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.

8Introduction to the CNC1/CNC2 box
Copyright©2005ConquerorDesignandEngineeringLtd.
2.2.4 Stepper motor plug
Pin
Signal
1
A phase +
2
A phase -
3
B phase +
4
B phase -
N.B. As delivered the stepper motor outputs are configured for 1 Amp/phase and for half-
stepping with power-save enabled. To change these settings please refer to the manual for
the MPC5 card.
**WARNING** 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 before connecting or disconnecting motors. Failing to observe
this precaution could permanenty damage your control box!

9 CNC1/CNC2 Installation Manual
Copyright © 2005 Conqueror Design and Engineering Ltd.
2.2.5 Feed-back/Encoder/Limit-switch plug
Pin
Signal
1
+5 volt supply
2
A-channel of axis encoder
3
B-channel of axis encoder
4
0-volts/ground
5
Limit+
6
Limit-
7
X&Y&Z Plug - No
connection
E/U Plug - Single-slot
spindle encoder input
8
X&Y&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.

10Introduction to the CNC1/CNC2 box
Copyright©2005ConquerorDesignandEngineeringLtd.
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/limit 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-way'
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 CPC1 9 WAY".

11 CNC1/CNC2 Installation Manual
Copyright © 2005 Conqueror Design and Engineering Ltd.
3Manual 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) and BN2 (button 2) combinations. the jog-
switches operate as normal in manual mode when neither BN1 or BN2 is pressed.
Keys pressed
Action
BN1 & X+
Enter manual mode.
BN1 & X-
Exit manual mode.
BN1 & Y+
Turnspindle/spindle-relayon
BN1 & Y-
Turnspindle/spindle-relayoff
BN1 & Z+
Toggle rapid and feed modes.
BN1 & Z-
Toggle coolant on/off.
BN2 & X+
Increase spindle speed (and turn on spindle if
necessary).
BN2 & X-
Decrease spindle speed (and turn off spindle
ifnecessary).
BN2 & Z+
Increase feed-rate.
BN2 & Z-
Decrease feed-rate.
If no button has been pressed for several minutes the machine will be switched out of
manualmode.

12Appendices
Copyright©2005ConquerorDesignandEngineeringLtd.
4Appendices
4.1 Compatible Motors
The following motors have been tested with the CNC1 and CNC2 box...
Motor Size
(W x H x L)
Voltage
Current
(Amps.)
Holding Torque
(mNM)
Holding
Torque
(Oz-In)
23 Standard
57 x 57 x 40
11.2
3.4
2.3
1.5*
0.33
1.0
1.5
2.2*
320
340
330
310
45
48
47
44
23 Standard
57 x 57 x 52
10.1
5.0
2.3
0.44
1.0
2.1
650
690
640
91
98
91
23 Standard
57 x 57 x 67
4.2
3.4
2.8*
1.6
1.9
2.5*
1,090
1,130
1,140
154
160
161
23 Standard
57 x 57 x 103
3.5*
2.9
1,480
210
23 High Perf.
57 x 57 x 41
4.6
2.1
1.0
2.1
470
480
67
68
23 High Perf.
57 x 57 x 55
6.2
2.9
2.1*
1.0
2.1
3.0*
980
980
980
138
138
138
23 High Perf.
57 x 57 x 79
4.2
3.3*
2.1
3.0*
1,610
1,630
228
231
34 Standard
82 x 82 x 62
5.8
3.0
2.8*
1.3
1.7
3.1*
1,820
1,500
1,820
258
212
258
34 High Perf.
82 x 82 x 67
7.0
3.6*
1.4
2.8*
2,800
2,800
396
396
34 High Perf.
82 x 82 x 94
4.8*
2.8*
4,800
680
42 Standard
108 x 108 x 179
3.7*
3.4*
9,900
1,400
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

13 CNC1/CNC2 Installation Manual
Copyright © 2005 Conqueror Design and Engineering Ltd.
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, I, J, K, F, R
Arc Clockwise Move
G03*
X, Y, Z, E, I, J, K, F, R
Arc Counter-Clockwise Move
G04
S
Dwell. S=Seconds to delay.
G05*
P
Spline function (Bezier curve) (only
availablewhen runningwith theEaziCNC
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, Z, E
HomeAxis
G40
-
Tool-nose compensation off (default mode)
G41
R
Tool-nosecompensation Left-of-Line
G42
R
Tool-nosecompensationRight-of-Line
G43
-
Tool-lengthcompensation (positive)
G44
-
Tool-length compensation (negative -
default mode)
G45
-
CancelTool-lengthcompensation.
G54
X, Y, Z, E
Set home/reset position.
G70
-
Imperialcoordinates(onlyavailablewhen
running with the EaziCNC software)
G71
-
Metric coordinates (default mode)
G90
-
Absolute coordinates (default mode)
G91
-
Incrementalcoordinates(onlyavailable
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.

14Appendices
Copyright©2005ConquerorDesignandEngineeringLtd.
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
-
CancelCannedCycle
G81*
X, Z, P
Turningcycle
G82*
X, Z, P
Tapercycle
G83*
X, Z, I, K, R, P
ArcClockwiseCycle
G84*
X, Z, I, K, R, P
ArcCounter-Clockwise Cycle
G85*
X, Z, P
FacingCycle
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 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.

15 CNC1/CNC2 Installation Manual
Copyright © 2005 Conqueror Design and Engineering Ltd.
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
-
OffsetOff.Cancel/Clear temporary origin
G56
X, Y, Z, E
Offset. Set temporary origin.
G80
-
Cancel/CompleteCannedCycle.
G81*
Z
Drill,Spot-Drill
G82*
Z, K
PeckDrill
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.

16Appendices
Copyright©2005ConquerorDesignandEngineeringLtd.
4.3 M-Codes
M-Code
Parameters
Description
M00
-
Programme Stop
M01
-
Optional 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
S
Spindle Start Clockwise + Coolant On
M14
S
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
RelayP 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

17 CNC1/CNC2 Installation Manual
Copyright © 2005 Conqueror Design and Engineering Ltd.
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
terminalandenablesuser 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
userfriendlyresponses.
<ESC>
-
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 not need to be completed
with a carriage return (CR).
D
n<CR>
Message-mode. Controls whether messages
are sent to the console.
n=0 - do not show messages
n=1 - show messages (including updates
whenmoving)
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