Conect 121 Upgrade. Copyright 2013 Conqueror Design and Engineering Ltd.

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2 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 6/06/03. 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. Warranty Updates are available from the website. We recommend getting the latest manual updates when working with the product.

3 Contents I Table of Contents Part Disclaimer of Liability and Limitation of Warranty Part Conect with Lander Electronics Inside... the box 3 Part 3 Removing the existing electronics and fitting new components 4 Part 4 Power supply 5 Part 5 Control cards 7 Part 6 Spindle and coolant circuits 8 Part 7 Rewiring the stepper motors 9 Index 0 I

4 Disclaimer of Liability and Limitation of Warranty Where items are supplied as components 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.

5 Conect with Lander Electronics Conect with Lander Electronics The Conect with Lander Electronics has the electronics housed in a separate enclosure (pictured above). The lathe is connected to the box via a number of plugged cables - one for the AC coolant pump, one for the DC spindle motor, one for the X stepper motor and one for the Z stepper motor.

6 3. Inside the box Inside the box there are cards mounted on both the top and bottom of a metal carrier plate. Upgrading the machine will require the following to be done.... The existing cards with the exception of the spindle motor drive card need to be removed.. The transformer and filter capacitor need to be removed. 3. The new power supply needs to be mounted to the carrier plate. 4. The M40 and STEP stepper motor cards () need to be mounted to the carrier plate. 5. The system needs to be rewired. 6. The stepper motor cables need to be rewired.

7 Removing the existing electronics and fitting new components 3 4 Removing the existing electronics and fitting new components The power supply card, existing transformer and capacitor can be removed from the top layer. The PCB on the bottom layer can be removed. The large heat-sink and resistors on the back panel can also be removed and will not be reused. When removing the existing components leave the wires connected into the plugs and mark any cables going to the 4 connectors to the lathe on the rear panel. Some of the cables may be reusable so it is better not to cut anything unless necessary. There should be sufficient space to mount all of the new components on the top layer. Ideally the M40 card should be mounted on a rubber or plastic pad using nylon bolts (M3) so that the heat-sink is isolated. The STEP cards can be mounted directly to the carrier plate.

8 5 4 Power supply Outputs 35V ~6.4A TR BR AC DC C 6800uF 40V 60VA 4V TOROIDAL TITLE: R K W5 5A 00V DATE: SIMPLE PSU //08 PAGE: BY: Alex Mackinnon REV: / The power supply should be wired as shown above. A common-block is provided to simplify the wiring of the power-supply...

9 Power supply 6 The suggested wiring for the common-block is LIVE-NEUTRAL-GND-DC. In a normal wiring system this will be BROWN-BLUE-BLACK-RED. Where a dual-voltage (0/40AC) transformer is supplied the AC connections are the BROWN and BLUE wires. The PURPLE and GREY wires should be joined together and isolated from other connections (this connects the two primary windings of the transformer in series). The RED & YELLOW wires should be joined and connected to one AC input of the bridge-rectifier and the BLACK & ORANGE wires should be joined and connected to the other AC input (this connects the two secondary windings in parallel). DO NOT confuse the BLACK and RED wires from the transformer with the BLACK and RED wires used for the DC supply in the rest of the circuit because they are AC before they pass through the bridgerectifier. The AC input from the rear panel connector should be routed through the front panel switch and onto the common-block where it can be distributed to the transformer, the spindle drive card circuit and the coolant relay. It is recommended that you connect the safety switch to the M40 directly as there is hard-wired safety but you can connect the AC supply through the safetyswitch if you prefer. The output DC from the bridge-rectifier can be connected to the common block, filter capacitor, bleed resistor and to the control cards - it is recommended to use BLACK for the GND/ NEGATIVE and RED for the POSITIVE. BEFORE plugging in any cards it is important to test the supply with a volt-meter to check that it is performing correctly.

10 7 5 Control cards The control cards (M40 and x STEP cards) need to be connected to the DC supply and connected together with the STEPBUS ribbon cable. The M40 card also requires.... connecting to the front panel buttons - these need to be wired to the X+. X-, Z+ and Zterminals on the card [The multi-way switch is not used - if you purchased the hand-wheel option this can be fitted in place of the multi-way switch].. the LED on the front panel connecting to the RDY terminals [reverse the connections if the LED does not light when the green LED on the card is on]. 3. connecting to the emergency stop (UNLESS it has been connected into the AC supply). This connect to the STP terminals. 4. connecting to the spindle card - pin from the M40 to the MAX terminal, pin to the terminal between MIN & MAX and pin 3 to the MIN terminal. The STEP card needs to be configured as X and Z - on one card switch SW- needs to be on (this is the shipping default) to make it the X card, on the other card switch SW- needs to be switched off and switch SW-3 switched on - this will make it the Z card. On the X card the SW switches can be left on the default settings. On the Z card the switch SW-7 needs to be switched on to allow for the higher current required by the larger Z stepper motor. The ORANGE, WHITE, YELLOW and PURPLE wires from the X motor socket on the rear panel can be connected to the motor terminals on the X stepper card. The ORANGE, WHITE, YELLOW and PURPLE wires from the Z motor socket on the rear panel can be connected to the motor terminals on the Z stepper card.

11 Spindle and coolant circuits 6 8 Spindle and coolant circuits The AC supply to the spindle motor card needs to be routed through one of the supplied relays... Re lay - the smalle r spade conne ctors are the coil and the large r one s the switching circuit The NEUTRAL/BLUE connection is wired direct but the LIVE/BROWN connection needs to route through the normally open switching terminals of the relay (the two furthest from the coil terminals are the normally open contact if there are three terminals). The AC supply for the coolant relay needs to be connected through the other relay. The relays coils are wired to the M40 control card (see the M40 install manual for details).

12 9 7 Rewiring the stepper motors The stepper motor cables need to be rewired. They are currently wired for unipolar drive and need rewiring for bipolar drive. DO NOT PLUG IN THE STEPPER MOTORS BEFORE REWIRING THE CABLES! The current wiring is... Pin Pin wire colour BLACK WHITE RED YELLOW BLUE 7 GREEN 8 - The new connections should be... Pin Pin wire colour BLACK WHITE 3 RED 4 YELLOW Motor wire colour BLACK ORANGE RED YELLOW BLACK/WHITE & ORANGE/WHITE RED/WHITE & YELLOW/WHITE - Motor wire colour BLACK + ORANGE/WHITE ORANGE + BLACK/WHITE RED + YELLOW/WHITE YELLOW + RED/WHITE -

13 Index Index -DDisclaimer of Liability -LLimitation of Warranty -OOPTOCARD 0