CNC1/CNC2 Installation Manual - Conqueror Design & Engineering
Contents
1. CNC1 CNC2 Installation Manual Copyright 2005 Conqueror Design and Engineering Ltd CNC1 CNC2 Installation Manual Copyright 2005 Conqueror Design and Engineering Ltd All rights reserved Any dispute about the use of this software and or hardware or of these terms and conditions shall be resolved or arbitrated under English Law Manuals and accompanying documentation may not be copied or printed for the purposes of training advertising promotion or any other use without the permission of Conqueror Design and Engineering Limited Permission to copy and print manuals and documentation for personal use is granted to the owner user of the software supplied All trademarks are acknowledged to be the property of their respective owners This manual produced on 27 01 2005 Warranty This software and or hardware and accompanying documentation are provided as is and are not warranted to be fit for any specific purpose or usage The use of this software and or hardware is undertaken at your own risk and Conqueror Design and Engineering Limited will not be responsible for any loss of data time or income resulting from the use of this software and or hardware Contents I Table of Contents Part 1 Part 2 Part 3 Part 4 Disclaimer of Liability and Limitation of Warranty Introduction to the CNC1 CNC2 box Front panel controls esserne Rear Panel Connections 1 RS232 Serial Interface2. ssssussssusnnsusnnounnnnunnnnunnnnunnnnununnunnneunnnnunnnnnnnnnn Spindle Motor control plug 10 Relay drives plug s ssssussssusnnsusnnoununnunnnnunnnnunnnounnnnununnununnunnnnunnnnnnnnnnnnnnn Stepper motor plug sssssussssusensurnnnururnurnnnununnnnunnnnunnnnnnnnnnnnnnnnnnnnnnnnnn ennnen Feed back Encoder Limit switch plug succeer Spare and replacement plugs esserne Manual Operation without a Computer Appendices Additional G Codes for Lathe Operations 1 Additional G Codes for Milling Operations Index Copyright 2005 Conqueror Design and Engineering Ltd CNC1 CNC2 Installation Manual Disclaimer of Liability and Limitation of Warranty Where the CNC1 CNC2 box is supplied as a component and not as part of a complete control system it is assumed that the purchaser has sufficient electrical and electronic knowledge to handle the component competently It is further assumed that the purchaser has sufficient knowledge of safe working practices and the relevant Health amp Safety regulations which apply to working with electrical and electronic systems to work safely with the component Conqueror Design and Engineering Limited will not accept any liability for any damage to systems or personnel that may result from the incorrect installation or usage of the hardware supplied Nor will Conqueror Design and Engineering Limited replace or repair any supplied equipment that has been damaged as a result
3. bits 11 amp 12 2nd axis to home bits 13 amp 14 Brd axis to home bits 15 amp 16 4th axis to home Copyright 2005 Conqueror Design and Engineering Ltd 23 CNC1 CNC2 Installation Manual Control Capabilities parameter 20 bit 1 0 Control does not support G2 G3 directly 1 Control supports G2 G3 directly bit 2 0 Control does not support G5 directly 1 Control supports G5 directly bit 3 0 G17 default mode for circular interpolation 1 G18 default mode for circular interpolation bit 4 reserved bit 5 reserved bit 6 reserved bit 7 reserved bit 8 reserved bit 9 reserved bit 10 reserved bit 11 reserved bit 12 reserved bit 13 reserved bit 14 reserved bit 15 reserved bit 16 reserved Copyright 2005 Conqueror Design and Engineering Ltd Index 24 Index ore Connectors 4 9 Feedback Encoder Limit switch plug 4 Mains input 4 Motor connectors 4 8 Relay plug 4 7 RS232 5 spare and replacement 10 Spindle relay plug 4 6 Disclaimer of Liability 1 Front panel controls 3 G codes 13 Hand wheel 3 Introduction to the CNC1 2 Jog buttons 3 Lathe 13 14 Limitation of Warranty 1 M441UP 17 Command Set 17 Parameters 19 M codes 16 Mill 13 15 MPC4 17 Command Set 17 Parameters 19 MPC5 17 Command Set 17 Parameters 19 Parameters 19 Plugs 10 replacement 10 Stand alone operation 11
4. Copyright 2005 Conqueror Design and Engineering Lid
5. 310 44 23 Standard 10 1 0 44 650 91 57x 57x 52 5 0 1 0 690 98 2 3 2 1 640 91 23 Standard 4 2 1 6 1 090 154 57 x 57 x 67 3 4 1 9 1 130 160 2 8 2 3 1 140 161 23 Standard 3 57 2 9 1 480 210 57 x 57 x 103 23 High Perf 4 6 1 0 470 67 57x57x41 2 1 2 1 480 68 23 High Perf 6 2 1 0 980 138 57 x 57 x 55 2 9 2 1 980 138 2 17 3 0 980 138 23 High Perf 4 2 2 1 1 610 228 57 x 57 x 79 3 3 3 0 1 630 231 34 Standard 5 8 1 3 1 820 258 82 x 82 x 62 3 0 1 7 1 500 212 2 8 3 1 1 820 258 34 High Perf 7 0 1 4 2 800 396 82 x 82 x 67 3 6 2 8 2 800 396 34 High Perf 4 8 2 8 4 800 680 82 x 82 x 94 42 Standard 3 7 3 4 9 900 1 400 108 x 108 x 179 Torques quoted are for bi polar drive Motors voltages marked are compatible with the CNC2 box only Other motors with similar voltages and current requirements will also be compatible Copyright 2005 Conqueror Design and Engineering Ltd 13 CNC1 CNC2 Installation Manual 4 2 G Codes G Code Parameters Description G00 X Y Z E Rapid Move G01 X Y Z E F Feed Move G02 X Y Z E 1 J K F R Arc Clockwise Move G03 X Y Z E 1 J K F R Arc Counter Clockwise Move G04 S Dwell S Seconds to delay G05 P Spline function Bezier curve only available when running with the EaziCNC software G17 Use XY plane for circular interpolation Top G18 Use XZ plane for circular interpolation Front G19 Use YZ plane for circular interpolation Side G28 X Y
6. Z E Home Axis G40 Tool nose compensation off default mode G41 R Tool nose compensation Left of Line G42 R Tool nose compensation Right of Line G43 Tool length compensation positive G44 Tool length compensation negative default mode G45 Cancel Tool length compensation G54 X Y Z E Set home reset position G70 Imperial coordinates only available when running with the EaziCNC software G71 Metric coordinates default mode G90 Absolute coordinates default mode G91 Incremental coordinates only available when running with the EaziCNC software G92 X Y Z E Set datum point N B The E axis can also be programmed as U N B The codes marked with are modal Modal codes are active on any subsequent lines that do not have a code given Copyright 2005 Conqueror Design and Engineering Ltd Appendices 14 4 2 1 Additional G Codes for Lathe Operations G Code Parameters Description G33 X Z P I Threading synchronized cut P is pitch I is end pull out in X G80 Cancel Canned Cycle G81 X Z P Turning cycle G82 X Z P Taper cycle G83 X Z I K R P Arc Clockwise Cycle G84 X Z I K R P Arc Counter Clockwise Cycle G85 X Z P Facing Cycle G86 X Z P I K R Threading synchronized cut cycle X is pass offset pass depth P is pitch I is end pull out K
7. before connecting or disconnecting motors Failing to observe this precaution could permanenty damage your control box Copyright 2005 Conqueror Design and Engineering Ltd 9 CNC1 CNC2 Installation Manual 2 2 5 Feed back Encoder Limit switch plug ee e es F ep X amp Y amp Z Plug No connection E U Plug Single slot spindle encoder input X amp Y amp Z Plug No connection E U Plug Multi slot spindle encoder input The power requirement of any encoder used should not exceed 100 milli amps To connect a limit switch it should be connected between the limit switch input pin 5 or 6 and the ground connection pin 4 N B It is possible to use encoders which require a higher voltage than 5 volts by using the 12 volt supply from the relay plug and inserting a diode into the A and B lines For details please contact technical support Copyright 2005 Conqueror Design and Engineering Ltd Introduction to the CNC1 CNC2 box 10 2 3 Spare and replacement plugs Replacement plugs for the stepper motor connectors feed back limit switch connectors and relay connector can be obtained from Maplin Electronics at http www maplin co uk Stepper motor plug is 4 pin cable socket code FK24B LKG Line Socket 4 way Feed back imit switch plug is 8 pin cable socket code FK30H LKG Line Socket 4 way Relay connector is 5 pin cable socket code FK25C LKG Line Socket 5 w
8. e e es es es The emergency stop circuit can be connected through any safety switches cover switches etc Provided it is unbroken the spindle coolant and programmes can be run If the emergency stop circuit is broken then the spindle and coolant are forced off and any programme running will be stopped the machine can still be moved in manual mode The plug supplied has a link shorting pins 1 and 2 The motor outputs pins 3 4 5 and 6 are only available if the optional DCMOT1 card is fitted The relay connection pins 7 and 8 can carry 10 Amps 240 VAC The circuit is closed when spindle run is selected Copyright 2005 Conqueror Design and Engineering Ltd 7 CNC1 CNC2 Installation Manual 2 2 3 Relay drives plug ee 12 Volt supply Coolant relay Each relay drive is capable of sinking 500 milli amps of current but the combined current of all relays should not exceed 1 Amp Copyright 2005 Conqueror Design and Engineering Ltd Introduction to the CNC1 CNC2 box 8 2 2 4 Stepper motor plug ee N B As delivered the stepper motor outputs are configured for I Amp phase and for half stepping with power save enabled To change these settings please refer to the manual for the MPCS card WA RNING Never connect or disconnect a motor when the control box is powered up Allways turn off the control box and allow 2 3 minutes for the power supply capacitors to discharge
9. 40 Integer Back lash compensation for X axis steps 41 Integer Back lash compensation for Y axis steps 42 Integer Back lash compensation for Z axis steps 43 Integer Back lash compensation for E U axis steps 44 Integer Reserved 45 Integer Reserved 46 Integer Reserved 47 Integer Reserved 48 Integer Reserved 49 Integer Reserved Copyright 2005 Conqueror Design and Engineering Ltd Appendices 22 Configuration 1 parameter 0 bit 1 X axis direction bit 2 Y axis direction bit 3 Z axis direction bit 4 E axis direction bit 5 X axis home direction bit 6 Y axis home direction bit 7 Z axis home direction bit 8 E axis home direction bit 9 Turn off motor drives when inactive bit 10 Override Safety switch spindle and coolant will not run bit 11 Override Safety switch spindle and coolant will run MPC4 amp MPC5 only bit 12 LED4 shows busy state MPC4 MPC5 only bit 13 RELAY4 is reserved for motor reverse MPC4 MPC5 only bit 14 tool carousel on motor E delay is param21 1 0 25 secs bit 15 reserved bit 16 reserved Configuration 2 parameter 1 bit 1 X feedback active bit 2 Y feedback active bit 3 Z feedback active bit 4 E feedback active bit 5 X limit active bit 6 Y limit active bit 7 Z limit active bit 8 E limit active bits9 amp 10 Ist axis to home O X 1 Y 2 Z 3 E
10. ay A replacement spare plug for the DC motor 10 Amp relay Emergency Stop connector can be obtained from RS Components http www rswww com or Farnell Electronics http www farnell co uk RS Components code 372 254 Connector circular CPC cable plug 9 way 13 shell Farnell Electronics code 3195545 RECEPTACLE STD SLD CPCI 9 WAY Copyright 2005 Conqueror Design and Engineering Ltd 11 CNC1 CNC2 Installation Manual Manual Operation without a Computer If no computer is attached the machine can be used in a rudimentary manner using the following jog button and BNI button 1 and BN2 button 2 combinations the jog switches operate as normal in manual mode when neither BN1 or BN2 is pressed BNI amp Z Toggle coolant on off BN2 amp X Increase spindle speed and turn on spindle if necessary BN2 amp X Decrease spindle speed and turn off spindle ifnecessary If no button has been pressed for several minutes the machine will be switched out of manual mode Copyright 2005 Conqueror Design and Engineering Ltd Appendices 12 4 4 1 Appendices Compatible Motors The following motors have been tested with the CNC1 and CNC2 box Motor Size Voltage Current Holding Torque Holding W xHxL Amps mNM Torque Oz In 23 Standard 11 2 0 33 320 45 57 x 57 x 40 3 4 1 0 340 48 23 1 5 330 47 1 5 22
11. c hand wheel is rotated clockwise to move the axis in the positive direction and counter clockwise to move the axis in the negative direction Copyright 2005 Conqueror Design and Engineering Ltd Introduction to the CNC1 CNC2 box 4 2 2 Rear Panel Connections The rear panel contains the plugs for the mains supply the computer an AC DC spindle motor or any 10 Amp load 12 volt relay drives 4 stepper motors and 4 feed back encoder limit switch plugs N B The CNC2 box has only 3 stepper motor plugs and feed back encoder limit switch plugs AC Mains Inlet The AC mains connector is a standard kettle type plug A mains cable is provided The socket includes a 2 Amp fuse do not use a higher rated fuse it will reduce the level of protection Copyright 2005 Conqueror Design and Engineering Ltd 5 CNC1 CNC2 Installation Manual 2 2 1 RS232 Serial Interface RCD RTS TXD cis es Receive Data RCD Transmit Data TXD Ready To Send RTS PB Clear To Send CTS The serial port is configured as a standard PC AT 9 pin port A standard PC AT to PC AT serial cable a cross over cable can be used The default protocols are 19 200 baud 8 data bits no parity and 1 stop bit The board will use XON XOFF flow controls by default Copyright 2005 Conqueror Design and Engineering Ltd Introduction to the CNC1 CNC2 box 6 2 2 2 Spindle Motor control plug
12. etres P12 P13 P19 13 Integer Z divisor Z step size in millimetres P12 P13 P19 14 Integer E scale E step size in millimetres P14 P15 P19 15 Integer E divisor E step size in millimetres P14 P15 P19 16 Integer Scalar for Feed rates Steps sec 625 000 P17 Feed P16 17 Integer Divisor for Feed rates Steps sec 625 000 P17 Feed P16 18 Integer Decimal digits in coordinates Default 2 digits 19 Integer Divisor for coordinates Default 100 Copyright 2005 Conqueror Design and Engineering Ltd Appendices 20 Parameter Type Description 20 Control capabilities see detailed description below Do not alter 21 Delays for carousel tool post Forward delay low byte 1 0 25 secs Reverse delay high byte 1 0 25 secs 22 Time out for manual mode and automatic motor turn off 23 Integer Ramp Stages Maximum 16 24 Integer Ramp 0 25 Integer Ramp 26 Integer Ramp 2 27 Integer Ramp 3 28 Integer Ramp 4 29 Integer Ramp 5 30 Integer Ramp 6 31 Integer Ramp 7 32 Integer Ramp 8 33 Integer Ramp 9 34 Integer Ramp 10 35 Integer Ramp 11 36 Integer Ramp 12 37 Integer Ramp 13 38 Integer Ramp 14 39 Integer Ramp 15 Copyright 2005 Conqueror Design and Engineering Ltd 21 CNC1 CNC2 Installation Manual Parameter Type Description
13. is pass offset in Z and R is number of passes G94 Feed rates in mm in per minute G95 Feed rates in mm in per spindle revolution G96 Constant surface speed Feed rate specified in mm at 20 0 mm diameter Feed rate specified in inches at 1 0 inch diameter N B The E axis can also be programmed as U N B The codes marked with are modal Modal codes are active on any subsequent lines that do not have a code given Copyright 2005 Conqueror Design and Engineering Ltd 15 CNC1 CNC2 Installation Manual 4 2 2 Additional G Codes for Milling Operations G Code Parameters Description G50 Mirror Off Cancel any mirrored axis G51 X Y Z E Mirror Mirror selected axis around coordinate given G55 Offset Off Cancel Clear temporary origin G56 X Y Z E Offset Set temporary origin G80 Cancel Complete Canned Cycle G81 Z Drill Spot Drill G82 Z K Peck Drill G83 Z P Tapping G84 Z Bore G85 Z P Pocket cycle N B The E axis can also be programmed as U N B The codes marked with are modal Modal codes are active on any subsequent lines that do not have a code given Copyright 2005 Conqueror Design and Engineering Ltd Appendices 16 4 3 M Codes M Code Parameters Description M00 Programme Stop M01 Optiona
14. l Stop M02 Programme End same as M30 M03 S Spindle Start Clockwise M04 S Spindle Start Counter clockwise M05 Spindle Stop M06 R T X Y Z Tool Change M08 Coolant On M09 Coolant Off M13 Spindle Start Clockwise Coolant On M14 Spindle Start Counter clockwise Coolant On M15 Spindle Stop Coolant Off M30 Programme End same as M02 M47 R Return to Programme Start R is the repeat count if given M90 P Relay P On M91 P Relay P Off M92 P Wait for input P to be Low M93 P Wait for input P to be High M94 Index tool post Indexes the tool post if fitted forward M98 Motor Drives On M99 Motor Drives Off Copyright 2005 Conqueror Design and Engineering Ltd 17 CNC1 CNC2 Installation Manual 4 4 Command Set Command Parameters Description Ctrl B 2 Query Used by the EaziCNC software Ctrl E 5 Echo On Echoes characters back to the terminal and enables user friendly responses data sent to the terminal will have a tag i e P0 0 instead of just 0 Ctrl N 14 Echo Off Stops characters from being echoed back to the terminal and disables user friendly responses lt ESC gt Escape Stops any current moves or commands Clears the command buffers This command does not need to be completed with a carriage return CR At Returns the current position and status data in compressed hex format This command does n
15. nate to lt f gt SH lt CR gt Show Home Displays the currently set home starting position set by a G54 command ST lt CR gt Status Show current status T X Y Z Set display tool offset If no X Y or Z is given then the existing offset will be displayed T99 will list all tool offsets Any valid ISO line will also be interpreted and executed on the machine tool For a list of valid ISO G amp M codes see G Codes and M Codes Copyright 2005 Conqueror Design and Engineering Ltd 19 CNC1 CNC2 Installation Manual 4 5 Control Parameters Parameter Type Description 0 Binary Configuration 1 see detailed explanation below 1 Binary Configuration 2 see detailed explanation below 2 Integer Minimum Spindle Speed Default 200 RPM 3 Integer Maximum Spindle Speed Default 2000 RPM 4 Integer Maximum Cutting Feed Rate Default 400 mm min 5 Integer Rapid Feed Rate Default 800 mm min 6 Integer Pulses Revolution on Threading Synchronizing Encoder Default 360 7 Integer Default Circular Interpolation Mode 0 XY 1 XZ 2 YZ 8 Integer X scale X step size in millimetres P8 P9 P19 9 Integer X divisor X step size in millimetres P8 P9 P19 10 Integer Y scale Y step size in millimetres P10 P11 P19 11 Integer Y divisor Y step size in millimetres P10 P11 P19 12 Integer Z scale Z step size in millim
16. of such incorrect misuse or installation Copyright 2005 Conqueror Design and Engineering Ltd Introduction to the CNC1 CNC2 box 2 2 Introduction to the CNC1 CNC2 box The CNC1 CNC2 box has been designed to control CNC lathes milling machines PCB drills routers etc In fact any machine which has 1 2 3 or 4 stepper motor driven axes The stepper motors can also optionally be controlled in a closed loop mode with the addition of standard quadrature encoders in either strip or rotary form The CNC1 box has a built in power supply which can output 10 Amps The CNC2 box has a built in power supply which can output 16 Amps A machine fitted with a CNC1 CNC2 can be operated in a simplified stand alone manual mode for cleaning and maintenance etc without requiring a host computer Copyright 2005 Conqueror Design and Engineering Ltd 3 CNC1 CNC2 Installation Manual 2 1 Front panel controls The front panel controls are from left to right the axis jog buttons for the X and Y axis arranged in a cross around the green Enter BTN1 button the Z axis jog buttons 3 status LEDs the electronic hand wheel and the power switch When in manual mode the jog buttons can be used to rapidly position an axis and then the hand wheel can be used to control the precise position The hand wheel automatically switches to operate the last axis that was moved with one of the jog buttons The electroni
17. ot need to be completed with a carriage return CR n lt CR gt Message mode Controls whether messages are sent to the console n 0 do not show messages n 1 show messages including updates when moving n 2 debugging mode EC Error Clear Clears any error state on the machine N B this clears user stops power up errors etc it will not and cannot clear errors such as safety activated ES Error Status Displays the error code of the machine Error codes 0 No error 1 Stopped by user 2 Stopped safety activated 3 Power interrupted 4 X limit triggered 5 Y limit triggered 6 Z limit triggered 7 E limit triggered Copyright 2005 Conqueror Design and Engineering Ltd Appendices 18 Command Parameters Description I n lt CR gt Info lt n gt is the item of information 0 board ID 1 firmware version 2 firmware date 3 processor type lt blank gt firmware banner MA lt CR gt Manual Mode To exit manual mode the lt ESC gt command must be sent P n Rv lt CR gt Parameter Query or set a parameter See control parameters for a description P99 will display parameters 0 to 19 P199 will display parameters 20 to 39 SX f lt CR gt Set X coordinate to lt f gt SY f lt CR gt Set Y coordinate to lt f gt SZ f lt CR gt Set Z coordinate to lt f gt SE f lt CR gt Set E coordi
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