M401 Installation Manual - Conqueror Design & Engineering Ltd
Contents
1. and the cards can be configured to identify as X Y Zor U If other drive cards are used then it will probably be necessary to use a terminal block or Y cables to connect the shared signals to the different cards The digital outputs REI and RE2 are also available on this connector These outputs may be used to drive or sink 25 mA 5 Volt Miniature 5 volt relays or solid state relays can be used to boost the control of these outputs up to any level Copyright 2013 Conqueror Design and Engineering Ltd Introduction to the M401 card 6 2 4 Relay drivers ve u1 cs PWM L m e e e es m A A A A SPINDLE REL L Relay 1 Output sink Usually used for spindle on off Relay 2 Output sink Usually used for coolant on off The M401 card has 2 relay drivers each capable of driving a 150 milli Amp 12 volt load The REL connector is used to connect external relays or loads to the board The relays are interlinked with the safety circuit the STP connector If the safety circuit is broken then the supply to the relays will be interrupted and they will turn off Copyright 2013 Conqueror Design and Engineering Ltd M401 Installation Manual 2 5 Connectors for Ready LED Jog buttons Limit switches the Encoder and the Safety Circuit The connectors for the Ready LED jog buttons limit switches and the safety circuit are located along the top and bottom edges of the board pe SE Lu Z Z y Yt Me ONE CU2. Conqueror Design and Engineering Ltd Appendices Ea forward steps 22 Integer Time out for manual mode and automatic motor turn off Default value is 2344 which gives a 5 minute delay Delay in seconds P22 32 pull in rate 23 Ineger Ramp stages Maximum 16 pe dnegr qRamO p25 Integer gRampl O 26 Integer Ramp pT Integer Ramp3 O 28 Integer p29 Integer Ramp p80 Integer Ramp 0 pt Integer Ramp 32 Iteger Ramp p83 Integer Rampo o O p84 Integer Ramp 10 p85 Integer Ramp p36 Integer Ramp 12 pT Integer Ramp 13 38 Integer p39 teger Ramp 15 p40 Ineger Back lash compensation for X axis steps pt Integer Back lash compensation for Y axis steps 42 Integer Backlash compensation for Z axis steps Integer Back lash compensation for E U axis steps Back lash compensation for V axis steps Integer Back lash compensation for W axis steps L1 1 Maps P46 P19 P47 P46 P 19 P49 P48 P19 P49 P48 P19 divisor high byte Y encoder scale scale low byte divisor high byte Copyright 2013 Conqueror Design and Engineering Ltd 25 26 2 28 29 30 3l 32 33 34 35 36 37 38 39 40 41 42 43 45 46 47 48 25 M401 Installation Manual i ae Z encoder scale scale low byte divisor high byte ae re IN U
3. Ltd 19 M401 Installation Manual 20 to 39 lt CR gt Show Home Displays the currently set home starting position set by a G54 command CR gt CR Staws Show current status p S S SE S 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 2013 Conqueror Design and Engineering Ltd Appendices 6 2 G Codes X Y Z U Rapid Move co P a nnd with the EaziCNC software C D with the EaziCNC software G7 GIS Use XZ plane for circular interpolation Front GIO Use YZ plane for circular interpolation Side X Y Z U G40 Tooknosecompenstionoff defautmode G i R Tool nose compensation Left of Line G2 R jToonosecompenationRigtofline G3 jToklnghcompensa on posive G44 Too length compensation negative default mode GAS Cancel Toolength compensation with the EaziCNC software Metric coordinates default mode x Absolute coordinates default mode Incremental coordinates only available when running with the EaziCNC software Set datum point N B The codes marked with are modal Modal codes are active on any subsequent lines that do not have a code given Copyright 2013 Conqueror Design and Engineering Ltd 21 M401 Installation Manual 6 3 M
4. M401 card eeeeeesseeeeeeesee enne nennen nn nnnn mennun inne nnn nnne nn nnn 3 2 RS232 Serial Interface 0 ccccceeeeeeeeeeeeeeeeeeeeeaeeeseseeeseeeceaeeeseseeeseaeaeaneaseseeesessaeanaeeeees 4 3 Connector for Stepper Motor Drives c ccccceeeseeeeeeeeeeeeeeeeeeeeeeeseeeeeeeseeeeeeeseeeeeeeseeneeeees 5 LABLCIEAMCD ICH 6 5 Connectors for Ready LED Jog buttons Limit switches the Encoder and the Safety Circuit Quadrature encoders oie detecto ti decies code vac eee deo etos te cese ie 9 6 Spindle Speed Output a a aee aa aare aa e a aaae aaa a aaar Naaa iaeano eect 11 Part3 Manual Operation without a Computer 13 Part 4 Connecting motor drive cards 14 1 X641SC stepper motor card interface board s sssssssssnsnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nnnm 15 Part5 Mechanical Mounting Details 17 Part6 Appendices 18 UT Command Set ctsccs ems 18 PAMCOONDLI IM M 20 3 M GOU6S nie eintreten ierIRtUAR seatsdceasanueateeanssecaiencadiseaasdeagnacseedecays a aeaa 21 4 Control P ramelters intei nen T 22 5 Firmware upgrade repair eeeeeeesee eene nennen nennen nnne nn nhnnne nn nh nn e nnn nnne nn nnn 26 Index 27 Copyright 2013 Conqueror Design and Engineering Ltd 1 M401 Installation Manual 1 Disclaimer of Liability and Limitation of Warranty Where the M4
5. encoder scale scale low byte divisor high byte i ae re ae V encoder scale scale low byte divisor high byte LE ae W encoder scale scale low byte divisor high byte Integer Number of steps to retract from limit after a G29 Enable disable feedback for axes Bits Ta reserved 5 W 4 V 3 UJ 2 REM CNEEEEE NEM NEN Control capabilities read only bit O uses raw steps bits 1 3 reserved bit 4 supports U amp V 6 axis bit 5 supports feedback closed loop bits 6 15 reserved Copyright 2013 Conqueror Design and Engineering Ltd Appendices 6 5 Firmware upgrade repair The M401 has user upgrade able firmware stored in an EEPROM in the micro controller on the card In normal usage the firmware upgrade is initiated from within the EaziCNC software but it is possible to force the card into a boot strap mode to allow the firmware to be upgraded if there is a programming failure Please contact support for details of the procedure If the M401 card is in boot strap mode the green Ready LED on the card will flash very rapidly as soon as the power is connected To stop the card powering up in boot strap mode make sure that BTN 1 is not closed pressed during power on Copyright 2013 Conqueror Design and Engineering Ltd M401 Installation Manual Index si 3rd party stepper motor drives 15 Additional drive cards 14 Board layout 3 boot strap 26 Cx Connector
6. for controllers which use an AC signal to set the speed Most DC speed controls and AC 3 phase inverters are compatible with the circuit The spindle on off function is for use with those speed control cards which have a low voltage low current logic signal for enabling the motor If a voltage higher than 24 volts or a current more than 40 milli amps needs to be switched then a relay connected to the relay drive RE1 will need to be used The card also has a PWM output which has the raw pulse width modulated speed control signal at TTL levels PWM output TTL level Copyright 2013 Conqueror Design and Engineering Ltd Introduction to the M401 card 12 Copyright 2013 Conqueror Design and Engineering Ltd 13 M401 Installation Manual 3 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 BN1 button 1 combinations The jog buttons operate as normal in manual mode when BN1 is not pressed BNI amp Y Turn spindle spindle relay off BNI amp Z Toggle rapid and feed modes BN1 amp Z Toggle Coolant on off If no button has been pressed for several minutes the machine will be switched out of manual mode When in manual mode the status LED the green LED with flash to indicate that the jog buttons are active Copyright 2013 Conqueror Design and Engineering Ltd Connecting motor drive cards ow 4 Connecting motor
7. positions 3 Connectors 7 External stepper motor drives 5 Jog button 7 Limit switches 7 Ready LED RDY1 7 Relay connector REL 6 RS232 4 Safety circuit STP 7 Spindle Control SPINDLE 11 D Disclaimer of Liability 1 oy e Firmware upgrade 26 ie Introduction to the M401 2 L Limitation of Warranty 1 Q Quadrature encoders 9 26 Stand alone operation 13 STEP1 5 14 STEPHP1 5 14 za Threading support 7 X X641SC 15 Copyright 2013 Conqueror Design and Engineering Ltd
8. 01 card 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 of such incorrect misuse or installation Copyright 2013 Conqueror Design and Engineering Ltd Introduction to the M401 card 2 2 Introduction to the M401 card The M401 card 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 Copyright 2013 Conqueror Design and Engineering Ltd 3 M401 Installation Manual 2 1 Components of the M401 card sw 42 e m em e w e me m e mj mu DC1 RN NEN MeS RPS s5 BTN1 Z zt y YT x EA wexeuvusscacu CONQUEROR DESIGN amp ENGINEERING WWW eaziFform co uk PWM cs Or nee meoo meso meso meso 9 SPINDLE ES P I
9. Codes moo Programme Stop Mol JjOptomlStp 5 MO j PrgrmmeEnd samasM30 i Spindle Start Clockwise M05 JjSpndeSp S S Return to Programme Start R is the repeat count if MO P JWatfoipuPiobelow MO P JWatfoipuPiobeHih M98 A pMutrDrivesOn 00 O M9 pjMoorDresOTf Copyright 2013 Conqueror Design and Engineering Ltd Appendices 22 6 4 Control Parameters Parameter Type Description Configuration 1 bit 0 X axis direction bit 1 Y axis direction bit 2 Z axis direction bit 3 U axis direction bit 4 X axis home direction bit 5 Y axis home direction bit 6 Z axis home direction bit 7 U axis home direction bit 9 turn off motors when idle bit 10 reserved bit 11 reserved bit 12 reserved bit 13 Relay 4 is reserved for motor reverse bit 14 tool carousel on motor U bit 15 reserved bit 16 Enable hand wheel to be used for feed rate override Configuration 2 bit 0 X limit active bit 1 X limit active bit 2 Y limit active bit 3 Y limit active bit 4 Z limits active bit 5 Z limits active bit 6 U limits active bit 7 U limits active bit 8 X limit positive is NC normally closed bit 9 X limit negative is NC normally closed bit 10 Y limit positive is NC normally closed bit 11 Y limit negative is NC normally cl
10. HE The card is supplied with EaziCNC 3 editing and programming software for Microsoft Windows Please refer to the separate EaziCNC 3 manual for details on operating the EaziCNC 3 software Copyright 2013 Conqueror Design and Engineering Ltd Introduction to the M401 card 4 2 2 RS232 Serial Interface J1 RXD TXD CONN D9 Receive Data RCD Transmi Data TXD 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 115 200 baud 8 data bits no parity and 1 stop bit The board will use XON XOFF flow controls by default Copyright 2013 Conqueror Design and Engineering Ltd 5 M401 Installation Manual 2 3 Connector for Stepper Motor Drives z H wv Ot 5 H ue if H W m U4 aof sd 3 RNE A O3 7 g 5 G g E MOTORS Re 11 O BN1 cy EEE a fale 7 4 4E 4 ejmeeej meeej mee e Z A aX LIMZ LIM LIMxX 4 STPE Clock Step pulse for E U motor DIR Motor step direction Shared by all drives 5 3 ENABLE Used to idle the stepper motor drives when not in use 9 REI digital output 1 RE2 digital output 2 Connector MOTORS at the centre right of the M401 card can be used to attach separate stepper motor drive cards If the stepper motor drive card STEP1 or STEPHP1 is are used then the connections to the cards can be made via a straight ribbon cable bus
11. M401 Installation Manual Copyright 2013 Conqueror Design and Engineering Ltd M401 Installation Manual Copyright 2013 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 26 06 2013 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 ofthis 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 Warranty Updates are available from the website We recommend getting the latest manual updates when working with the product Contents Table of Contents Part 1 Disclaimer of Liability and Limitation of Warranty 1 Part2 Introduction to the M401 card 2 1 Components of the
12. N S NA i sz iva d s wjs mo momo momo mio uie P O epp R1 PWM g meeejmeoemeeeimeoe ENC LIMZ L IM L IMX In each case the square pad located inside each connector indicates pin1 this is also marked by a triangle RDYI Ready LED connect to the Anode of an LED connect to the Cathode of an LED The Ready LED allows an off board LED to show the same status as the on board RDY LED the green LED The external LED will be driven at approximately 2 5mA X X Y Y Z and Z Axis Jog button and BN1 connectors Button signal Short to pin 2 to activate button 1e connect the switch across the 2 pins STP Safety circuit connector LIMX LIMY and LIMZ Limit s witch connectors Pm joo Femeton aa Positive travel limit signal Short to pin 2 to activate limit 1e Copyright 2013 Conqueror Design and Engineering Ltd Introduction to the M401 card ELA Lo connect the switch across the 2 pins Ground 0 volts 3 Negative travel limit signal Short to pin 4 to activate limit 1e connect the switch across the 2 pins Ground 0 volts The LIMY connector can be used for threading support or synchronized drive on a mill router wire eroder Two optical sensors can be connected to the limit and the limit A single pulse per rev sensor should be connected to the Y limit and a multi slot sensor to the Y limit If only synchronized drive is to be used then only the multi slot sensor needs to be
13. clearance all around where possible Copyright 2013 Conqueror Design and Engineering Ltd Appendices EM 6 Appendices 6 1 Command Set Ctr 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 aa MN to the terminal and disables user friendly responses Escape Stops any current moves or commands Clears the command buffers This command does At Returns the current position and status data in compressed hex format This command does not need to be completed with a carriage return CR Message mode Controls whether messages are sent to the console n 0 do not show messages n 1 show messages including updates when 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 1 Stopped by user 2 Stopped limit triggered 3 Power interrupted 6 Checksum Error 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 Manual Mode To exit manual mode the lt ESC gt command must be sent 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 Copyright 2013 Conqueror Design and Engineering
14. connected The power for the sensors can be drawn from the V 5 connector or the ENC connector and either pin 2 or 4 of the LIMY connector can be used for GND OV If the threading function is to be used then the Y limits should be disabled in the configuration The encoder connector can be used for attaching a quadrature encoder for jog wheel use ENC encoder connector Quadrature A signal Quadrature B signal Ground 0 volts Copyright 2013 Conqueror Design and Engineering Ltd 9 M401 Installation Manual 2 5 1 Quadrature encoders Quadrature encoders output 2 pulse trains A and B which are out of phase The quadrature in the name is derived from the fact that there are 4 states for the 2 signals to be in A off with B off A on with B off A on with B on and A off with B on The sequence of these states determines the direction of rotation of the encoder 0123456789 012345267289 CLOCKWI SE A LEADS B V ILILILIL s J LL LI LI LI COUNTER CLOCKWISE B LEADS A For feedback from the motors optical encoders are usually used because they place no load on the drive system and can cope with the high speeds that motors Copyright 2013 Conqueror Design and Engineering Ltd Introduction to the M401 card 10 and shafts may turn at The encoder pictured is a rotary encoder with a slotted disk the disk determines the resolution of the encoder in this case 400 counts rev Optical encoders al
15. drive cards The M401 can be connected to up to 4 stepper motor drive cards The connection for additional drive cards is a 10 pin IDC connector If our STEP1 or STEPHPI cards are used then a simple ribbon cable with bussed connectors can be used to connect the cards together each STEP1 or STEPHPI card is then set to be either X Y Z or E U using the jumpers JP1 on the card N B If using STEPI or STEPHP1 cards remember to remove the jumpers JP3 so that the 5 volt lines of all the cards are not connected This will reduce heat dissipation in the voltage regulators If 3rd party cards are used then you may find it convenient to use the optional OPTOCARD1 opto isolator card or the X641SC stepper converter to simplify splitting the step clock and direction signals between several cards Copyright 2013 Conqueror Design and Engineering Ltd 15 M401 Installation Manual 4 4 X641SC stepper motor card interface board The X641SC card is useful for interfacing to 3rd party stepper motor drive cards The X641SC separates the drive signals to discrete connectors instead of the ribbon cable bus used by our stepper motor drive cards Each output pin can drive a 25ma load and there are also opto isolated outputs for converting the signals for non logic voltage levels or across power busses Each X641SC card can address 4 stepper motor drive cards and each card address can be set as X Y Z U V or W The direction signal is also buffe
16. in outs are Clock Step pulse ve emitter Clock Step pulse ve collector Direction signal ve collector Direction signal ve emitter Each opto isolator can sink 50 mA at up to 50 volts Total power for each opto isolator should not exceed 200 mW The jumper blocks J2 J3 J4 and J5 are used to select which clock step signal is used for each of the motor outputs M1 M2 M3 and M4 also the opto coupled M1I M2I M3 and M41 Only one jumper should be placed on each block the X Y Z U V and W markers on the board indicate the positions for the Ist 2nd 3rd 4th 5th and 6th axes The jumper J6 should only be fitted if the opto isolated connections are going to be used power dissipation can be reduced if the opto isolators are not required Generally if a motor drive card has logic level 5 volt inputs then the opto isolators do not need to be used they only need to be used if the motor drive card requires higher voltage or is connected to a power rail that does not share a common ground with the control card Copyright 2013 Conqueror Design and Engineering Ltd M401 Installation Manual 5 Mechanical Mounting Details S Y 67 ane m S 70 mm S YX Ap LS 90 06 mm Above is the drawing of the base of the M401 card heat sink The outer 4 holes in the base can be used for mounting the card The card should be mounted with 10 mm of additional
17. osed bit 12 Z limit positive is NC normally closed bit 13 Z limit negative is NC normally closed bit 14 U limit positive is NC normally closed bit 15 U limit negative is NC normally closed Copyright 2013 Conqueror Design and Engineering Ltd M401 Installation Manual RPM RPM 4 Maximum Cutting Feed Rate Default 400 mm min 5 nteger Rapid Feed Rate Default 800 mm min E 45 00 Integer Pulses Revolution on Threading Synchronizing Encoder Default 360 Setting this to O will cause the slots to be counted 7 Default Circular Interpolation Mode 0 XY 1 XZ 2 YZ P8 P19 P8 P19 10 Integer Y scale Y step size in millimetres P11 P10 P19 11 Integer Y divisor Y step size in millimetres P11 P10 P19 2 Integer Z scale Z step size in millimetres P13 P12 P19 P15 P14 P19 P15 P14 P19 sec 625 000 P17 Feed P 16 Divisor for Feed rates Steps sec 625 000 P17 Feed P 16 1 13 Integer Z divisor Z step size in millimetres P13 P12 P19 1 Integer Decimal digits in coordinates Default 3 digits Divisor for coordinates Default 1000 20 Binary Low byte Control capabilities Do not alter igh byte X Y and Z axis mapping 21 Integer Delays for carousel tool post Forward delay low byte 1 0 25 SECs Reverse delay high byte 1 0 25 secs For stepper driven carousels 32768 high bit steps 100 Reverse is half of Copyright 2013
18. red for each motor output for use with 3rd party cards that may not support the shared direction signal that our cards use Multiple X641SC cards can be connected and a system mixing our stepper motor drive cards and 3rd party drive cards is possible x LW NZ ZW VA o 20 p b D b j 5 1 BS h fs J J J xy ZU V MW x Y zu ZU WV OW x Y ZU vM EHHEHEHEHEEREHREHHREHRHHE amp Eng ig Q f iH D X WILJLS m a Form co uk COmTIQueror Design For easy reference the logic output connector and the opto isolated connector are in line with the jumper block which selects the axes The logic connectors are 5 pins while the opto isolated connectors are 4 pins The enable signal is not present on the opto isolated output The J1 pin out is as follows this is compatible with M64x and X641 cards VEC G3 vol Ground 0 volts STPX Clock Step pulse for X motor STPY Clock Step pulse for Y motor Copyright 2013 Conqueror Design and Engineering Ltd Connecting motor drive cards 16 STPZ Clock Step pulse for Z motor ae STPU Clock Step pulse for E U motor DIR Motor step direction Shared by all drives NE RN Enable shared by all drives pou STPV Clock Step pulse for V motor STPW Clock Step pulse for W motor The M1 M2 M3 and M4 connector pin outs are Each logic level output on the M1 M2 M3 and M4 connectors can sink or source 25 mA The M11 M2I M2I and MAI connector p
19. so come in strip or linear forms and there are other types of non contact encoders that can be used such as capacitance strips or magnetic proximity switches For the hand wheel a mechanical cheaper encoder switch can be used these operate using a wafer switch but provide the same quadrature outputs as an optical encoder they are just not suitable for high speed or long life applications Another advantage of these mechanical encoders is that they often have detents a cogging feel as they are rotated The encoder shown is a Bourne ECW 1J B24 AC0024 it provides 96 counts per revolution and Is the encoder we use for the hand wheel on the CNC1 CNC2 and CNC3 boxed controllers Copyright 2013 Conqueror Design and Engineering Ltd M401 Installation Manual 2 6 Spindle Speed Output X u1 cs PWM L ss meeejn A A A A SPINDLE REL L Analogue positive supply AN Analogue signal ANS Analogue negative supply AN Spindle on signal SO Spindle on common SO The M401 has an optically isolated analogue output for spindle speed control and an isolated switch for spindle on off control SPINDLE The optically isolated analogue output is suitable for use with cards that either have provision for a DC signal to control the speed or use a low current potentiometer to set the speed It is not suitable for thyristor type controllers which pass a substantial part of the motor current through the potentiometer or
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