Conqueror CNC1 User manual

Copyright © 2005 Conqueror Design and Engineering Ltd.
CNC1/CNC2 Installation Manual

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.
CNC1/CNC2 Installation Manual
Copyright © 2005 Conqueror Design and Engineering Ltd.
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.

Table of Contents
Part 1 Disclaimer of Liability and
Limitation of Warranty 1
Part 2 Introduction to the CNC1/CNC2
box 2
................................................................................................................................... 31 Front panel controls
................................................................................................................................... 42 Rear Panel Connections
......................................................................................................................................................... 5RS232 Serial Interface
......................................................................................................................................................... 6Spindle Motor control plug
......................................................................................................................................................... 7Relay drives plug
......................................................................................................................................................... 8Stepper motor plug
......................................................................................................................................................... 9Feed-back/Encoder/Limit-switchplug
................................................................................................................................... 103 Spare and replacement plugs
Part 3 Manual Operation without a
Computer 11
Part 4 Appendices 12
................................................................................................................................... 121 Compatible Motors
................................................................................................................................... 132 G-Codes
......................................................................................................................................................... 14Additional G-Codes for Lathe Operations
......................................................................................................................................................... 15Additional G-Codes for Milling Operations
................................................................................................................................... 163 M-Codes
................................................................................................................................... 174 Command Set
................................................................................................................................... 195 Control Parameters
Index 24
IContents
I
Copyright©2005ConquerorDesignandEngineeringLtd.

1 CNC1/CNC2 Installation Manual
Copyright © 2005 Conqueror Design and Engineering Ltd.
1Disclaimer 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 & 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.

2Introduction to the CNC1/CNC2 box
Copyright©2005ConquerorDesignandEngineeringLtd.
2Introduction 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.

3 CNC1/CNC2 Installation Manual
Copyright © 2005 Conqueror Design and Engineering Ltd.
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
electronic hand-wheel is rotated clockwise to move the axis in the positive direction and
counter-clockwise to move the axis in the negative direction.

4Introduction to the CNC1/CNC2 box
Copyright©2005ConquerorDesignandEngineeringLtd.
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!

5 CNC1/CNC2 Installation Manual
Copyright © 2005 Conqueror Design and Engineering Ltd.
2.2.1 RS232 Serial Interface
Pin
Signal
2
Receive Data (RCD)
3
Transmit Data (TXD)
7
Ready-To-Send (RTS)
8
Clear-To-Send (CTS)
5
Ground
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.

6Introduction to the CNC1/CNC2 box
Copyright©2005ConquerorDesignandEngineeringLtd.
2.2.2 Spindle Motor control plug
Pin
Signal
1
Emergency stop
2
Emergency stop
3
Motor armature +
4
Motor armature -
5
Motor field +
6
Motor field -
7
Relay
8
Relay
9
Earth
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.

7 CNC1/CNC2 Installation Manual
Copyright © 2005 Conqueror Design and Engineering Ltd.
2.2.3 Relay drives plug
Pin
Signal
1
+12 Volt supply
2
Coolantrelay
3
Relay1
4
Relay2
5
Relay3
Each relay drive is capable of sinking 500 milli-amps of current but the combined current of
all relays should not exceed 1 Amp.