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INSTALLATION MANUAL - Acu-Rite

1. EL a lt N Oconr OOAWHN All numbers XX in the following section refer to the listed items in this exploded view unless otherwise specified Position the belt over the ball screw pulley 5 Attach the top cover 2 with six 6 10 24 x 5 8 BHCS 3 Remove the Access cover 8 if it is installed MillPWR 43 Motor installation Attach the motor to the casting assembly with four 4 5 16 18 x 1 1 4 SHCS 10 and 5 16 Hex locking flange nut 4 Do not tighten fasteners Reach up through the access hole on the underside of the casting and place the belt around the motor pulley Belt Tension Put tension on the belt by sliding the motor assembly away from the spindle Tighten the four motor mounting bolts while maintaining tension on the belt Attach the access cover plate c 0 ad a 6 ad Y hom ad E A lt N O Console Installation Use the instructions supplied with the arm mounting kit to install the console 44 Il Il 10 High Low Range Switch Installation The High Low Range switch is relocated to the side of the Z axis casting Bracket Installation Attach the mounting bracket with two 2 10 32 x 1 2 SHCS Switch installation Ensure that the spindle motor is disconnected from its power source Attach the high low range switch on to the bracket A cable is provided to re wire the switch if it has become necessary MillPWR
2. MillPWR Il 3 X Axis Motor Drive Installation X axis Bearing sleeve Installation Insert the Bearing sleeve 16 or sleeve 14 or spacer 15 onto the right end of the ballscrew correct pieces and quantities are included See X axis handle exploded view on page 22 X Axis Bearing Housing installation Insert the bearing housing with the bearing installed onto the right end of the ballscrew Slide the assembly up to the end of the table and insure that the bearing is seated on the bearing sleeve or sleeve bearing journal gt Check that the bearing sleeve or sleeve has extended through to the outside edge of the bearing To extend the bearing sleeve or sleeve if needed remove the housing and bearing sleeve or sleeve Insert arbor washer s as needed Re install the bearing sleeve or sleeve and housing Attach the bearing housing to the table using the existing fasteners Do not tighten fasteners at this time Place the square key 3 in the slot at the end of the ballscrew Place the torque tool see Ballscrew Torque Tool ID 2003 7397 on page 2 over the shaft and key With the spanner wrench locked into position at the casting end torque the spanner nut to 50 ft lbs at the bearing end by turning the ballscrew clock wise with the torque wrench attached to the Ballscrew Torque Tool 2 ad a C ad YN d 2 de O jad Q 2 BL A lt A Mm
3. The following section is for a MILLPWR system that is using MillPWR 35 Il 7 Limit Switch Installation rotary Encoder Limit switch exploded view Hardware list ca o O O LL gt hom ad c 2 a O ad Y Ea O E Y E mal pa I 1 ID 385004 161 10 24 x 5 8 SHCS 2 ID 2003 439 Quick release knob 3 ID 2013 393 Cover plate 4 ID 387530 120 4 40 x 1 4 PHMS 5 ID 4100 152 2 56 x 1 2 PHMS 6 ID 2003 435 Switch plate holder 7 ID 4100 184 10 32 x 3 8 BHCS 8 ID 2003 246 Pointer 9 ID 2003 440 Nylon brush not shown 10 ID 4180 131 1 4 Cable clamp not shown 11 ID 2013 441 8 32 x 3 8 BHCS not shown 12 ID 2003 436 Limit switch 13 ID 387901 139 Limit switch 14 ID 4100 159 6 32 x 1 4 SHCS items in the previous exploded view unless S All numbers XX in the following section refer to the listed otherwise specified 36 The upper and lower limit switches are supplied attached to the mounting plates The nylon brushes are factory installed to the inside of the cover plate The engagement switch 13 is a part of the wire harness Limit switch installation switch be positioned where resistance can be felt on the A quick change tooling system requires that the upper limit quill quick feed lever Remove the Quick Release knob Attach the upper and lower limit switch mounting plates to the casting with the 4 40 x 1 4 PHMS 4 Do not tight
4. Ballscrew 15 Ballscrew 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 ID 385004 401 ID 387900 284 ID 387900 119 ID 387900 114 ID 387900 175 ID 2013 319 ID 385004 161 ID 2003 307 ID 2013 304 ID 4100 154 ID 4180 123 ID 4150 111 ID 2013 317 ID 2013 210 ID 4100 118 ID 4180 121 S All numbers XX in the following section refer to the listed MillPWR Jam Nut 1 2 20 Handwheel Lock nut replacement Dial replacement Dial Holder replacement Cover Y axis housing 10 24 x 5 8 SHCS Belt Pulley 30T 10 32 x 1 4 SHSS Plug 5 16 Locking Hex flange nut Y axis housing DC Motor assembly 5 16 18 x 1 1 4 SHCS key 1 8 Square x 1 lg 15 e a a amp er Y ed 2 de A LA sj 2 A lt gt N Y Axis Motor Drive casting installation Move the saddle to approximately 3 from the front of the knee Attach the Y axis housing 29 to the front of the knee with four 4 3 8 16 x 1 1 4 SHCS 4 and 3 8 Flat washer 5 Do not fully tighten fasteners at this time Place the alignment tool see Ballscrew Alignment Tool ID 2003 7387 on page 2 A over the ballscrew shaft and into the bearing bore Adjust the housing until the tool slides freely over the shaft and into the bearings Do not remove the tool at this time Secure the housing in place by securing the four 4 3 8 16 x 1 1 4 SHCS torque to 35 ft lbs AN Warning The too
5. Remove the two 2 short screws 1 on the heat sink end of the motor assembly Save screws for re assembly Loosen the four 4 long screws 2 approximately 1 Do not remove Open all motors that are to be tuned Slide the heat sink away from the housing to expose the potentiometers arii ED PRPS aoe LLTI rriat 1 ALLA ae he ae Use the non conductive spacers 1 supplied for the Z Axis 54 lll X Axis Manual Tuning Power up the MILLPWR system Corr reo 00 100 Press FIND HOME All axes will move to their home position JoB SETUP Press the SETUP key on the operator console Sonte Paeron Using the arrow keys highlight INSTALLATION SETUP and O A peris Enter the installation setup Access Code 1111 O gt q I ee J O EE Highlight SERVO TUNING with the arrow keys and press ENTER Z Axis options will not appear when a two 2 axis system has been installed Manually position the table to It s center of travel and the saddle to it s center of travel using the hand wheels Press the X SERVO softkey Press the MANUAL TUNING softkey AUTO MANUAL TUNING TUNING SERVO TUNING X FOLLOWING ERROR Press the GAIN TEST softkey The table will move and the values in the Following Error field will fluctuate STATUS SET POTENTIOMETER TO O Note the table will move when executing the next step MillPWR 55
6. L 9 gt lt A a MillPWR 23 c 2 ad BL O ad Y E O EL A lt N LO Il 5 Z Axis Quill Installation Z axis ballscrew exploded view Hardware list ID 2003 439 ID 382250 155 ID 2003 433 ID 2003 450 ID 4100 153 ID 2003 432 ID 2003 434 ID 4100 109 ID 4100 157 ID 2003 421 ID 67200 454 ID 4150 900 ID 2003 396 ID 4100 150 ID 384600 093 ID 2003 420 ID 2003 438 ON O11 Rh WN e ee daa a O NO oR WN O 24 Quick Release Knob 1 4 20 x 1 4 SHSS Shaft Spacer 8 32 x 3 4 SHCS Clamp Shaft Retainer 1 4 20 x 3 4 SHCS 3 8 24 x 1 1 2 SHCS Nut Block Drive Key 1 2 13 Ext Hex Coupling Nut Ballscrew 6 32 x 1 4 SHSS 10 24 x 7 8 SHCS Disengage Feed bracket Alignment Bushing items in the above exploded view unless otherwise S All numbers XX in the following section refer to the listed specified Check the actual Quill Travel During this installation in order not to cause damage to the quill skirt the recommended travel must not be exceeded The spindle must be removed in order to drill and tap the quill for the nut block Refer to the machines operator reference manual Z Axis Nut Block Installation Attach the disengage bracket 16 on to the shaft where the engagement crank was removed See Power feed transmission engagement crank on page 7 Use the 10 24 x 7 8 SHCS 15 Insert the 6 32 x 1 4 SHSS 14 Secure in place Il
7. Insert the 1 8 square key into the key slot closest to the ballscrew motor housing Slide the 60 T pulley 2 flat side towards the mill over the 1 8 square key up against the journal on the ballscrew Secure the pulley in position by tightening the two 2 1 4 20 x 1 2 SHSS 3 to 48 in lbs of torque Place the belt 24 onto the 60 T pulley Y axis motor installation incrementally at 45 This feature is provided to allow The motor mounting plate allows the motor to be rotated clearance from machine components if necessary c 2 a amp er Y 2 de A LA sj 2 A lt gt N Insert the motor assembly 30 through the rear of the housing Attach the motor to the housing with four 4 5 16 18 x 1 1 4 SHCS 31 and four 4 5 16 locking Hex Flange nuts 28 Do not tighten at this time Place the square key in the slot on the shaft of the motor Slide the 30 T pulley 25 flat side towards the motor and position in line with the 60 T pulley Secure the pulley in position by tightening the two 2 10 32 x 1 4 SHSS 26 to 48 in lbs of torque Place the belt on the pulley Apply pressure on the belt but not excessive secure the motor in place to 15 ft lbs of torque Place the cover plate 22 on the housing and secure in place with 6 10 24 x 5 8 SHCS 23 Place a washer 1 onto the ballscrew shaft Re install the dial assembly If additional clearance
8. While the table is moving adjust the gain potentiometer 2 with the non conductive flat tipped screwdriver until the value in the Following Error is between 0 and 20 S Adjust the potentiometer slowly Pause periodically to let the value settle y Ati pussereeere 1 bed RENTAR EN Press the STOP TEST soft key to lock in the value O E gt q I Press the BALANCE TEST softkey TABLE WILL MOVE AT LEAST 2 DURING THE TEST AUTO MANUAL STOP GAIN BALANCE TUNING TUNING TEST TEST TEST Set the velocity value by completing the next step SERVO TUNING X While the servo motors are on adjust the balance potentiometer 3 with the non conductive flat tipped screwdriver until the velocity reading in Status field reaches 0 00 gt Adjust the potentiometer slowly Pause periodically to let OS delle celia tit lt aibegu dat J Mies nA Press the STOP TEST soft key to lock in the value Press the STOP TEST soft key again to return to SERVO TUNING 56 lll Y Axis Manual Tuning Highlight SERVO TUNING with the arrow keys and press ENTER Manually position the table to it s center of travel and the saddle to it s center of travel using the hand wheels Press the Y SERVO softkey O gt q I Press the MANUAL TUNING softkey TABLE WILL MOVE AT LEAST 2 DURING THE TEST AUTO MANUAL STOP GAIN BALANCE TU
9. Press ENTER Select the Z axis using the arrow keys and press ENTER If a LINEAR encoder is being used press the LINEAR soft key To change encoder type exit then re enter to continue To change the count setup direction press the opposite soft key of what is displayed i e NEGATIVE is displayed then press the POSITIVE soft key Press USE NEW SETTINGS soft key to save the new setting If a ROTARY encoder is being used press the ROTARY soft key Set the ROTARY ENCODER LINES parameter to 1000 Press USE NEW SETTINGS soft key to save the new setting To change the count setup direction press the opposite soft key of what is displayed i e NEGATIVE is displayed then press the POSITIVE soft key Press USE NEW SETTINGS soft key to save the new setting 50 Confirm the control loop parameters Confirm the following parameters or make the appropriate changes as necessary Press the SETUP key on the operator console Using the arrow keys highlight INSTALLATION SETUP and press ENTER Enter the installation setup Access Code 1111 Using the arrow keys highlight the axis CONTROL LOOP and press ENTER For each axis X Y and Z CONTROL LOOP parameters are KP No Motion 3 000 KD No Motion 0 000 KP Feed 6 500 this field is automatically controlled by the KF value KD Feed 6 500 this field is automatically controlled by the KF value KF Feed 1 0600 Press the RESET soft key if the parameters
10. 45 e 2 ad a O ad Y os O Y O e am O ol os D L q Y 2 m O D O Q o 2 Q q q Il 11 Cable Connections Cable attachment and Installation AOUN a AOUN AOUN Refer to the following chart to connect the cables Failure to correctly connect all cables could result in a table run a way condition when powered up This view is typical to all three 3 motor housings X AXIS To Z motor 2 X AXIS From Y motor 1 X AXIS From X Axis encoder X AXIS To Controller X Axis Servo Y Axis To X motor 2 Y Axis From Controller Servo Power Y Axis From Y Axis encoder Y Axis To Controller Y Axis Servo Z Axis Open Z Axis From X motor 1 Z Axis From Z Axis encoder Z Axis To Controller Z Axis Servo Connect the X axis scale cable 3 to the X axis motor assembly Connect the Y axis scale cable 3 to the Y axis motor assembly Connect the Z axis scale cable 3 to the Z axis motor assembly If the system that is being installed is not equipped with the Z axis control connect the Z axis encoder to the Z axis encoder connector on the rear of the operator console When using the Multiple Scale Coupling feature connect the cable for the encoder mounted on the knee to the W axis encoder connector located on the rear of the operator console Connect the X axis motor assembly cable 4 to the X axis servo connector located on the rear of the operator
11. ahh eet eee PR ted ete 58 EAS IMAN TUNNO a shaw wd eels ened pea we RET hee 59 o e Galt tora 60 II 2 Automatic Tuning DPS AO UNO diia dei 61 VARAS AUTO AIN 63 EARS AUO TUNN Oreo A adnan ttn 65 IV 1 Trouble Shooting MillPWVR MOGUC UO asiaa asii 67 SWAG ENG TaD Esna a a a ae 67 VI 1 Introduction to MilIPWR System Overview Components MillPVVR Console Mounting Arm for Console Acu Rite s Precision Glass Scales 1 2 3 4 5 6 7 8 9 uyr Axis DC Motor Drive Axis Drive Housing Axis DC Motor Drive Axis Drive Housing Axis DC Motor Drive NN gt x xX lt Axis Drive Housing This installation manual was written specifically for the Hardinge Bridgeport Series standard vertical knee mill 9 x 42 and 9 x 48 tables If the MILLPWR system is being installed on a different machine additional installation instructions have been included with this MILLPWR system MillPWR A ad c 2 ad O O om q q A sj c 9 O O hom q Preparation Reviewing Section 2 Mill Disassembly on page 5 and Section II 1 MINPWR Installation on page 9 prior to initiating the installation will help reduce installation time and aid in having the MIlIPW R system operate correctly Assemble together the recommended tools listed for the X and Y axis installation Recommended tools required for the Z
12. are changed Press the USE hard key if the parameters are not changed Press the USE NEW SETTINGS soft key O q I Recheck and verify these parameters for each axis Press the DATUM soft key then Press FIND HOME Insure that all cables are routed so that enough slack is available for full movement of all axes MillPWR 51 Travel Limits Press the SETUP key on the operator console Using the arrow keys highlight INSTALLATION SETUP and press ENTER Enter the installation setup Access Code 1111 Select TRAVEL LIMITS using the arrow keys Press ENTER Select the X AXIS TRAVEL and using the hand wheel move the table to the left until it stops Turn the hand wheel two 2 full turns to bring the table back to the right Press the SET RIGHT LIMIT soft key Press ENTER Using the hand wheel move the table to the right until it stops Turn the hand wheel two 2 full turns to bring the table back to the left Press the SET LEFT LIMIT soft key Press ENTER Select the Y AXIS TRAVEL and using the hand wheel move the table completely forward until it stops Turn the hand wheel two 2 full turns to bring the table back in Press the SET OUTSIDE LIMIT soft key Press ENTER Using the hand wheel move the table completely back until it stops Turn the hand wheel two 2 full turns to bring the table forward Press the SET INSIDE LIMIT soft key Press ENTER Select the Z AXIS TRAVEL thre
13. cable and relief insert into the slot provided with the clamp on the top side Adhesive clamp Attach three 3 clamps as shown and attach the cable as shown 8 Grease Fitting Using a high quality lithium soap based grease add grease until it begins to escape trom the ballscrew nut 9 Plug Remove grease fitting 8 and replace with previously removed plug Save fitting for future use Insure that the ball nut has been properly greased Use high quality Lithium soap based grease ll 7 Limit Switch Installation rotary Encoder ii ES SS Attach the pointer as shown items 7 and 8 Refer to the exploded view Attach the cover plate 3 with the fasteners 1 and attach the quick release know 2 Refer to the exploded view 38 ll Il 8 Precision glass scale Installation optional Exploded view Hardware list o c 2 4 a c 0 a 2 O mar Y L O Y Y Y a O c 2 EL O E 0 00 I 1 ID 385004 161 10 24 x 5 8 SHCS 2 ID 2003 439 Quick release knob 3 ID 2013 393 Cover plate 4 ID 387530 120 4 40 x 1 4 PHMS not shown 5 ID 4100 152 2 56 x 1 2 PHMS 6 ID 2003 435 Switch plate holder 7 ID 4100 184 10 32 x 3 8 BHCS 8 Encoder 9 ID 385101 103 M4 x 8mm SHSS not shown 10 ID 4180 131 1 4 Cable clamp not shown 11 ID 385032 105 8 32 x 3 8 BHCS not shown 12 ID 2003 431 Reading head bracket items in the previous exploded view unless otherwise All nu
14. either move the table or press any key on the operator console to restore the display 2 If the power indicator light is not illuminated power has been interrupted Follow the recommendations for No Power No Power Check that power switch on the rear of the console Is on Turn console off for a minimum of 5 seconds then turn back on Check that power cord is properly connected Check that there are no blown fuses or tripped breakers Check that your power source meets the specifications required for the system Refer to the Operators Manual LCD display failure Contact Heidenhain Corporation for repair or replacement procedures MillPWR 67 O e Q Q K Y Lo 2 E gt Symptom Operator console displays a flashing cursor indicates a Non System Disk error Operator console keypad does not function properly System powers up but motor s will not move table 68 Probable Cause A floppy diskette is in the floppy disk drive System begins to power up but cannot get past flashing cursor A floppy disk drive is not functioning properly System needs to be reset Emergency stop button has been pressed Graphics Only selected in Run Options Corrective Action Remove the floppy diskette or flash drive and restart the system Re establish machine tool zero using the Find Home routine The system software has been co
15. good condition Increase tool diameter or reduce depth of cut Secure tool Secure as recommended by the machine tool manufacture Replace the spindle bearings as instructed in the machine s reference manual Realign the machine s spindle Tighten the quick release knob Should none of these recommendations correct the problem contact Heidenhain Corporation for repair or replacement procedures A Aligning the Z Axis Casting eccerre 34 Automatic TUNING cocccocccccnnoccnnnnncnnncnononnnonnnoss 61 B Ballscrew installation X AXIS ooccoocccoocconnco 11 C Cable attachment and Installation 46 Cable COMMECTONS sisters ias 46 Canle AQUINO riani eA 47 Console Installation occoocconccconnconcconnnonos 44 Controller ROUtINg lt secscscndindenoanitestscianstentaleacwacioientansi 47 H High Low Range Switch Installation 45 I Installation Requirements occcoccccccncncccnnoncncnnos 2 L Limit Switch Installation rotary Encoder 37 Locknut Torque TOO sesos 2 M Machine Tool Gib Adjustment ccce 48 Manual TUNING cerrar otto 49 N Nut Block Drill Template incen 2 Nut Block installation ccecce 10 P Power feed transmission engagement crank 7 Precision glass scale Installation optional 39 R Removing the Clutch Assembly n 8 Removing the LeadSCrews cccccceeeeeeeeee eee es 6 Removing the X axis hardware essc 5 Removi
16. in the casting while the spanner nut is being torque Assistance should not be required The spanner or adjustable wrench will lock it s self in place gt Remove all tools from the machine 20 ll X axis 60 T Pulley installation incrementally at 45 This feature is provided to allow S The motor mounting plate allows the motor to be rotated clearance from machine components if necessary Insert the 1 8 square key into the key slot on the ballscrew motor housing end Slide the 60 T pulley 10 flat side towards the mill over the 1 8 square key up against the journal on the ballscrew Secure the pulley in position by tightening the two 2 1 4 20 x 1 2 SHSS 11 to 48 in lbs of torque Place the belt 8 onto the 60 T pulley X Axis Motor Installation Attach the X axis motor drive housing cover 6 with eight 8 1 4 20 x 1 2 SHCS 5 c 2 pur amp C nar Y 2 de A LA O ad EL ras lt A mM Position the motor assembly so that the drive belt is on the 30 T pulley on the motor Attach the motor to the housing with four 5 16 18 x 1 1 4 SHCS 31 and 5 16 locking Hex Flange nut 28 Do not tighten Apply pressure on the belt by pushing on the motor but not excessive secure the motor in place to 15 ft lbs of torque Re install the rear access cover MillPWR 21 c 2 ad amp O ad Y O Lo e L 2 ae lt A J Il 4 X A
17. indicator s secure the upper casting by fully tightening the mounting bolt on one side The indicator should remain at it s 0 00 reading 0 001 The face of the casting should be parallel with the face of the quill horizontally Move the indicator to the other side as shown if one is being used and secure the other mounting bolt Lower the nut block to the end of it s travel Relocate the Dial indicator and repeat the same process Raise and lower the nut block It will move freely through It s entire travel If any binding of the ballscrew is felt repeat the alignment procedure Lower the quill until the shaft bottoms out Torque all four 4 10 32 x 5 8 SHCS to 60 in lbs Fully tighten the 3 8 16 x 2 HHCS 12 Raise and lower the nut block to insure it moves freely through It s entire travel If any binding of the ballscrew is felt repeat the alignment procedure ll 6 Z Axis Motor Casting Installation Insert the 1 8 square key x 1 lg 20 into the slot location at the top of the ballscrew Attach the pulley sliding it against the journal Secure in place by tightening the two set screws If necessary remove the oil cap to attach the pulley Reinstall the oil cap once the pulley has been installed a rotary encoder for the Z axis If the MILLPWR system that is being installed is using a liner glass scale encoder see Precision glass scale Installation optional on page 39
18. it will not interfere with milling functions MillPWR 2 Mill Disassembly Removing the Clutch Assembly Disconnect the spindle motor from the power source Remove the clutch arm cover 1 Remove the spring loaded clutch assembly 2 6 Clutch arm cover Overload clutch Safety clutch spring Overload clutch locknut Clutch ring Overload clutch trip lever assembly Q 7 N 2 A N onl Rh WN With the spindle motor disconnected from the power source remove the high low range switch The high low switch will be relocated following the zZ installation The Z axis component removal is complete To continue installing the MINIPWR system proceed to the section labeled INSTALLATION Il 1 MilIPWR Installation X Axis Ballscrew Installation Components 1 X Axis Ballscrew 2 xX Axis Ballscrew hardware kit 3 Nut Block 4 Four 4 3 8 16 SHCS previously removed Do not remove the ballnut from the ballscrew it can not be re assembled Preparation Check that the saddle is completely clean Activate the oil pump and verify that oil flows freely to the gibs saddle ways and ballscrews Check the table ways and gib for burrs scratches etc If necessary use a fine stone to smooth their surfaces Check that the gibs are flat If necessary replace them Installing an auto lube system is recommended to ensure that the ballscrew continuously receive
19. lt N Press the GAIN TEST softkey The table will move and the values in the Following Error field will fluctuate MILLPWR adjusts the motor s settings The table will stop moving and the TEST COMPLETED message will appear in the STATUS field when the test is complete The messages in the STATUS field will change as the STATUS field when the test is complete proceed S If the TEST COMPLETED message does not appear in with Manual Tuning instead Press the BALANCE TEST softkey Do not touch the table during the balance test MILLPWR will wait for the electrical current from the motors to level off then it will begin adjusting the balance It will find the minimum and maximum voltages needed to move the table Once those values have been identified MILLPWR will verify them This test could take several minutes The balance test is complete when Test completed appears in the Status field When the balance test has ended press the STOP TEST soft key If this is a three 3 axis system proceed with Auto Tuning the Z Axis Servo Motor If this is a two 2 axis system press the USE NEW SETTINGS soft key 64 TABLE WILL MOVE AT LEAST 2 DURING THE TEST AUTO MANUAL STOP GAIN BALANCE TUNING TUNING TEST TEST TEST SERVO TUNING Y STATUS TEST COMPLETED Z Axis Auto Tuning Manually position the quill to it s center of travel EE JOB S
20. 0005 7 Indicator holder with magnetic base 8 Measuring Standards e g gage blocks 9 Feeler gages 10 Pinned surface gage Pliers 1 Slip joint 2 Needle nose 3 Diagonal side cutter small Punches 1 Center punch 2 Transter punches 1 4 through 7 16 3 Pinset Screwdrivers 1 Phillips 2 pt 2 Small non conductive flat tip Sockets 1 Hex Head set 1 8 through 5 8 2 1 Socket Wrenches 1 Tap Handle 2 6 adjustable 3 12 adjustable 4 Combination 3 8 through 11 16 5 Torque 5 75 ft lb rating 6 Torque 20 250 in lb rating Miscellaneous 20 ft extension cord Files flat half round etc 1 4 Countersink Deburring tool Gear puller optional oP WN MillPWR A ad c 2 ad O O om q q Tools for Z axis Installation Special tool for the Z axis installation is available A Z axis Locknut Torque Tool ID 2003 7447 Additional tools required for installation of the Z axis Sockets 1 3 4 Socket z A ad e 0 sj O O hom 4 q Wrenches 1 9 16 Open End 2 required 2 3 4 Open End 3 7 8 Open End 4 3 4 Open End Crowfoot 5 7 8 Open End Crowfoot 6 Ratchet Wrench 3 8 or 1 2 and extension 7 Hex Wrench set Standard English with short arm 8 Provided by ACI Hex Wrench M1 5 9 Provided by ACI Hex Wrench M2 Miscellaneous 1 Retaining Ring Pliers 2 Grease Gun 3 high quality lith
21. 2003 458 ID 2003 457 ID 2003 412 ID 4100 155 ID 2003 443 ID 2003 417 ID 4180 121 Z Axis Housing 1 13 x 2 HHMS 1 2 Flat washer 10 32 x 1 2 SHCS Ball Nut Stop 1 2 13 Hex Nut 3 8 Hex Nut 3 8 Flat washer 10 32 x 3 4 SHCS Bearing Retainer Radial bearing 3 8 16 x 2 HHCS Angle Contact bearing Preload Bearing Shim Angle Contact bearing Bearing Retainer 10 32 x 1 2 SHCS Spanner nut Pulley 24 T Key 1 8 sq x 1 lg All numbers XX in the following section refer to the listed items in the previous exploded view unless otherwise specified Lower the nut block to the bottom of the quill travel Position the ballscrew approximately 3 1 2 from the top of the ballscrew nut The bearing assembly 13 through 17 have been factory installed Casting installation Insert the ballscrew through the bottom of the casting 1 then lift over the top of the ballscrew Set bearing bore onto the top of the ballscrew 32 Install the 3 8 16 x 2 HHCS 12 through the hole in the casting and the lower bushing Attach the 3 8 x 1 2 Hex nut 7 and flat washer 8 Leave loose at this time Raise the quill until the top to the ballscrew shaft seats into the top bearings Place the radial bearing 11 into the bearing retainer 10 When attaching the bearing retainer insure that the bearing slides over the shaft of the ball screw ll 6 Z Axis Motor Casting Installation Attach th
22. 24 x 1 1 2 SHCS and the 1 4 20 x 3 4 SHCS Attach the nut block with both screws Sc 2 a amp er YN 5 O aL A lt N LO Repeat the alignment procedure of the nut block gt Torque the 3 8 24 x 1 1 2 SHCS to 30 ft lbs and the 1 4 20 x 3 4 SHCS to 9 ft lbs 28 ll Reinstall the Engage Disengage mechanism Insert the ballscrew into the nut block from the top c 9 ad L ad Y 5 O E gt lt N LO MillPWR 29 c 2 ad AS C ad Y E O EL A lt N LO Tighten the screws of the Engage Disengage mechanism until the heads of the screws are flush with the plate Attach the quick release knob Using the quick release knob secure the ball screw in place Remove the plug from the ball screw and save Install the grease fitting into the ball screw 30 C NENT i uo ejje su Huljsed 1030 A SIXY Z 9 II Il 6 Z Axis Motor Casting Installation S Items 13 through 17 have been factory installed Z axis motor casting exploded view 31 MillPWR c 2 ad E O ad Y O ad Y Q ad EL gt lt N do Hardware list SOON OORWN dh O N 2 2 2 2 2 oO ON OO OI RP W DN ID 2013 391 ID 4100 158 ID 4160 114 ID 4100 155 ID 2003 485 ID 4150 106 ID 4150 107 ID 4160 113 ID 385026 104 ID 2003 413 ID 2003 416 ID 4100 151 ID 2003 457 ID
23. 5 Z Axis Quill Installation The following steps are to be preformed by removing one head locking nut at a time Remove each head locking nut in the order show replacing each one ata time with 1 2 13 x 1 3 4 extension coupling nut 12 Tighten each nut to 25 ft lbs Repeat the tightening procedure using the same sequence to 50 ft lbs each The spindle must be properly aligned Refer to the machines operator reference manual to align the spindle at this time Insert the Alignment Bushing 17 into the lower casting tab Remove the Quick Release knob 1 from the Nut Block assembly mounting hole Insure that the quill is positioned to allow The nut block will mount to the quill using the quill stop clearance for the nut block mounting surface With the Quill locked in position quill must not come out of the machine remove the Spindle MillPWR 25 Attach the Nut Block assembly to the Quill with the 3 8 24 x 1 1 2 SHCS 9 Do not fully tighten fastener at this time Inspect around the mounting surface of the nut block assembly to insure that clearance Is provided between the casting and nut block The mounting surface of the nut block is contoured to match the radius of the quill This makes the nut block self aligning when secured in place If it becomes necessary for some reason to check the alignment mount a dial indicator to a magnetic base and attach it to the table top Position the indica
24. ETUP TOOL LIBRARY SCALE FACTOR DISPLAY OPTIONS ELECTRONIC EDGE FINDER JOB CLOCK FEED RATE SETTINGS O E 5 2 pur lt ud lt N Use New CANCEL SETTINGS CHANGES gt Highlight SERVO TUNING with the arrow keys and press ENTER gt Press the Z SERVO softkey gt Press the AUTO TUNING softkey TABLE WILL MOVE AT LEAST 2 DURING THE TEST AUTO MANUAL STOP GAIN BALANCE TUNING TUNING TEST TEST TEST SERVO TUNING Z N Note the quill will move when executing the next step AREER 5 BALANCE STATUS e TEST COMPLETED MillPWR 65 O 5 2 a sj lt N Press the GAIN TEST softkey The quill will move and the values in the FOLLOWING ERROR field will fluctuate MILLPWR adjusts the motor s settings The quill will stop moving and the TEST COMPLETED message will appear in the STATUS field when the test is complete The messages in the STATUS field will change as the STATUS field when the test is complete proceed S If the TEST COMPLETED message does not appear in with Manual Tuning instead Press the BALANCE TEST softkey Do not touch the quill during the balance test MILLPWR will wait for the electrical current from the motor to level off then it will begin adjusting the balance It will find the minimum and maximum voltages needed to move the quill Once those values have been identified MIL
25. LPWR will verify them This test could take several minutes The balance test is complete when TEST COMPLETED appears in the STATUS field When the balance test has ended press the STOP TEST soft key Press the USE NEW SETTINGS soft key to save the new settings 66 TABLE WILL MOVE AT LEAST 2 DURING THE TEST AUTO TUNING MANUAL TUNING STOP TEST GAIN BALANCE TEST TEST SERVO TUNING Z SIUS TEST COMPLETED IV 1 Trouble Shooting MillPWR Introduction The Troubleshooting Guide is intended to help quickly diagnose a problem and implement the recommended corrective action Using the Table The table is arranged in three columnns Symptoms are listed in the most common and easiest to check order First locate the symptom that best describes the problem that requires correction Then identify the probable cause that most closely matches the problem Implement the corrective action This guide primarily pertains to the system with some application to the machine tool as well It does not address inadequate tooling improper feed rates or spindle speeds 1 Trouble Shooting MillPWR Symptom Probable Cause Corrective Action Operator console displays a System has remained idle for Check that the power indicator light blank screen approximately 20 minutes and is in located in the upper left corner of the screen shaver mode console is illuminated If the power indicator light is illuminated
26. NING TUNING TEST TEST TEST SERVO TUNING Y FOLLOWING ERROR Press the GAIN TEST softkey The table will move and the values in the FOLLOWING ERROR field will fluctuate STATUS SET POTENTIOMETER TO O S Note the table will move when executing the next step While the table is moving adjust the gain potentiometer 2 with the non conductive flat tipped screwdriver until the value in the FOLLOWING ERROR is between 0 and 20 Adjust the potentiometer slowly Pause periodically to let the value settle Ti r de n ae Tuni i Senge te eh ha E E y li E o T A a oye ie i e gm Ps eT pi E la e a PLE q5 fen PAE E gt m z ing a k ae ke tke ee A A hes LT 4 Y tne h hy a e ae ETN ee a ES a ais n i ak si Tal 7 i a FREER ERPS EE SE l 14014 LHL O s a ie ri Fa aa Lae Press the STOP TEST soft key to lock in the value MillPWR 57 Press the BALANCE TEST softkey TABLE WILL MOVE AT LEAST 2 DURING THE TEST AUTO MANUAL STOP GAIN BALANCE TUNING TUNING TEST TEST TEST Set the velocity value by completing the next step SERVO TUNING Y O E gt q I While the servo motors are on adjust the balance potentiometer 3 with the non conductive flat tipped screwdriver until the velocity reading in STATUS field reaches 0 00 Adjust the potentiometer slowly Pause periodically to let the value settle TERR R
27. PER EEE AUSIRE A El Press the STOP TEST soft key to lock in the value Press the STOP TEST soft key again to return to Servo Tuning Press the USE NEW SETTINGS soft key to save changes and exit setup Re attach Heat Sinks Power down the MILLPWR system Slide the heat sink against the housing and secure in place by tightening the four long fasteners Insert and tighten the two 2 shorter screws 58 lll Z Axis Manual Tuning Highlight SERVO TUNING with the arrow keys and press ENTER Manually position the table to it s center of travel and the saddle to it s center of travel using the hand wheels S Manually move the Z Axis to It s center of travel Press the Z SERVO softkey O gt q I Press the MANUAL TUNING softkey TABLE WILL MOVE AT LEAST 2 DURING THE TEST AUTO MANUAL STOP GAIN BALANCE TUNING TUNING TEST TEST TEST SERVO TUNING Z FOLLOWING ERROR Press the GAIN TEST softkey The quill will move and the values in the FOLLOWING ERROR field will fluctuate STATUS SET POTENTIOMETER TO O S Note the quill will move when executing the next step While the quill is moving adjust the gain potentiometer 2 with the non conductive flat tipped screwdriver until the value in the FOLLOWING ERROR is between 0 and 20 Adjust the potentiometer slowly Pause periodically to let mp the value settle Press the STOP TEST soft key
28. X axis housing 22 to the left end of the table with four 4 3 8 16 x 1 1 4 SHCS 20 and 3 8 Flat washer 21 Do not fully tighten fasteners at this time gt Insert the alignment tool see Ballscrew Alignment Tool ID 2003 7387 on page 2 over the shaft and into the bearing bore Adjust the housing until the tool slides freely over the shaft and into the bearings Do not remove the tool at this time gt Secure the housing in place by securing the four 4 3 8 16 x 1 1 4 SHCS torque to 35 ft lbs gt Install the Roll pins 3 16 Dia x 2 lg 19 Drill a 3 16 diameter hole through both the housing and into the end of the table Guide holes have been provided in the housing one on each side of and above the bearing retainer plate 14 Insure that no chips fall into the bearing area X axis Ballscrew Torque procedure Remove the alignment tool and turn the ballscrew from the left side of the table clockwise out into the bearings Insure that the bearings seat properly on the ballscrew journal With the bearings seated do not move the ballscrew Insert the spanner lock nut 12 on to the ballscrew shaft with the tapered side facing the machine and hand tighten Place the torque tool see Locknut Torque Tool ID 2003 7388 on page 2 over the shaft and onto the spanner lock nut Place a spanner wrench onto the Locknut Torque Tool or use an adjustable wrench Proceed with the next step
29. ad Connect black lead from nut block limit switch 3 White lead Connect white lead from nut block limit switch 4 Black lead Connect short black lead from motor housing 5 1 4 Cable clamp Attach engagement harness and reading head cable to the casting with the 2 1 4 cable clamps 6 Cable strain Place the strain relief around the cable and relief insert into the slot provided with the clamp on the top side Adhesive clamp Attach two 2 clamps as shown and attach the cable as shown 8 Grease Fitting Using a high quality lithium soap based grease add grease until it begins to escape from the ball screw nut 9 Plug Remove grease fitting 8 and replace with previously removed plug Save fitting for future use Insure that the ball nut has been properly greased Attach the cover plate 3 with the fasteners 1 and attach the quick release know 2 Refer to the exploded view ll 8 Precision glass scale Installation optional 42 Il 9 Z Axis Motor Installation Exploded view S Reattach the quick release knob Hardware list ID 2003 210 Z Axis Motor Assembly ID 2013 392 Cover plate ID 385004 161 10 24 x 5 8 SHCS ID 4150 111 5 16 Hex locking flange nut ID 2013 437 Belt ID 2013 418 Pulley 24 T ID 4180 121 1 8 square key x 1 lg ID 2013 348 Access plate ID 385032 105 8 32 x 3 8 BHCS 0 ID 4100 118 5 16 18 x 1 1 4 SHCS not shown e 2 pur amp O ad Y hom jad
30. are listed on page 4 Installation Requirements MINPWR requires a dedicated 110 volt 20 20 amp 50 60 Hz circuit and a 20 amp receptacle Sufficient workspace should be provided to slide the table completely off the end of the saddle The minimum space required is dependent on the actual table s length scales are included with each scale Instructions included with encoder mounting hardware kits supercede the scales instructions Installation Instructions for ACU RITE s precision glass Tools X amp Y Axis Special tools for the X and Y axis installation are available A Ballscrew Alignment Tool ID 2003 7387 B Ballscrew Torque Tool ID 2003 7397 C Nut Block Drill Template ID 2003 7398 subject to updates D Locknut Torque Tool ID 2003 7388 Additional tools required for installation of the X and Y axis Drills and Taps 1 Drill set 7 32 through 1 2 2 Drill and Tap set 4 40 through 3 8 16 3 1 4 Center Drill 4 3 8 Variable speed drill heavy duty Drivers 1 Hex Key set 0 05 through 1 2 Ball driver 2 Hex Key set 1 5mm through 10mm Ball driver Hammers 1 Ball Peen 12 oz 2 Plastic soft faced 7 8 1 face diameter Measurement Tools amp Levels 1 Measuring tape 12 Ft 2 Machinists Level 4 in Tubular level optional 3 Machinists Square 4 in 4 Caliper 12 Dial or Digital 5 Depth Micrometers 6 Dial Indicators 001 and 0
31. by ACU PEN TE INSTALLATION MANUAL Introduction MILLPWR Installation Manual Symbols within Notes Every note is marked with a symbol on the left indicating to the Installer the type and or potential severity of the note MillPWR Introduction UOI INpPOI UY Table of Contents Introduction VE MMOS WII OS ta crc cea nat ca ee reas eee ac cel er te rte es 1 Introduction to MilIPVVR DY Se FIV CCW as recanted saa cad aasnle A 1 Preparati arnan a a SNE TRE a PS RRC ICCC RTO TC BEN Pe RME ICIS 2 STAN SOULE TVS ICS ais 2 KOSS A E TAS rada 2 Tools Tor zZ axe AS tala O e Dt E 4 Additional tools required for installation of the Z AXIS c ooccoccccccncccncccncnnncnnanonaso 4 2 Mill Disassembly Table and Lead Screw Tema A TE 5 Removing the X ed SAMOS as 5 Pre IIO WING NS ala aos 5 Removing the Y axis hardware aa 6 Removing the Less Stand ds 6 Removing the Z axis hardware ista ii 7 REMOVING the UCAS SEMO ei a a a T 8 Il 1 MillPWR Installation AAS B AIS Cre WINS tall O A aan 9 E O E ES TT 9 ICES OG Asta lO Nito ds eto eel Laos ae teo ee ll pd ea 10 IIS Che WINS talla OM dessa ceecedetsacccsnedeueosendeayesccescdeacanataescanenscameasaeersaeath alle den 11 ae A A T 11 ION IZOVI all al lane adi 12 ROLFI MESHES kts O Nee nee ae eee ee ee eee TRC et one ee ee neat eee Tene 12 Y Axis Ballscrew Installation suture lone aces e e e 13 AMS SAM ir AA O ito 14 MillPWR Il 2 Y Axis M
32. console Connect the Y axis motor assembly cable 4 to the Y axis servo connector located on the rear of the operator console Connect the Z axis motor assembly cable 4 to the Z axis servo connector located on the rear of the operator console Connect the X axis AC power cable 1 to the Z Axis motor housing 2 Connect the X axis cable 2 to the Y Axis motor housing 1 Connect the Y axis cable 2 to the Controller Servo Power 46 View of the rear of the console TOUCH TEST PENDANT PROBE 8 0 8 W AXIS ENCODER o o SERIAL EE PORT EDGE FINDER B o o o o o l o o o Z AXIS Y AXIS SERVO SERVO Cable Routing Route all cables in a neat and orderly fashion Keep cables approximately 16 above the floor Use the nylon wire ties provided Il 11 Cable Connections Controller Routing gt Route all cables in a neat and orderly fashion to the Control as shown Insuring that machine movement is not restricted Use the nylon wire ties provided MillPWR 47 Il 12 Machine Tool Gib Adjustment A 0 0005 Dial Indicator and magnetic base is required for this adjustment Y Axis Gib Position the table to the right side of the saddle Position the dial indicator base on the knee Tighten the X axis table locks Position the dial indicator on the table Set the indicator to 0 00 then push and pull on the right end of the table Adjust the Y Axis gib un
33. e 3 axis systems only move the quill completely upward but just before the limit switch is tripped Press the SET TOP LIMIT soft key Press ENTER Move the quill completely downward but just before the limit switch Is tripped Press the SET BOTTOM LIMIT soft key Press ENTER Press the USE NEW SETTINGS soft key O gt gt q I 52 Introduction MILLPWR s gain and balance potentiometers must be manually tuned upon initial startup as well as each time a motor assembly is replaced MILLPWR includes an automatic tuning feature that is used to fine tune the gain and balance The automatic tuning feature has a limited adjustment range In the event that the required adjustments exceed the automatic tuning circuitry s range MILLPWR will need to be manually tuned first Please note that tuning is critical to ensuring that MILLPWAR s software table movement quill movement for systems equipped with Z Axis control and servo outputs are synchronized during use O ES E q Mill PWR 53 Manual Tuning Tools required 1 7 64 Allen wrench 2 Small non conductive flat tipped screwdriver 3 Non conductive spacers 2 provided with systems that include the Z Axis control Power down the MILLPWR system O gt q I Accessing the Gain and Balance potentiometers These views are typical to all three axes X Y and Z
34. e following message DSP fault X Y or Z axis position error check failed 1 Trouble Shooting MillPWR 2 X Y and or Z axis precision glass From the DRO display move each axis scales stopped counting manually to verity that the precision glass scales count If the scales don not count perform the following e Press the emergency stop button e Swap the X and Y axis servo connections e In the DRO display move each axis manually to check if the scales count If a scale does not count follow the instructions for the Scale s miscount in certain areas only on the following page Next swap the X Y or Z axis servo connections and continue to check for a scale counting error If a precision glass scale does not count follow the instructions for The scale s miscount in certain areas Do not release the emergency stop buttonn until you hhave restored the X Y and Z axis servo connectors to proper locations MillPWR 69 O e Q Q K Y Lo 2 E gt Symptom System powers up but motor s will not move table cont d Table runaway Table or quill will move in one direction only Machine does not move at the correct speed moves very sluggishly or does not move the correct distance Table has stiff movement 70 Probable Cause The scale s miscount in certain areas only Check the servo amplifier and servo card LEDs LEDs will blink quickly
35. e retainer with four 4 10 32 x 5 8 SHCS 9 Do not tighten fasteners at this time MillPWR 33 Using the quill handle position the ballscrew nut to about 1 4 from the top of the ballscrew travel Install the spanner nut to the top of the ballscrew 18 taper side of the nut should be downward towards the bearings Place the spanner nut torque tool over the spanner nut See Z axis Locknut Torque Tool ID 2003 7447 on page 4 Using a torque wrench tighten the spanner nut to 30 ft lbs holding the bottom of the ballscrew in place with a 9 16 open end wrench c 9 ad AY 6 ad Y O jad Y Q S ad AL a lt N fe Aligning the Z Axis Casting Referring to the exploded view drawing insert four 4 1 2 13 x 2 SHCS 2 with flat washer 3 through the casting Insert a second set of four 4 1 2 flat washers 3 and attach four 4 1 2 13 hex nuts 6 Attach the casting to the coupling hex nuts previously installed onto the quill Do not secure at this time 34 ll Run the quill up and down through it s full travel Position the quill at the top of It s travel until the top of the ball nut reaches the stop Position the face of the casting so that It is parallel with the face of the quill horizontally Place an indicator or two indicators as shown and set to 0 000 This will be used as a reference while securing the casting in place While monitoring the
36. eading head bracket installation dia 40 Scale POSON O T EA A a A 40 Scale ACI INC I erena E E E a E aia 40 Reading head IVS Tea PLN OR aici tase ia ibid 41 GCS WIR ta lato aiii 41 Engagement Limit switch installation siiiderheds vis caittinue Vokes hits ieM ies yaar inia Veit en 41 Il 9 Z Axis Motor Installation EXO ACAO er E Re ner Ser et ta METE ONE OREN rn OREO rr oR RTE Ta ROPES CRE eT ETO Re 43 AA A nw Ea TE VRE A EE ANA AE ene A 43 Mision A 44 A A A tees rea aes ed 44 Co eE Ea so eo a hee AE ets re scree eae nee E AE nen ate E 44 Il 10 High Low Range Switch Installation BAS MAS tall al Odes e e a te do do hid sates a 45 SIMCO TAS AO o ee ene AETA T 45 Il 11 Cable Connections Cable attachment and InstallatiOD oooccooccoocncnoccnnononononnnnnnnnnnononononnnononos 46 SO SiR OUT Ag aes ase ea E at tune aster 47 CONTA aye 0 Ada asnan di 47 Il 12 Machine Tool Gib Adjustment A 48 SS O T N 48 MillPWR II 1 Manual Tuning A e a cedaecaeneeas 49 A A A 49 pe CU as aeaas dhe acdeestniedag A 49 COUCE CUO ranee or acta Satin aaa A tan grantee anata tease acount ait 50 CHANGINGSCOUN TE CINECTIO uds onde AE 50 Conima the COMMOl lOOD parainete S neria a aie eas 51 SMV MICS its A 52 Lp iddeye Ufo Ni AE 53 Mantal TONIO ennan an iar O oS 54 Accessing the Gain and Balance potentiometers occoocccoccnnccncncncnncnnnononcnnononnnos 54 AA Mantal MUNI ia 55 ASNO and 57 aii o SA eases etek ok eet
37. en in place at this time Adjust the upper limit switch so that it trios when the nut block is within 0 05 to 0 10 of it s upper max travel Secure bracket in place Adjust the lower limit switch so that It trips when the nut block is within 0 05 to 0 10 of It s lower max travel Secure bracket in place Engagement Limit switch installation a Q O O e LL hom ad c 2 ad AS O ad Y os O ho Y h mal pa I Attach the limit switch 14 to the quick release assembly with 2 6 32 x 1 4 BHCS 13 Re attach the quick release knob Turn the knob clockwise until it is fully closed Adjust the limit switch until the switch trips Secure the bracket and switch in position Loosen the quick release clamp and the switch should open Turn the knob clockwise until it is fully closed this is when the switch should close Insure that the switch is properly positioned MillPWR 37 Route the wire harness inside the casting as shown If switches have been removed from the wire harness complete the following 1 Black lead Connect black lead from engagement switch 2 Longest lead Connect long black lead from reader head cable 3 White lead Connect white lead from engagement switch 4 White lead Connect white lead from reader head cable 5 1 4 Cable clamp Attach engagement harness to the casting with the 1 4 cable clamp 6 Cable strain Place the strain relief around the
38. f adjustment Is necessary raise one end of the nut block using shim stock to elevate it until both measurements are within 0 005 of each other MillPWR 11 Horizontal alignment Now place the probe of the indicator so that it touches the front side of the ballscrew and set it to zero Without changing any settings to the indicator set up move the base to the other end of the saddle and compare the two measurements Position the nut block so that both measurements are within 0 005 of each other Torque the four 4 3 8 16 SHCS to 35 ft lbs Insure that alignment is maintained Torque the nut block fasteners to 35 ft lbs to properly secure It in place e 0 a amp er Y a Roll Pin installation Do not proceed without verification that the X axis ballscrew is properly aligned Before proceeding insure that the saddle way covers are clear Drill two 2 3 16 holes x 1 deep one 1 on each side through the nut block flange Insert a 3 16 x 1 roll pin into each hole Drive pins flush with top surface of nut block flange 12 Y Axis Ballscrew Installation Components 1 Y Axis Ballscrew 2 Oil line not shown 3 Oil line fittings not shown Do not remove the ballnut from the ballscrew it can not be re assembled Preparation Position the saddle to the front of the knee away from the column Y Axis Ballscrew installation Feed the plastic oil line1 throug
39. h the opening in the saddle to the right side of the nut block 2 Install an oil line fitting 3 onto the flange of the ballnut on the right hand side note It s location Connect the oil line to the fitting on the ball nut Insert the ballscrew into the nut block Note it s orientation and ensure that there is clearance for the crown gear Attach the ballnut to the nut block with three 3 10 32 x 3 4 SHCS Torque the three 3 10 32 x 3 4 SHCS to 30 in lbs S No alignment is necessary for the Y axis ballscrew Cut the oil line to length and connect it to the oil line on the machine Insure that the oil line does not interfere with the crown gear or other obstructions Slide the saddle through it s full travel while insuring that the oil line is free to move with the saddle movement The Y axis scale should be installed at this point Use the bracket kit instructions to install the encoder MillPWR 13 Il 1 MilIPWR Installation c 2 a amp O er Y a Table Installation Components 1 Table 2 Xaxis gib 3 Xaxis gib adjustment screw Preparation Check that the saddle ways are clean free of chips dirt and are in good condition Activate the oil pump Verify that the gibs saddle ways and ballscrews are receiving oll Position the X axis gib locks so that there is clearance for the table to slide back on to the saddle Coat the saddle ways with oil En
40. is needed add another washer Insert the handwheel 18 on to the shaft and lock in place with the jam nut 17 MillPWR 17 Hardware list c E O er Y ed 2 m lt sj EL A lt A mm ID 4100 118 ID 2013 210 ID 2013 304 ID 4100 154 ID 385004 164 ID 2013 313 ID 4150 111 ID 2103 306 9 ID 4180 121 10 ID 2003 305 11 ID 4100 176 12 ID 387900 115 13 ID 385004 164 14 ID 2013 367 15 ID 2003 305 16 ID 2003 374 17 ID 2003 305 18 ID 2003 370 19 ID 387900 399 20 ID 4100 142 21 ID 2003 372 22 D 2013 311 23 ID 2013 348 24 D 385032 105 CON UM RP WN 18 Il 3 X Axis Motor Drive Installation X axis Exploded view factory installed to the proper torque specification Do not S The bearing and outer bearing retainer plate have been remove them 5 16 18 x 1 1 4 SHCS DC Motor assembly Pulley 30 T 10 32 x 1 4 SHSS 1 4 20 x 1 2 SHCS Cover X Axis Housing 5 16 18 Locking Hex Flange Nut Belt key 1 8 Square x 1 lg Pulley 60 T 1 4 20 x 1 2 SHSS Spanner lock nut 1 4 20 x 1 2 SHCS Bearing retainer Angle contact bearing Preload bearing shim Angle contact bearing Seal Nilos Ring Roll Pin 3 16 x 2 lg 3 6716 Xx 2 SHCS 3 8 Flat washer X axis housing Cover Plate 8 32 x 3 8 BHCS X Axis Ballscrew X Axis Motor Drive casting installation Position the ballscrew and table approximately centered on the saddle Attach the
41. isabled The quill has reached a limit switch The drive belt is loose The quill is over extended The feed rate and or spindle speed require adjustment Corrective Action Release lock Lubricate the ballscrew with a high quality lithium soap based grease Re align the Z axis assembly Replace the radial bearing and or angular contact bearings on the Z axis ballscrew Check that the program step is correct and that there is information in the Z axis fields for the Z axis Tighten the quick release knob for the Z axis drive system Refer to Z axis Conventions Enable the Z axis refer to Setup Move the quill toward the center of trhavel Adjust the drive belt tension Should none of these recommendations correct the problem contact Heidenhain Corporation for repair or replacement procedures Shorten the quill distance and raise the knee Adjust the feed rate and or the spindle speed 73 1 Trouble Shooting MillPWR 2 Symptom O e Q Q K Y Lo 2 E gt Poor dimensional accuracy 74 Probable Cause The tool is worn The tool diameter is too small for the depth of cut The tool is not secure in the tool holder The machine s ram and or head is loose The spindle bearings are worn The machine s spindle is out of alignment The quick release knob for the Z axis drive is loose Corrective Action Replace with tool in
42. ium soap based grease 2 Mill Disassembly This section describes in detail the removal of components from the mill in preparation for the MIlIPWR installation Table and Lead Screw removal 2 Mill Disassembly Removing the X axis hardware Remove vises fixtures etc from the table Table must be free from any components Remove the following components from each side of the table 1 Jam nut 2 Handle 3 Dial locknut 4 Daal 5 Dial Holder 6 Bearing retainer 7 Bearings 8 Bearing casting Removing the Table Position the table so that it is centered over the saddle gt Remove the X axis gib Position the cart to either side of the knee centered under the table Raise or lower the knee so that the table is at the same height as the cart Slide the table onto the cart until it is clear of the saddle MillPWR 5 Removing the Y axis hardware Position the saddle all the way forward on the knee Remove the following components Items noted with an asterisked will be re used Jam nut Handle Dial locknut Dial Dial Holder Bearing retainer Bearings Bearing casting 0 JO O11 PR WN D T 0 pos A N Removing the Leadscrews Remove the two 2 screws 1 holding the Y axis leadscrew 2 to the nut block Remove the leadscrew 2 and Acme nut 3 by placing the handle P back on the leadscrew and un
43. l must slide freely over the shaft and into the bearings after the fasteners have been torque Y wee yao riek i oi Es Os TF P da Install the Roll pin 3 16 Dia x 1 lg 6 Drill a 3 16 diameter hole through both the housing and knee casting Guide holes have been provided in the housing one on each side to the bearing retainer plate 9 Insure that no chips fall into the bearing area Y axis Ballscrew Torque procedure Remove the alignment tool and turn the ballscrew clockwise out into the bearings Insure that the bearings seat properly on the ballscrew shaft With bearings seated do not move the shaft Insert the spanner lock nut 7 on to the ballscrew shaft with the tapered side facing the machine and hand tighten Place the torque tool see Locknut Torque Tool ID 2003 7388 on page 2 over the shaft and onto the spanner lock nut Place the square key 13 in the front slot of the ballscrew Place the torque tool see Locknut Torque Tool ID 2003 7388 on page 2 over the shaft and key Place a spanner wrench onto the Locknut Torque Tool or use an adjustable wrench While holding the spanner wrench torque the spanner nut to 50 ft lbs by turning the ballscrew counter clock wise with the torque wrench attached to the Ballscrew Torque Tool Remove all tools c 2 a amp er Y 0 2 A E sj BL A lt gt N 16 ll Y axis 60 T Pulley Installation
44. mbers XX in the following section refer to the listed specified The upper and lower limit switches are supplied attached to the mounting plates Nylon brushes are factory installed to the inside of the cover plate MillPWR 39 C c 0 ad a c 2 jad 3 O ad Y 2 O Y Y Y a O c 2 ML O d E 0 00 I Reading head bracket installation Attach the reading head bracket with two 2 8 32 x 3 8 BHCS 11 and 12 Position the bracket so that it is flush with the front of the nut block Scale Positioning Place the scale into the casting as shown The top end of the scale rest against the underside of the casting The scale sets on two machined surfaces and inserts into L shaped hooks Scale attachment Using two 2 M4 x 8mm SHSS 9 apply loctite to the threads and insert into the left side of the casting Fully tighten both screws securing the scale in place 40 Reading head installation Move the quill so that the reading head bracket mounting holes align with the reading head casting mounting holes Insert the two 2 8 32 x 3 4 low head SHCS through the reading head and into the bracket Do not tighten Place loctite on the three 3 M3 x 12mm SHSS and insert each into the reading head Adjust each screw so that when lightly tightening stop as soon as resistance is felt Fully tighten the two 2 8 32 x 3 4 low head SHCS Remove the two 2 alignment bracke
45. mum and maximum voltages needed to move the table Once those values have been identified MILLPWR will verify them This test could take several minutes The balance test is complete when Test completed appears in the Status field When the balance test has ended press the STOP TEST soft key Proceed with Auto Tuning the Y Axis Servo Motor 62 TABLE WILL MOVE AT LEAST 2 DURING THE TEST AUTO MANUAL STOP GAIN BALANCE TUNING TUNING TEST TEST TEST SERVO TUNING X STATUS TEST COMPLETED Y Axis Auto Tuning Manually position the table to it s center of travel and the saddle to it s center of travel using the hand wheels Highlight SERVO TUNING with the arrow keys and press ENTER Z Axis options will not appear when a two 2 axis system is being installed gt Press the Y SERVO softkey Press the AUTO TUNING softkey N Note the table will move when executing the next step MillPWR OFF FEED 0 0 100 JOB SETUP TOOL LIBRARY SCALE FACTOR DISPLAY OPTIONS ELECTRONIC EDGE FINDER JOB CLOCK FEED RATE SETTINGS INSTALLATION SETUP Use New CANCEL SETTINGS CHANGES TABLE WILL MOVE AT LEAST 2 DURING THE TEST AUTO MANUAL STOP GAIN BALANCE TUNING TUNING TEST TEST TEST SERVO TUNING Y FOLLOWING ERROR STATUS TEST COMPLETED 63 O 5 a sj lt N O 5 2 a sj
46. ng the Y axis hardware esce 6 Removing the Z axis hardware ccce 7 S Symbols within NOTES occoocccccccccccoccnononcncnnononon System OvervieW acicate tinride ces 1 T Fable removal sucia dada arras 5 Table Installation curar ba 14 TOONS A E OU III E E 4 PESAS E E AE 2 Tools for Z axis Installation 4 Trouble Shooting MINPWIR n se 67 X X axis Ballscrew Torque procedure 19 X Axis Bearing and casting installation 20 X Axis Bearing Handle Installation 23 X Axis Motor Drive casting installation 19 X Axis Motor Installation o n 21 Y Y Axis Ballscrew Installation oo oo o 13 Y axis Ballscrew Torque procedure 16 Y Axis Motor Drive casting installation 16 Y Axis Motor Drive Installation 17 Z Z Axis Motor Casting Installation 31 Z AXIS Motor Installation ninia 43 Z Axis Nut Block Installation 25 Z Axis Quill Installation coooccooncnocnno 24 Z axis Locknut Torque Tool invciiniain siria 4 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 ISO 9001 CERTIFIED CE 660070 21 Ver 00 e Subject to change without notice 11 09
47. ode 1111 Select ENCODER SETUP using the arrow keys Press ENTER Select the axis to be changed using the arrow keys and press ENTER Using the arrow keys highlight SCALE RESOLUTION Press the 1 MICRON or 2 MICRON soft key depending on which one matches the encoder installed Press the USE NEW SETTINGS soft key to save the new setting Set the SCALE RESOLUTION for each encoder installed MillPWR 49 Ill 1 Manual Tuning O gt gt q I Count direction The count direction that is required and what the Console will be setup for is as follows Table moving left is X axis positive Table moving from back to front of machine is Y axis positive Quill moving up is Z axis positive Table moving down is W axis positive Changing count direction To change the count direction for the X Y Z and W axis Select ENCODER SETUP using the arrow keys Press ENTER Select the axis to be changed using the arrow keys and press ENTER To change the count direction press the opposite soft key of what is displayed i e NEGATIVE is displayed then press the POSITIVE soft key Press the USE NEW SETTINGS soft key to save the new setting To change the count direction for the Z axis Press the SETUP key on the operator console Using the arrow keys highlight INSTALLATION SETUP and press ENTER Enter the installation setup Access Code 1111 Select ENCODER SETUP using the arrow keys
48. oir or oll lines are blocked disconnected System is not repeating or circles are not round System is out of tune Machine tool related problems Improper position feedback from precision glass scales Incorrect Dimensions Programming error MillPWR Corrective Action Check that there is sufficient oll in the reservoir Should none of these recommendations correct the problem contact Heidenhain Corporation for repair or replacement procedures Check that the knee ram head bolts turret to column bolts and head to knuckle bolts are properly fastened and are secure Check the gibs for wear and for proper adjustment Refer to the machine tool operation manual Align the spindle Refer to the machine tool operation manual This system can compensate for machine tool wear through its linear error compensation feature Refer to Setup in the Operation Manual Check each scale reading head for proper installation Insure that the mounting brackets and fasteners are secure Check that the proper dimensions were entered for each step of the program Incorrect scale resolution setting Refer to Operators manual for encoder resolution setting Check that the correct tool information was entered for each step of the program 71 1 Trouble Shooting MillPWR 2 O e Q Q K Y Lo 2 E 2 Symptom Probable Cause Machine tool related problems System is o
49. otor Drive Installation MAISEXDOACA Vasallo lid 15 o A 15 Y Axis Motor Drive casting installation seriada 16 Y axis Ballscrew Torgue proced re ta As 16 AUS GOT Fulle y IAS O ranen enn AAA EEA ES 17 YAS IO LON N aO aa A abris 17 Il 3 X Axis Motor Drive Installation A AXIS EXD OOS MEVA aiii N 18 Harwal e diS Ca A No 18 X Axis Motor Drive casting installation ocooccconcccncccnnonconncncnonnconnnnononononnnos 19 X axis Ballscrew Torque procedure ais 19 X axis Bearing sleeve Instalar dai ad 20 X Axis Bearing Housing installation rta id Abs 20 X axs 60T Puleyi stalat Oi tratara latidos 21 KPIS MOr INStalla tiO in ai 21 Il 4 X Axis Handle Installation AMAS hande expoded VIEW aiia iA AE AEE 22 EO E E TENE A AAEN aden in naan et 22 SECURING the Beano CaS tin aran nd 23 Il 5 Z Axis Quill Installation Z axis ballscrew exploded VIC Wise 24 a A O A a eas a A a tn 24 Z Axis Nut Block Installation cerrado datada 25 Il 6 Z Axis Motor Casting Installation Z axis motor Casting exploded VIEW ooccocccccncccnoccnoccconnnonnnncnnnnnnnnnnnnnnnnnnnnnoneninnnoss 31 E215 41019 taO e E soe ci 32 ANONIMO Me ZAS CS SUING ld 34 Il 7 Limit Switch Installation rotary Encoder Lt Swiere plode d MEW osa dls 36 ONV E domo 36 TPIS SLOT INS ta laa tinas 37 Engagement Limit switehinstalatiO eusian i aa N A eae hes 37 Il 8 Precision glass scale Installation optional EXPIOASA VIC WV aiaiai e e IE E EN A 39 HAWAI ica 39 R
50. rrupted or may not have been properly installed Re install the system software and power up the system again Remember to Find Home Power up the system again then check that the LED on the front of the floppy drive is illuminated Listen for the Spinning sound that is typically made when It is being accessed Should none of these recommendations correct the problem contact Heidenhain Corporation for repair or replacement procedures Power down the system Wait for approximately 5 seconds then power the system up Remember to re establish machine tool zero using the Find Home routine Should this recommendation fail to correct the problem contact Heidenhain Corporation for repair or replacement procedures Check the message bar for the following message Emergency stop button is pressed Release the emergency stop button Review selection in Run Options Symptom Probable Cause Corrective Action Manual Positioning selected in Review selection in Run Options Run Options Motors are not receiving power Check that the power connection at each motor assembly and at the Servo Power connector on the rear of the console are properly seated Improper X Y and or Z axis Message bar reads X Y or Z servo servo connection unplugged fault Check that the connections on the rear of the console are properly seated Improper scale connection Check the message bar for th
51. s oll MillPWR c 2 a is O er Y a c 2 a AS C er Y O Nut Block installation From the front of the mill the nut block will be positioned and installed into the saddle with the threaded holes facing to the left Place the nut block into the saddle with the holes facing forward Rotate the nut block 90 clockwise Position the nut block so that the threaded holes are facing to the left of the saddle 10 Ballscrew installation Attach the nut block with the four 4 3 8 16 SHCS that were previously removed Do Not Tighten Install an oil line fitting onto the flange of the ball nut Insert the ballscrew into the left side of the nut block Attach the ballnut to the nut block with three 3 10 32 x 3 4 SHCS Torque the three 3 10 32 x 3 4 SHCS to 30 in lbs Connect the oil line to the fitting on the ball nut the table Do Not Tighten the four 4 3 8 16 SHCS until noted to do so S The oil line fitting must not interfer with the underside of c 2 a ai O er Y a Vertical Alignment Place a pinned surface gage base with a 001 dial indicator attached onto the rear of the saddle surface Place the probe of the indicator so that it touches the top side of the ballscrew and set to zero Without changing any settings to the indicator set up move the base to the other end of the saddle and compare the two measurements I
52. screwing it from the nut block 9 Repeat this procedure to remove the X axis leadscrew 4 5 and 6 Disconnect the oil lines from the nut block 7 Remove the four 4 SHCS 8 and roll pin 9 that attach the nut block to the saddle Save the SHCS for re assembly Remove the nut block 7 by turning it counter clockwise 90 then lifting up standard milling machine is provided All other makes and models will require the reuse of the existing nut block for the MillPWVR system Mark the orientation of the saddle way covers before removing S A pre drilled nut block for the Hardinge Bridgeport Series The disassembly of the X and Y axis is now complete Ifa z axis control is also being installed proceed with Removing the Z axis Hardware If this is a two 2 axis system being installed proceed to the Installation section Removing the Z axis hardware Refer to the milling machines reference manual s when removing components from the mill head Remove the following components from the mill Z axis Handwheel Power feed transmission engagement crank Reverse trip ball lever and screw Snap ring Trip lever pin feed trip lever set screw and steel nut Micro screw quill stop Micrometer adjusting nut or quick release nut assembly Quill stop nut and cap screw ON O11 RP WN The Trip Feed assembly is now disabled It is optional to remove it as
53. sure that the X axis gib locks do not fall into the saddle Table installation Inserting the table into the right side of the saddle move the X axis ballscrew to the left until the end of the screw is flush with the right side of the saddle Do the opposite if inserting into the left side of the saddle Adjust the knee height level to the table same as done when it was removed With table properly aligned to the saddle slide the table onto the saddle Oil the gib and insert it into position Attach the gib adjustment screw but do not tighten at this time S Inspect gib prior to installing If damaged or worn replace 14 Il 2 Y Axis Motor Drive Installation Y axis Exploded view factory installed to the proper torque specification Do not S The bearing and outer bearing retainer plate have been remove them Hardware list ID 2003 373 ID 2003 305 ID 4100 176 ID 385004 165 ID 2003 372 ID 387900 124 ID 387900 115 ID 385004 164 9 ID 2013 367 10 ID 2003 346 11 ID 2003 374 12 ID 2003 370 13 ID 4180 121 14 ID 2013 363 15 ID 2013 364 16 ID 2013 365 ON UM RP WN items in this exploded view unless otherwise specified Arbor Washer Pulley 60T 1 4 20 x 1 2 SHSS 3 8 16 x 1 1 4 SHCS 3 8 Flat washer Roll pin 3 16 Dia x 1 lg Spanner lock nut 1 4 20 x 1 2 SHCS Bearing retainer Angle contact bearing Preload bearing shim Seal Nilos Ring Key 1 8 sq x 1 lg Ballscrew 12
54. til the indicator reading is 0 001 Loosen the X Axis table locks gt 0 YN 5 lt 2 O 8 b O N X Axis Gib Position the dial indicator base on the saddle Tighten the Y Axis table lock Position the dial indicator on the table Set the indicator to 0 00 then push and pull on the right end of the table Adjust the X Axis gib until the indicator reading is 0 001 Loosen the Y Axis table locks 48 ll lil 1 Manual Tuning Initial Setup The following initial parameter setup must be preformed before any MILLPWR Console operations can be executed Flash Card Before Power up Place the MILLPWR Flash Card into the card slot The flash card must be Inserted in the card slot before power up to be recognized Refer to the Users Manual for specific information pertaining to the flash card The flash card can be removed or inserted anytime when the power is off Do not remove the card when the console is on if the red activity light is blinking Power up Power up the MILLPWR Console The software will automatically load and run The Console will prompt to FIND HOME Press the CANCEL soft key Do not use the FIND HOME or MOVE TABLE features Encoder Setup Press the SETUP key on the operator console Using the arrow keys highlight INSTALLATION SETUP and press ENTER Enter the installation setup Access C
55. to lock in the value MillPWR 59 Press the BALANCE TEST softkey TABLE WILL MOVE AT LEAST 2 DURING THE TEST AUTO MANUAL STOP GAIN BALANCE TUNING TUNING TEST TEST TEST Set the velocity value by completing the next step O i E O gt SERVO TUNING Z lt S q While the servo motor is on adjust the balance potentiometer 3 with the non conductive flat tipped screwdriver until the velocity reading in STATUS field reaches 0 00 Adjust the potentiometer slowly Pause periodically to let the value settle Press the STOP TEST soft key to lock in the value Press the STOP TEST soft key again to return to SERVO TUNING Press the USE NEW SETTINGS soft key to save changes and exit setup Re attach Heat Sink Power down the MILLPWR system Remove the spacers and set the heat sink against the housing Secure in place by tightening the four long fasteners Insert and tighten the two 2 shorter screws and tighten 60 IlI lil 2 Automatic Tuning Automatic tuning allows the MILLPWR system to further enhance Its operating performance X Axis Auto Tuning Manually position the table to it s center of travel and the saddle to it s center of travel using the hand wheels 3 axis system is being installed Insure that the table is at Manually move the Z Axis to It s center of travel if a three least 2 below the quill Highlight SERVO TUNING with the arro
56. tor needle to the inner wall of the nut blocks vertical bored hole Set the indicator to 0 000 With the quill still locked raise and lower the knee to indicate the inside bore from top to bottom c 0 ad amp ad Y 5 O BL A lt N LO The measured reading must be within 0 001 from top to bottom of the bore S To align the nut block use an adjustable wrench as shown Repeat the indicating procedure raise and lower the knee to indicate the inside bore from top to bottom Making adjustments as necessary until the alignment is within 0 001 from top to bottom of the bore 26 ll Remove the quick release components from the nut block 10 With the correct alignment being maintained transfer punch the lower hole in the nut block to the quill Il 5 Z Axis Quill Installation Remove the nut block and drill and tap the hole location for a 1 4 20 through Clean the inside and outside of the quill thoroughly removing all chips and debris Test fit the nut block with both mounting screws Insure that neither screw protrudes into the spindle bore If necessary grind the screws to the correct length MillPWR 27 Reinstall the spindle into the quill Insert the drive key into the nut block counter bore hole The key may have to be ground or filed to allow the nut block to seat properly gt Apply Loctite onto the threads of the 3 8
57. ts A from the reading head and scale case Limit switch installation Attach the upper and lower limit switch mounting plates to the casting with the 4 40 x 1 4 PHMS 4 Do not tighten in place at this time Adjust the upper limit switch so that It trios when the nut block Is within 0 05 to 0 10 of it s upper max travel Secure bracket in place Adjust the lower limit switch so that It trios when the nut block is within 0 05 to 0 10 of It s lower max travel Secure bracket in place switch be positioned where resistance can be felt on the S A quick change tooling system requires that the upper limit quill quick feed lever o c 0 q a c 0 a ais O mar Y L O Y Y Y a O c 2 EL O E 0 00 I Engagement Limit switch installation Attach the bracket to the quick release assembly with 2 6 32 x 1 4 SHCS 13 Re attach the quick release knob Turn the knob clockwise until it is fully closed Adjust the limit bracket until the switch trips Secure the bracket in position Loosen the quick release clamp and the switch should open Turn the knob clockwise until it is fully closed this is when the switch should close Insure that the switch is properly positioned MillPWR 41 Route the wire harness inside the casting as shown If switches have been removed from the wire harness complete the following 1 Black lead Connect long black lead from motor housing Black le
58. ut of tune Poor Finish Dull tool Incorrect feed rate and or spindle speeds System is out of tune Gibs are worn or out of adjustment Worn spindle bearings 72 Corrective Action Measure the tool diameter to check for tool wear Check that the correct scale factor is being used Machine tool wear The system can compensate for wear through its linear error compensation LEC feature Refer to Setup in the Operation Manual perform the manual and auto tuning procedures for each axis Should none of these recommendations correct the problem contact Heidenhain Corporation for repair or replacement procedures Replace with tool in good condition Check that the correct feed rates hhave been entered for each step of the program Check the spindle speed perform the manual and auto tuning procedures for each axis Should none of these recommendations correct the problem contact Heidenhain Corporation for repair or replacement procedures Refer to the machine operation manual Refer to the machine operation manual Symptom Quill handle is difficult to move Z axis drive system will not engage Unusual chatter from the quill MillPWR Probable Cause Quill lock is engaged Inadequate lubrication Z axis motor assembly is misaligned Damaged or worn bearings The Begin End or Feed field for the Z axis is blank The Z axis is disengaged The Z axis Is d
59. w keys and press ENTER Z Axis options will not appear when a two 2 axis system is being installed Press the X SERVO softkey Press the AUTO TUNING softkey AN Note the table will move when executing the next step MillPWR OFF FEED 0 0 100 JOB SETUP TOOL LIBRARY SCALE FACTOR DISPLAY OPTIONS ELECTRONIC EDGE FINDER JOB CLOCK FEED RATE SETTINGS INSTALLATION SETUP Use New CANCEL SETTINGS CHANGES TABLE WILL MOVE AT LEAST 2 DURING THE TEST AUTO MANUAL STOP GAIN BALANCE TUNING TUNING TEST TEST TEST SERVO TUNING X FOLLOWING ERROR o H STATUS TEST COMPLETED 61 O 5 a sj lt N O 5 2 a sj lt N Press the GAIN TEST softkey The table will move and the values in the FOLLOWING ERROR field will fluctuate MILLPWR adjusts the motor s settings The table will stop moving and the TEST COMPLETED message will appear in the STATUS field when the test is complete The messages in the STATUS field will change as the STATUS field when the test is complete proceed S If the TEST COMPLETED message does not appear in with Manual Tuning instead Press the BALANCE TEST softkey Do not touch the table during the balance test MILLPWR will wait for the electrical current from the motors to level off then it will begin adjusting the balance It will find the mini
60. when there is a fault The X Y and or Z axis servo connections located on the rear of the console are not connected to the correct axis Loss of encoder feedback Position is beyond travel limits Encoder resolution is not set correctly The table is locked The gibs are tight or are out of adjustment Corrective Action Remove the scale s clean the glass and reading head using the Acu Rite encoder cleaning kit Should none of these recommendations correct the problem contact Heidenhain Corporation for repair or replacement procedures While pressing the MOVE TABLE soft key on the console watch the LEDs on the servo cards Troubleshoot as follows Assistance is required for this procedure RUN When this LED remains on the motors are being actively controlled It will turn off if 1 Power is lost to the amplifier 2 A fault LED is on Check that the cables are properly connected to the correct axis Refer to instructions The scale s miscount In certain areas only Move the table quill within the travel limits You may want to consider adjusting the travel limits If so refer to Setup in the Operation Manual Check the encoders installed on the machine and make sure that the SCALE RESOLUTION parameter is set correctly Insure table locks are loose Refer to the machine tool operation manual for adjustment procedures Symptom Probable Cause Not enough oil in oil reserv
61. xis Handle Installation X axis handle exploded view S Completing the handle assembly Hardware list ID 4100 186 ID 4160 901 ID 4180 121 ID 387900 121 ID 387900 118 ID 387900 119 ID 387900 175 ID 387900 195 9 ID 2003 373 ON OO O11 RP WN 11 ID 2003 315 13 ID 387900 196 14 ID 2013 904 15 ID 2013 901 15 ID 2013 903 16 ID 2013 910 1 4 20 x 1 FHCS Retaining washer Key 1 8 Square x 1 lg Handwheel Lock Nut replacement only Use existing Dial replacement only Use existing Dial Holder replacement only Use existing Radial bearing Arbor washer Existing fasteners Bearing housing replacement only Use existing Ballscrew 03 Shim washer Sleeve 525 lg Bearing sleeve 1 lg Bearing sleeve 3 lg Spacer 1 lg items in the above exploded view unless S All numbers XX in the following section refer to the listed otherwise specified 22 Securing the Bearing casting Position the table to the left so that It s nearly flush with the right side of the knee This aids in the alignment of the casting Torque each fastener to 35 ft lbs Slide the shim onto the ballscrew and position the dial holder assembly onto the ballscrew Insert the 1 8 square key 3 into the key slot on the ballscrew Slide the Handwheel 4 onto the end of the ballscrew Secure the Handwheel with the Retaining washer 2 and flat head screw 1 c ad aS C ad Y 2 Lo

INSTALLATION MANUAL - Acu-Rite

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