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upgrade instructions to install a linear z-axis scale · 2014. 7. 7. · installation millpwr® 3...

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  • Upgrade Instructions to Install a Linear Z-axis Scale · 2014. 7. 7. · INSTALLATION MILLPWR® 3 Fig. 5 Fig. 7 Fig. 4 Fig. 6 2. Using the two (2) 8-32 x 3/8" BHCS, install the reading
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INSTALLATION MILLPWR ® 2003-778 Rev. A Upgrade Instructions to Install a Linear Z-axis Scale 1. Turn off power to controller. 2. Completely remove the top cover (with cooling fins) of the Z-axis servo motor with the six(6) 6-32 SHCS and associated wire connections. 3. Unplug the servo control wire assembly from J10 (red connector) (refer to Fig.1). 4. The rotary encoder cable connector (J9) black connector is located behind the J10 connector. Unplug the rotary cable (refer to Fig.2). 5. Using a wire tie, tie-off the rotary encoder cable to the servo board cable (refer to Fig.3). 6. Clip off the excess wire tie. 7. Plug the servo control wire assembly back into the J10 connector. 8. Replace the top cover. 9. In MILLPWR’s Installation Setup mode, change the encoder setup (Z-axis) from rotary to linear. 10. Press SETUP. 11. Arrow to Installation Setup. Press ENTER. 12. Enter passcode 8891. Press ENTER. 13. Arrow to Encoder Setup. Press ENTER. 14. Arrow to Z-axis Encoder. Press ENTER. 15. Press LINEAR (lower left-hand corner softkey). 16. Press USE NEW SETTINGS soft key. 17. Continue with precision glass scale installation using the instructions on the following pages (excerpted from the MILLPWR Installation Manual). Fig. 1 Fig. 3 Fig. 2 1

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  • INSTALLATIONMILLPWR ®

    2003-778 Rev. A

    Upgrade Instructions to Install a Linear Z-axis Scale

    1. Turn off power to controller.

    2. Completely remove the top cover (with coolingfins) of the Z-axis servo motor with the six(6) 6-32 SHCS and associated wire connections.

    3. Unplug the servo control wire assembly from J10 (red connector) (refer to Fig.1).

    4. The rotary encoder cable connector (J9) black connector is located behind the J10 connector.Unplug the rotary cable (refer to Fig.2).

    5. Using a wire tie, tie-off the rotary encoder cable to the servo board cable (refer to Fig.3).

    6. Clip off the excess wire tie.

    7. Plug the servo control wire assembly back intothe J10 connector.

    8. Replace the top cover.

    9. In MILLPWR’s Installation Setup mode, change the encoder setup (Z-axis) from rotary to linear.

    10. Press SETUP.

    11. Arrow to Installation Setup. Press ENTER.

    12. Enter passcode 8891. Press ENTER.

    13. Arrow to Encoder Setup. Press ENTER.

    14. Arrow to Z-axis Encoder. Press ENTER.

    15. Press LINEAR (lower left-hand corner softkey).

    16. Press USE NEW SETTINGS soft key.

    17. Continue with precision glass scale installationusing the instructions on the following pages (excerpted from the MILLPWR Installation Manual).

    Fig. 1

    Fig. 3

    Fig. 2

    1

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    Installing the Optional ACU-RITE Precision Glass Scale

    Carefully read the MSDS sheet(s) before using Loctite® 242® thread lock.

    1. Apply Loctite to the threads of two (2) 8-32 x 3/8" BHCS.

    You will need the following components:

    • ACU-RITE Precision Glass Scale• Loctite® 242® thread lock and MSDS information sheets• Reading head bracket• Strain relief bushing

  • INSTALLATIONMILLPWR ®

    3

    Fig. 5

    Fig. 7

    Fig. 4

    Fig. 6

    2. Using the two (2) 8-32 x 3/8" BHCS, install the reading head bracket flush with the front edge of the nut block (refer to Figure 4).

    3. Place the scale inside the Z-axis casting. Position the scale so that the top is flush with the top of the Z-axis casting (refer to Figure 5).

    4. Apply Loctite to the threads of two (2) M4 x 6 mm SHSS.

    5. Place the two (2) M4 x 6 mm SHSS into the holes located on the left side of the Z-axis casting (refer to Figure 6).

    6. Tighten both M4 x 6 mm SHSS.

    7. Apply Loctite to the threads of three (3) M3 x 8 mm SHSS.

    8. Install the three (3) M3 x 8 mm SHSS into the reading head. Adjust the screws so that they just touch the read-ing head bracket.

    9. Apply Loctite to the threads of two (2) 8-32 x 3/4" SH low head screws.

    10.Using the two 8-32 x 3/4" SH low head screws, attach the reading head to the reading head bracket .

    11. Tighten both screws.

    12.Remove the two (2) alignment brackets from the reading head by sliding themaway from the read-ing head and twistingthem 90°(refer to Figure 7).

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    ®

    Note: If a MACH-1TM Quick Change Tooling System is installed on the milling machine, position the upper limitswitch at the point just below where you can feel resist-ance from the MACH-1 system on the quill feed handle.

    1. Remove the quick release knob from the nut block.

    2. Using four (4) 4-40 x 1/4" PHMS, attach the upper and lower limit switches to the motor casting (refer to Figure 8).

    Note: Do not tighten the four (4) 4-40 x 1/4" PHMS untilinstructed to do so.

    3. Adjust the upper and lower limit switches until they make contact with the nut block (move the spindle as needed). This should be within approximately 1/16" to 1/8" inside the nut block’s upper and lower maxi-mum travel.

    4. Adjust both switches until you hear them “click.”

    5. Tighten all four PHMS.

    Note: In the Setup mode (refer to the MILLPWROperation Manual), be sure to set the software limits within the upper and lower limit switches.

    Fig. 8

    Upper Switch

    Lower Switch

    Installing the Upper and Lower Limit Switches

    Installing the Limit Switches

    You will need the following components:

    • Upper and lower limit switches (pre-wired to engagement switch)• Engagement limit switch/bracket• 1/4" cable clamps (2)• Adhesive nylon wire clips (3)

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    1. Connect the shortest limit switchwire to the bottom terminal on the lower limit switch (refer to Figure 10).

    2. Connect the longest limit switch wire to the bottom terminal on the upper limit switch (refer to Figure 10).

    3. Check that the inside surface of the motor casting is clean.

    Connecting the Limit Switches

    Fig. 10

    1. Using two (2) 6-32 x 1/4" BHCS, attach the engagement limit switch bracket to the top of the engagement block (refer to Figure 9).

    Note: Do not tighten the two (2) 6-32 x 1/4" BHCS until instructed to do so.

    2. Turn the quick release knob clockwise until the engagement block is closed.

    3. Adjust the engagement limit switch until you hear it “click.”

    4. Tighten the two (2) 6-32 x 1/4" BHCS.

    Installing the Engagement Limit Switch

    Fig. 9

    UpperLimit

    Switch

    Connectlongest

    limit switchwire here

    LowerLimit

    Switch Connectshortest

    limit switchwire here

    Black Leadengagementswitch

    White Leadfrom engage-ment switch

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    ®

    4. To secure the reading head cable, install a 1/4" cable clamp to the reading head casting (refer to Figure 11). Use an M3 x 6 mm PHMS.

    5. Secure the reading head and engagement cable with a 5/16” cable clamp to theinside of the casting using a 6-32 PHMS (refer to Figure 11). Cable is marked with the location of the clip. Attach P-clip to right side of casting with the cable away from the face of the casting.

    6. Place the cable spiral wrap around the encoder and engagement switch cable at the marked location. (refer to Figure 11).

    7. Place the strain relief bushing around the reading head and limit switch cable, at the end of the heat shrink. (refer to Figure 11).

    8. Close the strain relief bushing to secure the cable. Slide the strain relief bushing and cable into the slot located on the left side of the Z-axis casting. Make sure the flat sides of the bushing are placed vertically into the slot. See drawing below.

    9. Finish routing the reading head and limit switch cable and the limit switch wires as shown (refer to Figure 11). Secure them with adhesive clamps.

    Note: Check that the cables are positioned so that they don’t interfere with the motor casting or any moving parts.

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    Fig. 11

    Strain reliefbushing

    Readingheadand limitswitchcable

    Limit switchwires andencodercable

    Engagementlimit switch

    Adhesive clamp

    Adhesiveclamp

    5/16” cableclamp

    Adhesive clamp

    1/4" cableclamp(attach toreadinghead cast-ing)

    Spiralwrap

  • INSTALLATIONMILLPWR

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    ®

    1. If necessary, remove the quick release knob from the nut block assembly.

    2. Place the tip of the grease gun into the grease fitting on the ballscrew nut (refer to Figure 12).

    Fig. 12

    3. Add grease until it begins to escape from the ballscrew nut seals.

    Note: Excessive grease could cause friction on the ballscrew. Under normal operating conditions, the ballscrew should be checked every 200 hours of operation to ensure that it is receiving adequate lubrication.

    4. Remove the grease fitting from the ballscrew nut. Store it in a secure locationfor use the next time the ballscrew needs lubricated.

    5. Reinstall the plug that was removed from the ballscrew nut on page 3-24 of the MILLPWR Installation Manual.

    You will need the following components:

    • Grease gun• High-quality lithium, soap-based

    grease

    Lubricating the Ballscrew


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