key. Nine key, Decimal key. Plus / Minus key. Axis Keys ‘Axis keys open the datum, or preset form, Soft Keys Soft keys execute the key directly above it in the bottom menu bar of the display screen. 2.6 Overview of Components 192.6.3 Navigation keys Left arrow key to move cursor to the left right. up arrow key to move cursor up. e Right arrow key to move cursor to the 0 down arrow key to move cursor down. 2.6.4 Calculator Function keys blank key opens the user defined MILLing function deta input form. CALC key opens the trig calculator catc Plus ke : . inus key. Multiplier « x lultiplier key divide key. 2.6.5 Potentiometer for feed rate 20 ‘ACU-RITE Technical Manual MILLPWR°?26.6 ing Function keys § Function tool key opens the Tool data input menu. rect key opens the rectangle MILLing deta input menu. circle key opens the circle MILLing data input menu, holes key opens the hole pattern data input menu, Pos key opens the positioning data input menu. line key opens the line MILLing data input menu, are key opens theare MILLing data input menu. blend key opens the Blend MILLing data input menu, 2.6.7 Peripherals Supported: USB memory devices; e.g. a memory stick. Networking 2.6 Overview of Components 22.6.8 Touch Probe Systems KT 3D Grounding Edge Finder Touch-trigger edge finder with cable connection for workpiace setup and measurement during machining. Id. Nr. 272 714-04 kKT3D (inch) Id. Nr, 272 714-03 KT3D (metric) TS 220 Grounding Edge Finder Touch-trigger edge finder with cable connection for workpiece setup and measurement during machining, Id. Nr. 272 714-04 KTaD (inch) j Id. Nr. 272 714.08 KT3D (metric) 22 ACU-RITE Technical Manual MILLPWR?TS 640, TS 440 touch probe Touch-trigger probe with infrared transmission, for workpiece setup end measurement during machining, Id. Nr. 620 1890 Ts 640 Id. Nr. 820 048-0 Ts.440 Id. Nr. 631 22550 SE 840 transmitter- receiver unit Id. Nr. 626 001-20 SE 540 transmitter- receiver unit Ts 640 Ts 440 } | SE 640 SE 540 2.6 Overview of Components 232.6.9 Documentation Items supplied with the control include: MILLPWA® User's Manual }034384-20 24 ACU-RITE Technical Manual MILLPWRS?2.7 Brief Description SS Compact contouring control with integrated main computer, flat-panel display and MILLPWR® operating panel i Intel Celeron processor with 1 GHz = Working memory: 1GB DDR SDRAM '= Four position encoder inputs 1 Vpp Axes: 3 closed-loop axes ‘Axis feedback control Cycle time for path interp. Velocity feedforward control / Operation with following error Analog speed command interface = 10V 3ms ‘Options Software options can be enabled by entering a code number. Display 12.1-inch TFT color flat-panel display Program memory 2.5 GB (on CFR CompactFlash memory card) Input resolution and display step Up to 0.01 um for linear axes To 0.00001” for rotary axes Block processing time ems 2.7 Brief Description 25Interpolation Straight line Sexes Circle Zaxes Helix ‘Superimposition of circular and linear paths Error compensation & Linear and nonlinear exis error = Backlash ® Reversal peaks during circuler movements = Reversal error = Thermal expansion = Stiction § Sliding friction Monitoring functions Amplitude of encoder signals = Edge separation of encoder signals = Absolute position for encoders with distance-coded reference marks = Following error = Movement monitoring ® Standstill monitoring = Nominal speed value = Checksum of safety-related functions = Power supply m Buffer battery & Operating temperature = Cycle time of the PLC program Integral PLC PLC memory 256 MB on CFR memory card Program format Statement list PLC main memory (RAM) Dynamic, determined by the free main memory of the control PLC cycle time 12 ms (can be set) 26 ‘ACU-RITE Technical Manual MILLPWR°?Commissioning aids = Oscilloscope: = Trace funetion '= Table function = Watchlist function ‘= Logic diagram (integrated in oscilloscope) = Log Interfaces Fast Ethernet interface 100BaseT 2x USB 2.0 m= RS-232-CNV.24 with max. 115 Kbps = Expanded interface with LSV-2 protocol for data exchange and extemal operation of the control with HEIDENHAIN TNCremoNT. Permissible temperature range Operation: 0 t0 +40 °C (+32 °F to +113°F) Storage: -35 °C to +65 °C (-21 °F to +149 °F) Program entry = ACU-RITE conversational = ISO G-Code Fixed cycles = Drillingfboring cycles for drilling, peck drilling, reaming, boring, counterboring, tepping with or without floating tap holder '= Cycles for milling internal and extemal threads '= Roughing and finishing rectangular and circular pockets "= Cycles for face milling plane and oblique surfaces "= Cycles for milling linear and circular slots = Hole patterns on circle and line '= Contour pockets — also contour parallel = OEM cycles (special cycles developed by the machine tool builder) can also be integrated Touch probe cycles W Touch probe calibration = Compensating workniece titt manually and automatically 1 Setting the datum manually and automatically Contour elements Ww Straight line = Chamfer "= Circular path "= Circle center 1 Circle radius '= Tangentially connected arc = Corner rounding Contour approach and departure is Via straight line: tangential or perpendicular = Via circle 2.7 Brief Description 20Background programming Creating a program with graphical support while another program is being run Programming with variables 1 Mathematical functions sin aand cos a, *, 7, Sin a, 605 a, angle «from ala de? +b? <>) = Logical comparisons = Parentheses = tan a, arc sin, arc cos, arc tan, a", 6", In, log, absolute value of ¢ number, constant m, negation, truncation before or after decimal point = Functions for calculating a circle Programming aids = Online calculator = Context-sensitive help function = Graphic support for the programming of cycles = Comment blocks in the NC program = Integrated CAM, DXF converter Position data = Nominal positions for straight lines and circles in Cartesian or polar coordinates. = Absolute or incremental dimensional data = Display and input in mm or inches Tool compensation = Tool radius in the working plane and tool length Radius compensated contour look ahead for up to 99 blocks: Tool table (One tool table with any number of tools Cutting-deta tables For automatic calculation of spindle speed and feed rate from tool- specific data (cutting speed, feed rate per tooth) ‘Constant contour speed = With respect to the path of the tool center = With respect to the tool cutting edge Program jumps. 1 Subprograms = Program-section repeat = Any desired program as subroutine Coordinate transformation 1 Datum shift, rotation, mirroring = Scaling factor (axis specific) 5 Tilting the working plane ‘Actual position capture Actual positions can be transferred directly into the part program Test graphics Graphical simulation before @ program run, also while another program is being run = Plan view, view in three planes, 2-D view = Magnification of details 28 ACU-RITE Technical Manual MILLPWR°?Accessories Touch probe systems "= TS 220 triggering 3-D touch probe with cable connection, or = TS 440, TS 640 triggering 3-D touch probe with infrared transmission |= KT 3D Grounding Edge Finder. settings management Data transfer software TNCremoNT PLC development software PLCdesignNT ‘Software for configuration ConfigDesian Software options ‘Option 0 Option 8 Option 17 Option 18 ‘Additional Closed-Loop axis (648799-01) Programming rotary axis feedrate (648800-01) Touch Probe Cycles (648808-01) DNC Connectivity (648802-01) 2.7 Brief Description2.8 Software 2.8.1 Designation of the Software ‘The control features @ separate software for the NC and the PLC. The NC software is identified with an eight-digit number Type The MILLPWR® is shipped with the following NC software versions: 751 O05-xx MILLPWR' The MILLPWR° is approved for export to all countries. No export license is required for the NC software of the control HEIDENHAIN CORPORATION may release a new NC software version when it introduces extensive new functions. 2.8.2 PLC Software The PLC software is stored on the memory card of the MILLPWR&2, HEIDENHAIN CORPORATION offers a PLC basic program you can order directly from HEIDENHAIN CORPORATION. With the PLC development software PLCdesignNT, the PLC basic progrem can very easily be edapted to the requirements of the machine. = Separate machine setup for the PLC project With the help of PLCdesignNT (as of version 2.5) you can create a setup file for the PLC project. This makes it easy to update the PLC program. For more information on this topic, see the “Generate Machine Setup” chapter in the online help for PLCdesignNT 2.5. The PLC setup archive is installed on the control in the same manner as a software update 2.8.3 Enabling Software Options On the standard version of the MILLPWR®, three control loops (3 axes) are enabled. 30 ACU-RITE Technical Manual MILLPWR°?To enable options, proceed as follows: > While in the DRO mode, first press Setup key > Enter the code number 222 and confirm your entry by pressing OK. The following dialog box will appear: Control Type Control model — General Key Enter the master code number 65535 to enable all options for the duration of two weeks. NONE: Master code number has not been entered yet dd.mm.yyyy: Date up to which all options will be enabled. It is not possible to enable the options again by entering the master code number. EXPIRED: The two weeks since the master code number was entered have expired. Option column | Display of option numbers that can be enabled ‘Active column | X: Option is enabled Keycode column | Code number for the option to be enabled > Enter the code number for enabling the option under Keycode and confirm your entry by pressing the Enable key. HEIDENHAIN CORPORATION can give you the code number. The Option column shows all available options of the MILLPWR®. Options that are not enabled appear dimmed and the Keycode field will be active and awhite color. » Press the Caneel key to exit saving changes. The control may carry out a reset If the code number is correct, the enabled option is identified by the entry X in the Active colurnn 2.8 Software 312.8.4 Updating Software 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 (684138-xx). Please refer to the manual included with the drive for the backup procedure Use a blank USB memory stick (1 GB or larger) to update the software. Do not use any memory stick with a smaller storage capacity. AZIP file must be obtained which includes the software installation files. The ZIP can be extracted to the root of the empty USB drive. When the control software is started, if a USB drive is present which contains ¢ softwere update, the control will automatically start a software update. The required format for the software update on the USB drive is as follows: :\installsetup.zip. 32 ACU-RITE Technical Manual MILLPWR?2.85 Procedure for updating the software Shut down the control softwere using the normal method of pressing the ‘Shutdown soft key and then confirming the shutdown by pressing YES. Wait for the screen message which indicates that it is safe to switch off power, or restart. Insert the USB memory device containing the folder named “install” on the USB memary device Press ENTER to restart the system. After starting, the MILLPWR® Software Update screen will appear with ¢ confirmation box. If necessary, use the UP/DOWN ARROW keys to select the lan- ‘guage (e.g. English) and press ENTER A confirmation box will appear. If necessary, use the LEFT or RIGHT ARROW keys to select Yes, then press ENTER The software update will now be done automatically, taking approximately 10-20 minutes When the update is complete, it will prompt you to remove the USB drive and restart. At this time, remove the USB drive and press ENTER to restart After the system has restarted, it will start up normally to the control software. any issues are encountered, please either refer to the technical manual or contact your service representative for assistance. 2.8 Software 332.8.6 Data Backup For deta backup, HEIDENHAIN CORPORATION offers the PC software ‘TNCbackup free of charge. TNCbackup provides convenient functions for backing up end restoring data. TNCbackup is part of the TNCremoNT softwere package and can be downloaded from the HEIDENHAIN file base on the intemet. (http:/filebase heidenhain.com) HEIDENHAIN CORPORATION recommends that the machine manufacturer use the TNCbackup software to save all his machine-specific data and to supply them with the machine (e. g. on CD-ROM) The customer, 100, can save his data before exchanging the control. Itis also advisable that the customer save all of the files and programs created on the control at regular intervals on a PC. The CD-ROM supplied with the machine should therefore also contain the current version of TNCremoNT. Note The CNC USB Recovery Drive (684138-01), included with the purchase of the MILLPWR®, is the recommended method for data backup and re- storing. Refer to its bundled user guide for usage instructions. 2.9 Software Releases 2.9.1 NC Software 751 005-xx NC software 751 005-01 Release: 12/2011 ... Initial version 34 ACU-RITE Technical Manual MILLPWR°?2.10 PC Software Uti 2.10.1 Support ‘Support for Remote gnostics PC software Remote Diagnostics offers numerous possibilities for remote maintenance and remote diagnosis of the MILLPWR®2. Along with transmission of the screen contents, all keys of the control can be operated remotely, for example, In addition, comprehensive diagnostic possibilities, such as outputting of control logs, are available. The machine operator can initiate a SERVICE REQUEST via key, as well as establish an automatic connection between the control and Remote Diagnostics. The key is visible in the System Maintenance key's list, configured. Please contact HEIDENHAIN if you would like to purchase Remote Di ‘once the machine parameters described below have been agnostics. The following parameters are required for configuration of the service request: ‘Settings in the configuration editor MP number System Network CfaServiceRequest name 114601 host 114602 port 114803 content 114604 period 114805 timeout 114606 serverlp 114807 serverlpMask 114608 MP_name Logical name of the service host Format: String Input: Max. 500 characters The name identifies the remote service host and can be displayed on the user interface of the control Deft: No value, parameter optional Access LEVEL? Creation: RUN 2.10 PC Software UtilitiesMP_host Network address or host name of the remote service host Format: String Input: Max. 500 characters Enter the network address as four decimal numbers separated by periods (IP address in dotted-decimal notation) or as a fully qualified host name (e.9. 192.168.10.51 \HOMEWDATA\SERVICE Default: No value, parameter optional Access: LEVEL2 Creation: | RUN MP_port Port number of the remote service host Format: Numeric value Input: Initial value: 19001 ‘The control sends the service request report to the port entered here Default: No value, parameter optional Access LEVEL Creation: | RUN MP_content Contents of the message to the remote service host Format: String Input: Max. 500 characters ‘The contents serve to identify the machine, ¢.g. machine model and serial number. Default No value, parameter optional Access: LEVEL2 Creation: | RUN 36 ACU-RITE Technical Manual MILLPWR°?MP_period Duration of repeated transmission of the message to the service host Format Numeric value Input: Oto 101s] Transmission the report is repeated during the specified period of time in seconds until the function is activated or the time entered in the MP_timeOut parameter is exceeded Default No value, parameter optional Access: LEVEL2 Creation: RUN MP timeout Timeout in minutes for transmission of the message to the remote service host Format: Numeric value Input: 0 to 15 [min] Default: No value, parameter optional Access LEVEL? Creation: RUN 2.10 PC Software Util 37MP_serverlp Network address or host name of the server Format: String Input: Max. 500 characters The data traffic of the specified server(s) is checked. The default velue is the server given in the MP_host parameter Default: No value, parameter optional Access: LEVEL2 Creation: RUN MP serverlpMask Subnet mask of the server network Format: String Input: Max. 500 characters Enter the subnet mask of the server as four decimal numbers separated by periods (IP address in dotted-decimal notation). Default: No value, parameter optional Access: LEVEL2 Creation: RUN 38 ACU-RITE Technical Manual MILLPWR°?2.10.2 Management: HEIDENHAIN Corporation offers many other useful PC software utilities free of charge. These include TNCremoNT for transferring files, PLCdesignNT for managing the PLC program and PLC key menu, and ConfigDesign for managing configuration settings. These utilities can be downloaded at http:// filebase.heidenhain.com. 2.11 Save Service Files (On occasion, HEIDENHAIN Corporation may request the SERVICE FILES for a control. This is @ ZIP of various logs and files that can help troubleshoot any issues with the control. The following procedure describes how to generate the SERVICE FILES for a control. Press the SETUP key Press the "Error Log’ key Prass the ‘Log Files" key Press the "Service Files" key Press the ‘Ok’ key to accept the default file neme, or optionally change as desired The “Service Files" key will remain “checked” once pressed, and will return to normal state once the ZIP has been successfully generated. Once the key has returned to normal state, the ZIP file is aveilable. By default the file will be named *service1 zip’, and will be located at the root of the "V"" drive, which is the user-accessible drive of the control. Refer to the User Manual for instructions on how to copy this file to a USB drive or over the network. 2.11 Save Servi Files 3940 ACU-RITE Technical Manual MILLPWR°?3 Mounting and Electrical Installation 3.1 General Information & 3.1.1 Safety Precautions & Attention Keep the following in mind during mounting and electrical installation: National regulations for power installations Interference and noise immunity Conditions of operation Mounting attitude Danger Ensure that the main switch of the control or machine is switched off when you engage or disengage connecting elements or connection clamps. Danger Ensure that the equipment grounding conductor is continuous. Interrupti- ons in the equipment grounding conductor may cause damage to persons or property. Danger Incorrect or not optimized input values may lead to malfunction of the machine and may thus cause damage to persons or property. Modifications of the machine configuration should be done with caution and uncontrolled axis motions should be taken into account. Attention In order to be able to judge the behavior of an NC controlled machine, you need to have fundamental knowledge about drives, inverters, controls and encoders. Inappropriate use may cause considerable damage to persons or property. HEIDENHAIN CORPORATION does not accept any responsibility for direct or indirect damage caused to persons or property through incorrect use or operation of the machine. 3.1 General Information 41(Ar) Se Danger The interfaces for the PLC inputs/outputs, and PL connection comply with the requirements for basic insulation in accordance with IEC 742 EN 50 178. Only units that comply with the requirements of IEC 742 EN 50 178 for basic insulation may be connected, otherwise damage to persons or pro- perty may be caused, The maximum de voltage mean value of the PLC inputs is 31 V. 3.1.2 Degrees of Protection 3.1.3 Electromagnetic Compat Likely sources of interference Protective measures The following components fulfill the requirements for IP54 (dust and splash- proof protection). MILLPWR® (when properly installed) Handwheol This unit fulills the requirements for Low Voltage Directive 2006/95/EC, and EMC Directive 2004/108/EC, and is intended for operation in industrially zoned areas, Protect your equipment from interference by observing the following rules and recommendations. Interference is mainly produced by capacitive and inductive coupling from electrical conductors or from device inputs/outputs, such as: Strong magnetic fields from transformers or electric motors Relays, contactors and solenoid valves. High-frequency equipment, pulse equipment and stray magnetic fields from, switch-mode power supplies Power lines and leads to the above equipment Keep a minimum distance of 20 cm from the control and its leads to inter- fering equipment. Aminimum distance of 10 em from the control and its leads to cables that carry interference signals. For cables in metallic ducting, adequate decou- pling can be achieved by using a grounded separation shield, Shielding according to EN 50 178 Use potential compensating lines with 6 mm? cross-sections Use only genuine HEIDENHAIN cables, connectors and couplings 42 ACU-RITE Technical Manual MILLPWR°?3.2 Environmental Conditions 3.2.1 Storage and operating temperatures Limit values Device ‘Air approaching the Temperature range outside: device inthe console _| the console MILLPWR®= [32°F (0°C) 10 122°F (60°C) | 32°F (0°C) t0 113°F (45°C) Compact. | 32°F (0°C) to 150°F (70°C) | 32°F (OFC) to 113°F [ABFC) (no Flash card direct exposure to sunlight) Limit value for Because the MILLPWWR® is installed in the console, additional heat that is temperatur: generated from the surroundings must be ventilated and/or removed ‘the console The maximum permissible temperature of the air surrounding the console is 113°F (45°C). z& Attention The temperature of the air inside the console, which flows into the MILLPWR® devices, must not exceed a maximum temperature of +122°F (60°C) The console must be mounted in such a way that this maximum temperature of +122°F (50°C) is not exceeded. Please verify this through an appropriate temperature measurement. With the recommended temperature limits, active cooling is not required for a typical installation 3.2 Environmental Conditions. 43Humidity during Permissible humidity: operation Maximum 75% in continuous operation Maximum 95% for not more than 30 days @ year (randomly distributed) (AY Attention & Condensation on the electronics is not permitted! Condensation can form, for example, if warm, moist air flows along cool surfaces of the electronics. Therefore, cooling units with discontinuous. (e.g.two-position} temperature control must not be used. The resulting cyclic changes in temperature and humidity can cause condensation on the cool surfaces of the electronics. Furthermore, you must prevent condensate from reaching the electronics and ensure that it can drain away without causing damage. In tropical areas it is recommended that the control not be switched off, so that condensation is avoided on the circuit boards. Storage For all control components: ~4°F (-20°C) to 140°F (60°C). temperatures 3.2.2 Heat generation and cooling A heat exchanger or a cooling unit is preferable for controlling the internal temperature of the electrical cabinet. If filtered air is blown into the electrical cabinet for cooling purposes, the standard EN 61800-5-1 applies, which permits contamination level 2. B® Attention Be sure to take the measures required for preventing dust from entering the electrical cabinet. Dust depositing inside electrical devices may cause them to fail and impair the safety of the system 3.2.3 Installation elevation ‘The maximum elevation for mounting is 9,842 ft. (2000 m) above sea level. 3.2.4 Mechanical libration Permissible vibration: + 0.075 mm, 10 to 41 Hz 5 mis”, 41 Hz to 500 Hz Permissible shock: 100 m/s?, 11 ms during operation 300 m/s®, 11 ms during transport a4 ACU-RITE Technical Manual MILLPWR?