Compact 1000 Router

CNC Machine
User’s Manual

approved

http://www.denford.com
1
1: Contact Information
Address: Denford Limited,
Birds Royd,
Brighouse,
West Yorkshire,
HD6 1NB,
UK.
Telephone: General Enquiries 01484 728000
Fax: 01484 728100
e-mail: for sales enquiries contact, [email protected]
for machine servicing enquiries contact, [email protected]
for customer services, contact [email protected]
Technical Support: Visit help forum at www.denford.com
Telephone Denford Customer Services: 01484 728000
e-mail: [email protected]
Monday to Friday 8.30am - 4.30pm GMT
For international dialling:+44 and remove first 0 in each city code

1: Notes

Compact 1000 Router - User manual Page 2

Table of Contents

1 : Notes

Compact 1000 Router - User manual Page3

1: Contents
Contents Page
1: Contact Information ............................................................................................ 2
1: Notes .................................................................................................................. 2
1: Contents ............................................................................................................. 4
1: Warning Notices ................................................................................................. 5
1: About this Manual............................................................................................... 6
1: Introducing your Compact 1000 Router.............................................................. 7
1: Before Beginning to Setup.................................................................................. 8
2: Safety Features Overview and Precautions ....................................................... 9
2: Safety Features - Emergency Stop Button......................................................... 10
2: Safety Features - Interlock Guard Switch........................................................... 11
3: Unpacking and Lifting your CNC Machine.......................................................... 12
3: Choosing a Site for your CNC Machine.............................................................. 13
3: Removing Protective Coatings and Packaging .................................................. 14
3: Dust Extraction & General Wood Precautions.................................................... 15
4: Switching the Router On..................................................................................... 16
4: Switching the Router Off..................................................................................... 17
4: Homing the Machine Axes (Home Mode)........................................................... 18
4: Manual Control - Axis Definitions (Jog Mode) .................................................... 19
4: Front Machine Operators Panel ........................................................................ 20
5: Performing a Tool Change.................................................................................. 21
5: Setting Tools in the Router Motor ....................................................................... 23
6: Using the Work Clamp........................................................................................ 25
6: Fitting and Removing the Work Clamp............................................................... 27
6: Fitting and Removing the Datum Plate............................................................... 28
6: Planning Procedure for Maintenance Work........................................................ 29
7: Cleaning the Router Motor ................................................................................. 30
7: Maintenance of the Router Motor....................................................................... 31
7: Cleaning the Microswitches................................................................................ 31
7: Lubrication...........................................................................................................32
8: Maintenance Log................................................................................................ 33
9: Technical Support ............................................................................................... 35
9: Troubleshooting - Cutting Problems ................................................................... 36
9: Troubleshooting - VR CNC Milling Software....................................................... 37
9: Troubleshooting - Mechanical Problems ............................................................ 39
10: Specification of the Compact 1000................................................................... 40
10: EC Declaration of Conformity........................................................................... 41
10: Compact 1000 Series Noise Level Test Results............................................... 42
11: Glossary............................................................................................................ 43
12: Notes ................................................................................................................ 46

Compact 1000 Router - User manual Page 4

1: Warning Notices

Warranty Disclaimer.
The Warranty on your Router will be invalidated if any modifications are made to the machine
or any additional ancillary equipment fitted, or any adjustments are made to the controlling
devices without prior notification from Denford Limited. Please refer to the information held in
your separate Warranty pack, for specific details.
Do not carry out any portable appliance testing (PAT) on any of the supplied equipment.

Maintenance Disclaimer.
Always obtain permission from the person responsible for machinery in your establishment,
before accessing the electrical control panel or Router machine casings to carry out any
maintenance work. All work must be carried out by personnel suitably qualified for each
maintenance task, to avoid damage to both the machine systems and the maintenance
personnel. Denford Limited cannot accept responsibility for any damage and/or loss that
may occur through incorrect maintenance of your router.

Foreseen Use of Machine.

Your Router is designed for routing hard and soft woods, certain ceramics and plastics. In
each case, the appropriate tooling, speeds and feeds should be used as recommended by the
material supplier. Your Router is not intended for use with any ferrous or metallic materials.
Facility is provided for dust extraction. Always use the machine coupled to a vacuum system.
Do not attempt to use your Router for manual operations.
Do not remove the router head and attempt to use it independently of the machine.
If you have any doubts and/or questions regarding the specification, servicing, or features of
your machine, please contact Denford Customer Services.
Denford Limited reserves the right to change the specification and/or operating features
regarding this CNC machine without notice or documentation.

Compact 1000 Router - User manual Page 5

1: About this Manual

Using this manual This manual provides information describing how to transport, site,
setup and operate the basic functions of your Denford Router CNC
machine, including any operational features of hardware specific to
the Denford Router series.
This manual does not provide any information regarding the
software packages used please refer to the help section within the
appropiate software.
Please note that the Electrical Diagrams for your Router are not
included in this manual - they are delivered separately in the
standard equipment box supplied with your CNC machine.
If you have any doubts and/or questions regarding the specification,
servicing, or features of your Router, please contact Denford
Customer Services. Denford Limited reserves the right to change
the specification and/or operating features regarding this CNC
machine without notice or documentation.
Disclaimer Please note that due to the nature of hardware and software
developments, the specifications and features of this product can
change without notice. The information contained in this manual is
correct at the date of printing only - November, 2006. No liability can
be accepted by Denford Limited for loss, damage or injury caused
by any errors in, or omissions from, the information supplied in this
manual.
Screenshots Please note that any screenshots are used for explanation purposes
only. Any numbers, wording, window or button positions may be
different for the configuration of the CNC machine control software
being used to control your Router.
Language This manual is written using European English.
Contact Any comments regarding this manual should be marked for the
attention of our technical authoring team and referred to the
following e-mail address: [email protected]

Compact 1000 Router - User manual Page 6

1: Introducing your Compact 1000 Router
Congratulations on your purchase of a Compact 1000 series CNC machine. In this manual
you will learn how to setup and use your Machine correctly and safely.

Your Router is a full three axes CNC router with a large work area, allowing machining of
materials approaching 400 x 240mm in size. Suitable for all levels of education and training,
it is manufactured to meet industrial standards. Together with rapid traverse rates of up
to 5000 mm/min your Router is the ideal partner for intensive 3D applications, such as the
F1 in Schools Formula One Technology Challenge (www.f1inschools.co.uk) and the 4x4 in
Schools Technology Challenge (www.4x4inschools.co.uk). Your Compact 1000 Router is
designed with you in mind - making the processes involved both safe and easy to use.

Main Features:
• Designed specifically for Education and Training.
• Manufactured to industrial standards.
• Programming via International Standards Organisation format, incorporating controls
such as FANUC.
• CE approved for safety.
• Capable of cutting common resistant and prototyping materials, including Wood, MDF,
Wax, Plastics and Acrylics.
• Links to various CAD/CAM software packages.
• Totally enclosed high visibility interlocked guard.
• Feedrate override control.
• Dust extraction ready.

Compact 1000 Router - User manual Page 7

1: Before Beginning to Setup
Before beginning to set up your Compact 1000, please check your separate
order documentation, making sure that all items have been delivered to your
establishment. Any missing or damaged items should be reported to Denford
Customer Services as soon as possible.

The following equipment is supplied as standard with your Router CNC machine :
• Compact 1000 CNC machine. Note that the precise specification of your CNC
machine will depend on any options selected at the time of ordering (see below).
• 1 x Set of Workholding Clamps
• 1/4” Collet and 1/2” Collet
• 1 x Allen (hex) keys pack.
• 2 x Router head spanners.
• External USB Cable
• 1/4”Dia. Ball Nose Cutter
• 1 x Compact 1000 warranty pack (UK Machines only)
• 1 x CD-ROM containing Denford VR CNC Machine Control Software and
manuals, and Machine user’s manual.
• 1 x VR CNC Machine Control Software Security Key (dongle) or Flash screen
software (supplied on removeable media).

The following optional equipment may also be supplied with, or ordered for, your
machine:
• Additional Software: CAD/CAM, Offline CNC Machine Control.
• CNC Machine Control software security keys (dongles) or licence disks.
• Machine work bench and/or PC & PC workstation.
• Vacuum for dust collection.
• Additional work holding systems.
• Various tooling packages.
• On-screen representation of industrial control systems (FANUC 21i) and optional
link to industrial keypad.
• Courseware, project books and project material packages.
• Video conferencing system.

Compact 1000 Router - User manual Page 8

2: Safety Features Overview and Precautions
Safety Features Overview.
The following safety features are standard on your Router Emergency stop button.
• Manually operated, totally enclosed guard door with interlock switch.
• Option on control software to check CNC programs using toolpath graphics, prior to
machining.
• Automatic tool retraction and spindle stop for tool changing.

Safety Precautions.
Safety is very important when working with all forms of machinery but particularly when
working with CNC equipment, due to the hazardous voltages, speeds and forces that exist
in the hardware. Follow the rules below at all times, when using your Router.
General Safety Precautions :
• Wear clothing suitable for machine operation and follow the safe working procedures in
place at your establishment. When cleaning down machine, or handling tooling, consider
additional protective clothing such as respitory masks, eye protection, gloves and
overalls.
• Do not place any objects so that they interfere with the guards or the operation of the
machine.
• Never try to clean the machine if any part of it is rotating or in motion.
• Always secure the work on the table or in a fixture or vice.
• Ensure that the correct cable for the power source is used.
• Ensure the mains power is switched off (and preferably unplugged) before starting
any maintenance work on the machine. Post a notice informing others not to use the
machine since it is undergoing maintenance.
• Hazardous voltages can still exist immediately after switching the machine off. Always
wait at least 5 minutes before accessing the CNC machine electronics.
• If power fails turn off the mains power switch immediately and unplug the machine from
the mains power socket.
• Service the required areas at the intervals specified in this manual (see the Maintenance
section for further details).
• Observe caution when handling machine tooling or cleaning down machine, particularly
with regard to hot and/or sharp cutters. Consider wearing protective gloves.
• When an emergency stop is required, press the circular red emergency stop button,
located on the right side of the CNC machine front panel.
• If laser scanner fitted do not stare into laser beam. Refer to Scanner instruction manual
for all aspects of safe use of laser.

Compact 1000 Router - User manual Page 9

2: Safety Features - Emergency Stop Button

The emergency stop button is

located on the right front panel of
the CNC machine. To activate an
emergency stop, press the button
fully in until it clicks.

A circular, red emergency stop button is located on the right front panel of
your Router, as shown above. When pressed, it has the effect of stopping
all axes and spindle movements immediately. The guard interlock switch
will also close. When the safety guard door is in its closed position, this will
prevent access to the working area of the CNC machine.
To activate an emergency stop, press the button in until it clicks. The
emergency stop button will continue to cut all power to the machine drives
and continue to keep the interlock switch closed, until the release sequence is
performed.
To release a closed emergency stop button, push in and turn the button
clockwise until it springs back out.
After releasing an emergency stop, you may need to reset any CNC control
software messages and home the CNC machines axes.

Check the emergency stop button is released before attempting to power up

the Router

Compact 1000 Router - User manual Page 10

2: Safety Features - Interlock Guard Switch
Note - x An interlock guard switch is fitted to the front machine door. The
switch unit itself is attached behind the lower machine panel,
A closed safety guard
door cannot be opened accessible from beneath the front of the machine. The lock must be
when: manually released to enter the working area when the 24 volt circuit
• The machine is has failed and the door is clamped electrically.
switched off (ie, not in
use). To release the
interlock guard switch,
supply power to the
machine.
• The emergency stop Left: The interlock guard
button is fully pressed switch unit (circled) is
in. To release the lock, located behind the lower
push in and turn the front machine panel.
emergency stop button
counter-clockwise until
it springs back out to
its ready position.
• Machining is taking
place. The interlock
guard switch will An override facility is provided on the interlock guard switch, allowing
release when the
machining operations temporary removal of the guard lock feature. For manual interlock
have been completed release, the power supply must be switched off.
and the machine
controlling software is 1) Working beneath the front edge of the machine, locate the
operating in Jog Mode. interlock guard switch unit.
2) Using a small flat or crosshead screwdriver, loosen the manual
override locking screw until the circular black plastic lock screw
can be turned (refer to photograph below).
Warning - x 3) Using a 3mm allen key, turn the circular black plastic lock
screw one quarter turn to switch off the guard lock feature. If in
Danger of serious injury! doubt refer to the lock/unlock symbols embossed on the casing
Do not let unauthorised surface.
personnel use the
machine when the guard 4) If necessary, tighten the manual override locking screw slightly.
lock feature is disabled. If you need to leave the machine, post a warning note informing
Ensure the guard lock
feature is switched back unlocked Left: Looking directly at
marker
on as soon as possible. the face of the interlock
guard switch unit.
manual locked
override marker
locking triangular lock
screw screw position
marker

unlocked
marker

Compact 1000 Router - User manual Page 11

 3: Unpacking and Lifting your CNC Machine
Warning - x
If your Router has been supplied inside a delivery box, cut the top of the box
open and remove any packaging carefully. To obtain better access to the
Caution. machine, remove all the sides from the delivery box. Your Router weighs 90
Always use sensible KG . Take suitable precautions when manually lifting the machine from the
lifting precautions in packaging (see text below).
accordance with Health
and Safety Regulations
Denford recommends that four or more persons should be used to lift the
in your establishment. Router, one at each corner of the machine, as illustrated in the diagram
below. Always use sensible lifting precautions in accordance with Health
and Safety Regulations in your establishment. Ensure that your Router is
both secure and balanced before lifting. Do not tip the CNC machine whilst
lifting.

Caution: The back of the

machine is heavier than
the front.

When lifting the Router manually,

use one person at each corner of the
machine.

Caution: Do not trap your

fingers under the machine
cabinet edges.

Points to Note.
The majority of the weight is situated at the back of the machine.
Due to the small clearance at the base of the machine, take precautions to
ensure you do not trap your fingers under the edges of the machine cabinet,
when lowering your Router onto a table top.
If necessary use two 100kg (220 lb) rated lifting bars to help raise the
machine. Ideally lifting bars should be fed through or placed between the
hollow support runners. To transport your Router over longer distances, we
recommend the use of a suitably sized wheeled trolley.

Compact 1000 Router - User manual Page 12

3: Choosing a Site for your CNC Machine
Site your machine in a well ventilated room. The Router is a bench mounted machine, so it
should be sited on a bench of sturdy construction to take the weight of the machine and of a
height which enables comfortable operating and programming to take place.
Ideally, the user will operate the machine when standing at its front, with a clear view of
both the machine working area (through the transparent guard window) and the personal
computer being used as the controller unit (which should be angled towards the user), as
shown in the diagram below.
Sufficient room should also be provided for effective maintenance to be carried out around
the machine itself. In particular, leave enough space for removal of the large plate covering
the electronics at the right hand side of the cabinet. Positioning the PC on a movable
workstation may allow easier access to the various vents, connectors and switches on the
machine cabinet, when required.
Position any vacuum pumps used with the dust extraction at the rear, or under, the machine
table. Do not place the machine in a position which allows any of the cabinet vents to be
covered. Ensure all cables, pipes and flexes are routed to avoid the possibility of users
tripping over them.
Ensure Allow space to remove the electrical
that any panel cover plate at the side of the
Dimensional Data. inlet/exhaust cabinet.
Machine Length (left to vents are not
right ) 845mm (33”). covered or Router on suitable
blocked. table.
Machine height (top to
bottom 675mm (26.5”).
Machine depth (front to
back) 750mm (29.5”). Dust extraction
here.

Plan View showing Ideal Machine Computer desk, monitor,

Layout and Operating Positions. keyboard and mouse angled
towards Operator.
Machine
Operator.

Compact 1000 Router - User manual Page 13

3: Removing Protective Coatings and Packaging

Once your Router has been sited and connected electrically, the Warning - x
protective coatings and transit packaging must be removed to
prepare the machine for running:
Potential risk of ignition /
1) The protective plastic sheeting on the guard windows must be explosion!
removed and the glass and perspex cleaned with an antistatic Do not use any aerosol
cleaner. based or flammable
products to clean your
2) Tie-wraps may be used in the working area of the machine, to CNC machine.
prevent movement of components during transit. Additional items Carefully read and
from your order may also be supplied packaged inside the working follow any instructions
area. or notices included with
3) To gain entry to the working area of the machine, power must be cleaning products.
supplied to the machine, in order to release the switch unit that
locks the safety guard door. Note that the switch unit will also
remain locked when the emergency stop button is fully pressed
in.
Warning - Aerosol based or flammable products must not be used
to clean your CNC machine. To avoid the potential risk of ignition
/ explosion, ensure that any trapped solvent vapours can exit fully
from any enclosed areas on the CNC machine. Wait at least 1
hour before attempting to operate the CNC machine.

Denford Compact 1000 - User manual Page 14

3: Dust Extraction & General Wood Precautions
Your Router is designed to run with a dust extraction system, used to remove any
potentially harmful airborne wood dust particles from within the working area of the
machine.
The dust extraction system used should be independently tested to ensure that dust
is kept well below the maximum exposure limits set by law. Denford can supply dust
extraction systems for your machine, or you may wish to connect your own system.
The machine should only be used with the dust extraction system enabled.
Connect the pipe from your dust extraction system through hole in the left hand cabinet
wall to the hole on the left hand side of the spindle motor adaptor plate.

General Wood Dust Safety Precautions.

Obtain "material safety data sheets" from your material suppliers and enforce the
recommended precautions. Be aware that certain hardwood and man made material
dust particles, such as oak and MDF, could contain known carcinogens. Please
consult your materials supplier for further details.
Wood dust particles that remain inside the working area of the Vertical Router after a
part has been machined, should be removed using a vacuum.
NEVER USE A PRESSURISED AIRLINE for this purpose.
When emptying the dust extraction system base unit or cleaning down the machine,
wear suitable respiratory protective equipment that is CE marked. Other personal
protective equipment, such as eye protection, overalls and gloves should also be
considered.
Wood dust particles on the floor can cause slipping. This should be monitored by the
operator and removed before it becomes a hazard.
Launder overalls regularly, provide good washing facilities with hot and cold water, soap
and towels and encourage a high standard of personal hygiene.
The following health problems are among the effects associated with exposure to wood
dust particles:
• Skin disorders.
• Obstruction to the nose.
• Rhinitis.
• Asthma.
• Nasal cancer.

Denford Compact 1000 - User manual Page 15

4: Switching the Router On
Note - x Follow these instructions to switch on your Router:
The safety guard cannot
1) Check the Denford machine link cable is fitted securely between
be opened until the the USB port socket on the machine controller PC and the USB
Router is powered up socket, located on the right-hand panel of the router cabinet.
to release the interlock
guard switch. 2) Check that all access panels are in position and securely
fastened.
3) Check that all inlet/exhaust vents are clear from obstructions.
Warning - x 4) Check the flexible hose from your separate dust collection
vacuum system is securely fitted to the connection hole, located
at the top of the left side viewing window.
Do not connect cables
between any electrical 5) Plug the router mains supply cable into an available power
hardware with the socket. Switch the power socket on.
mains power switched
on, since this could 6) The on/off power switch is located on the right-hand panel of
seriously damage the Router cabinet immediately above the power inlet socket.
components inside your
CNC machine.
To switch machine on depress the left-hand side of switch.
The switch will illuminate when power is being supplied to the
machine.
Warning - x
If the Router does not begin its power-up routine, switch off the
mains power and check all connections and fuses.
Never attempt to access 7) Switch on the machine controller PC and start the CNC machine
the electronic hardware
systems of the machine control software.
with the mains power
switched ON. Establish a communication link between your machine controller
Note that hazardous and PC.
voltages can still exist When the ‘found new hardware’ box appears install the driver for
immediately after
switching off the power. the USB connection (VR CNC milling cd must be in the CD Drive
If the machine has - for help please contact technical support 01484 728000.)
previously been
switched on, wait at
least 5 minutes before
attempting to open the
electrical panel cover
plate.
Many electronic
components are
sensitive to electrostatic
damage - ensure
components and/or
personnel are suitably
earthed to minimise
this risk.

Denford Compact 1000 - User manual Page 16

4: Switching the Router Off
Warning - x Follow these instructions to switch off your Denford Router off:
1) Wait for the Router to fully complete any machining or processing
of any operational instructions.
Never attempt to access
the electronic hardware 2) Open the safety guard door and remove any finished parts from
systems of the machine the working area.
with the mains power
switched ON. 3) Close down the communication link between the CNC control
Note that hazardous software and the Router, then exit the CNC control software, as
voltages can still exist described in your separate CNC Control Software User’s Manual.
immediately after
4) Shut down and switch off the machine controller personal
switching off the power.
computer.
If the machine has
previously been 5) Power down the Router by depressing the right-hand side of
switched on, wait at the red on/off mains power switch. The on/off switch is mounted
least 5 minutes before
on the right-hand cabinet panel immediately above the power
attempting to open the
electrical panel cover inlet socket. Note that cutting the machine power will trigger the
plate. closing of the interlock guard switch. This will lock a closed safety
Many electronic guard door in position, preventing access to the machine working
components are area. The interlock guard switch will automatically reopen when
sensitive to electrostatic power is next supplied to your Router.
damage - ensure
components and/or
6) Switch off the mains power socket.
personnel are suitably
earthed to minimise
this risk.

Denford Compact 1000 - User manual Page 17

4: Homing the Machine Axes (Home Mode)
Note - x Immediately after establishing a communication link between the CNC
control software and the Router, all three axes of the CNC machine
The sequence of events
required to home the must be homed. The process is commonly referred to as homing the
router will depend on the machine, or datuming each of the three machine axes.
type of CNC machine When a communication link is first established between the router and
control software being the CNC machine control software, or when the CNC machine “loses”
used - please refer to
your separate CNC
position, the software will not know the true position of the machine
Machine Control head in relation to the three machine axes.
Software User’s Manual
for specific details.
Homing the CNC machine defines:
• The machine datum, by physically driving the machine head to a
fixed zero reference point.
• The constraints of three dimensional co-ordinate grid system used
for plotting any programmed movements, effectively the working
Note - x
envelope of the CNC machine.
The CNC machine
control software Jog
and Auto Modes will not After homing the machine, the zero position of the three dimensional
become available until co-ordinate grid system is referred to as the machine datum. You can
the machine has been find the position of the machine datum by switching the co-ordinate
configured by homing all display in your CNC control software to read Machine Co-ordinates.
three machine axes. The position of the machine datum is achieved when the X, Y and Z
panels of the co-ordinate display all read zero.
In addition to homing the CNC machine after it has first been switched
Note - x on, we also recommend homing the CNC machine after loading or
The machine datum configuring any offsets.
position is set by
Denford and can never
be moved, since it
defines the physical
movement capability of
the CNC machine.

Denford Compact 1000 - User manual Page 18

4: Manual Control - Axis Definitions (Jog)
Jog mode is used for manually controlling the CNC machine, moving the
three machine axes, changing tools, operating optional equipment and
configuring any offsets.

Axis Definitions.
X Axis - The X axis slides run at 90 degrees to the Y and Z axes, horizontally left and
right, when viewed from the front of the machine.
Minus (-) X movements run towards the left end of the machine and positive (+) X
movements run towards the right end of the machine.
Jog Keys to move axis - arrow keys left and right
Y Axis - The Y axis slides run at 90 degrees to the X and Z axes, horizontally
forwards and backwards, when viewed from the front of the machine.
Minus (-) Y movements run towards the back of the machine and positive (+) Y
movements run towards the front of the machine.
Note the Y movements refer to table movement. The Axis notations in the
above diagram refer to Tool movement relative to the table.
Jog Keys to move axis - arrow keys up and down
Z Axis - The Z axis slides runs at 90 degrees to the X and Y axes, vertically up and
down, when viewed from the front of the machine.
Minus (-) Z movements run down, towards the floor of the machine and positive (+) Z
movements run up, away from the floor of the machine.

Denford Compact 1000 - User manual Page 19

4: Machine Operators Panel
Feedrate Override Control.

The feedrate of the Router can be manually overridden during a

Note - x
machining operation, using the potentiometer control dial fitted to the
Feedrate override right end of the machine.
changes will only be
registered when an The feedrate can be overridden between 0% and 150%.
actual spindle speed or To increase rotate the control dial clockwise.
feedrate is being applied
by the CNC control To decrease rotate the control dial counter-clockwise.
software. The degree of adjustment applied is displayed in the CNC machine
control software.

Mains Power Switch.

To supply power to the CNC machine, depress left-hand side of red

switch immediately above the power inlet socket. To cut power to the
CNC machine, depress right-hand side of switch.
Do not cut the mains power when machining or processing of
any operational instructions is taking place. Note that cutting the
machine power will trigger the closing of the interlock guard switch.
This will lock a closed safety guard door in position, preventing
access to the machine working area. The interlock guard switch will
automatically reopen when power is next supplied to your Router.

Note - x
Emergency Stop Button.
Activating an emergency
stop will also trigger the The emergency stop button is a circular red push button. Pressing
interlock guard switch. the emergency stop button has the effect of stopping all axes and
This will prevent a spindle movements immediately. To active an emergency stop,
closed safety guard door press the button in fully until it clicks. The emergency stop button
from being opened.
will remain closed (continuing to cut all power to the machine drives)
until the release sequence is performed. To release a closed
emergency stop button, push and turn the button counter-clockwise
until it springs back out, then wait 6 seconds for the machine
systems to reset, unlocking the safety guard door.

Denford Compact 1000 - User manual Page 20

5: Performing a Tool Change
Standard Tool Change System.
The tool change system, supplied as standard with your Router, comprises four
elements:
i) The router motor with attached threaded shaft, bored to allow fitment of the cutting
tool and collet assembly.
ii) The collet and nut assembly - a tapered, tubular, split metal collet held inside the
locking nut, which threads directly onto the router motor threaded shaft. Different
sized collets and collet adaptors are available to allow use of cutting tools with
varying shank sizes.
Use a 4mm allen key to release the
bracket, used to secure the router
motor on the machine head plate.

(i) Router
Motor.

(ii) Collet
and Nut
Assembly.

(iii)
Cutting
tool.
Use the two C spanners to tighten the locking
nut onto the threaded shaft - one around the
nut, the other around the shaft.

Denford Compact 1000 - User manual Page 21

5: Performing a Tool Change
Warning - x Performing a Manually Requested Tool Change.
Before beginning a manual tool change operation, we recommend
you home the Y and Z machine axes and drive the X axis to roughly
Never open the safety the mid point on its axis. When the axes are in this position, the
guard door and enter
the working area when
maximum amount of free space will be available in the working area,
the spindle or machine allowing easier access to the tooling.
axes are moving.

Note - x
Performing an Automatically Requested Tool
When two or more tools
Change during the running of a CNC program.
are used in the same
CNC file:
On reading a tool change operation line in your CNC program,
Your new tool MUST be
refitted to router motor
all three machine axes will move to their home positions, via an
and machine head intermediate point, if programmed.
in exactly the same At this point, the software will pause the CNC program and a
position used when
originally configuring its
message window will be displayed, prompting you to manually
Z tool offset value. change tools.
Always wait for the spindle and machine axes to stop moving, before
attempting to open the safety guard door.
Replace the current tool number with the tool number specified in
the software message window (the tool profiles allocated to each
tool number may be listed at the beginning of your CNC program).
Close the safety guard door and clear the software message window
to resume your machining.

Denford Compact 1000 - User manual Page 22

5: Setting Tools in the Router Motor
Warning - x

Your Router must only

be used with standard Tools required:
1/4” or 1/8” shank • 2 x C Spanners (supplied).
routing bits, capable of
running safely at speeds
of 23,000RPM.

Removing a Tool.
Position the first C spanner around the locking nut on the end of
Warning - x the router motor shaft. Position the second C spanner around the
locating fixture on the router motor spindle.
To loosen the locking nut, when directly viewing the end of the router
Caution.
If the cutting tool has
motor shaft, turn the C spanner around the locking nut in an counter-
been recently used, it clockwise direction. Turn the C spanner around the router motor
may still be HOT. shaft in a clockwise direction, as shown in the photograph below.

C spanner
Right: around
Removing the locking nut.
Nut and Collet
Assembly.

C spanner
around router
motor shaft.

continued...
Remove the nut and collet assembly, then remove the cutting tool.

Denford Compact 1000 - User manual Page 23

5: Setting Tools in the Router Motor
Note - x Refitting a Tool.
Metric convertor collets Select the correct nut and collet assembly, according to the shank
(to allow fitment of size of your new cutting tool, as shown in the photograph below.
metric shank tools)
(a) (b) (c)
and various tooling Right: From left to right, collets to convert from
packages are available 1/2” to (a) 1/8” shank tools, (b) 3mm shank tools
as options. and (c) 6mm shank tools. The convertor collets fit
inside the 1/2” nut and collet assembly.

Right: 1/2” Left:

shank nut 1/4” shank
and collet nut and collet
assembly. assembly.

Hand thread the locking nut back onto the router motor shaft, then
insert the cutting tool into the nut and collet assembly. Position the
first C spanner around the locking nut on the end of the router motor
shaft. Position the second C spanner around the locating fixture on
the router motor spindle.
To tighten the locking nut, when directly viewing the end of the router
motor shaft, turn the C spanner around the locking nut in a clockwise
direction. Turn the C spanner around the router motor shaft in an
counter-clockwise direction, as shown in the photograph below.

C spanner
around C spanner
locking nut. around router
motor shaft.

Right:
Refitting
the Nut
and Collet
Assembly.

Check that the cutting tool is secure before putting the machine back
in to operation.

Denford Compact 1000 - User manual Page 24

6: Using the Work Clamp
Setting the Position of the Work Clamp.
Place the billet onto the machine table, so it is located correctly against the inside
edges of the datum plate. Set the work clamp in the open (unlocked) position. If you
have fitted the work clamp to the right end of the machine table, you must push the
handle back.
Slide the work clamp assembly along the machine table until the two flats on the
clamp plate are just touching the billet. Fully tighten the two hex bolts to firmly fix the
work clamp base plate in position on the machine table. At this stage, it should still be
possible to remove the billet.
To close (lock) the work clamp, pull the handle forwards. Press the end of the billet
down against the machine table, whilst locking the work clamp - this will prevent the
end of the billet from lifting. The handle should only need to be turned about one
quarter of a revolution before locking the billet firmly in position. If the billet can still
be moved, you must loosen the two hex bolts and reposition the work clamp base
plate so it is closer to the billet.

Press down
edge of
billet whilst
locking
clamp. Open clamp
(turn CCW).

Close clamp
(turn CW).

Now that the work clamp position has been set, the billet can be continually
withdrawn from the machine table, then replaced, always to the same position.
This is an advantage for jobs involving the repeat milling of pieces of work, such as a
small production run or a college class/group project.

Denford Compact 1000 - User manual Page 25

6: Using the Work Clamp
The work clamp, when used in combination with the datum plate, is
a quick and versatile method of securing most pieces of work to the
machine table.
In the example shown below, a polystyrene billet is taped onto a
sheet of MDF (medium density fibreboard), with its front and left-
hand edges aligned with the front and left-hand edges of the MDF
- this front, left upper corner will be configured as the workpiece
datum for the machine offsets. The MDF is used as a sub-table - a
safety measure to prevent damage occurring to the machine table
itself, should a problem occur when milling.

Tape Tip - x Plastic workpiece (billet).

Use plastic type double Strips of double sided tape.

sided tape, which can
be removed from your
billet without tearing.
If your billet material
comes supplied with a
protective film, affix the Sub-table
tape to this film, then (eg. sheet of MDF).
simply tear off the film (Towards fro
nt of machine
once machining has table).
been completed. Avoid The polystyrene/MDF block can then be added or removed from the
using tissue type double
sided tape, which is a machine table without having to reconfigure the machine offsets.
strip of tissue with a thin
coating of glue each
side - this type is very
Sub-table
difficult to remove from (eg. sheet of
your billet once it has MDF).
Work clamp.
been machined.

Datum
plate.

Polystyrene
billet.

continued...

Denford Compact 1000 - User manual Page 26

6: Fitting and Removing the Work Clamp
Removing the Work Clamp.
Using a 4mm allen (hex) key, loosen the two hex bolts clamping the work clamp
to the machine table. Do not completely remove the bolts at this stage, since this
will make removal of the individual tee nuts more difficult. Slide the entire work
clamp assembly to a free end of the machine table, release the tee nuts from their
respective channels and withdraw the work clamp assembly.
Fitting the Work Clamp.
Fit, align and clamp the datum plate. Loosely assemble the two hex bolts and tee
nuts through the two holes in the work clamp base plate. Move the work clamp
assembly to a free end of the machine table, then carefully align each tee nut with
the respective channels in the machine table and slide the clamp onto the table.
Before fully tightening the hex bolts, adjust the position of the clamp against your
chosen billet, as described on the next two pages.

Billet. Hex bolt.

Handle to open and

close work clamp.
Open clamp
(turn CCW).

Close clamp
(turn CW).
Work clamp
base plate.

To loosen bolts - turn

counter-clockwise
Hex bolt. (viewed from above).
T shaped To tighten bolts - turn
End view of machine table channel. clockwise (viewed
showing tee shaped channels. from above).

Denford Compact 1000 - User manual Page 27

6: Fitting and Removing the Datum Plate
Removing the Datum Plate.
Using a 4mm allen (hex) key, loosen the two hex bolts clamping the datum plate
to the machine table. Do not completely remove the bolts at this stage, since this
will make removal of the individual tee nuts more difficult. Slide the entire datum
plate assembly to a free end of the machine table, release the tee nuts from their
respective channels and withdraw the datum plate assembly.
Fitting the Datum Plate.
Loosely assemble the two hex bolts and tee nuts on the datum plate. Four holes
are provided on the plate for the tee nut assemblies - we recommend using the
two outermost holes, as shown in the photograph below. Move the datum plate
assembly to a free end of the machine table, then carefully align each tee nut
with the respective channels in the machine table. Slide the assembly to the
approximate position required. Using a 4mm allen (hex) key, tighten each of the
hex bolts, by turning each bolt in a clockwise direction until they just begin to grip
the datum plate to the table surface. It must still be possible to move the datum
plate, since final adjustments will be required to align the plate exactly “square” with
respect to the edges of the machine table - exactly parallel to the direction of the X
and Y machine axes. After adjusting the position of the datum plate, fully tighten the
two hex bolts.

Hex bolt.

Datum plate Machine

(L-shaped work table.
T shaped locating bracket).
channel.

To loosen bolts - turn

counter-clockwise
(viewed from above). Hex bolt.

To tighten bolts - turn End view of machine table

clockwise (viewed showing tee shaped channels.
from above).

Denford Compact 1000 - User manual Page 28

6: Planning Procedure for Maintenance Work
Warning - x When carrying out any maintenance, pay special attention to the
following items, ensuring safe and correct working procedures
in accordance with Health and Safety Regulations in your
Caution. establishment:
Wear safety glasses and • Before starting any maintenance work, define the task and obtain
a suitable respiratory
mask when cleaning the the information relevant to carry out the maintenance. Also,
machine. define the time period needed to complete the task, to obtain the
correct tools and order any spare parts, if required.
• During the maintenance work period, display a suitable notice
Warning - x
stating that the machine is under maintenance and should not be
used until the notice is removed.
Never open the safety • Safety must be a priority when carrying out any maintenance
guard door and enter
work. Covers and safety guards that are removed during the
the working area when
the spindle or machine maintenance work must be replaced after the task is completed.
axes are moving. • All work must be carried out by suitably qualified personnel.
• Never attempt to access the electronic hardware systems of the
Warning - x machine with the mains power switched ON.
• Hazardous voltages can still exist immediately after switching off
Caution. the power. If the machine has previously been switched on, wait
If the cutting tool has at least 5 minutes before attempting to open the electrical panel
been recently used, it access plate.
may still be HOT.
• When replacing electrical components, ensure the new parts are
of suitable replacement specification.
• All work completed on the machine, whether progressive, or
preventative, should be logged to ensure a complete service
record is available for future referral. We recommend the
following two pages are used to log any maintenance tasks
undertaken.
• When maintenance work has been completed, check that the
replaced or serviced parts work correctly, before allowing general
operation of the machine.

Denford Compact 1000 - User manual Page 29

7: Cleaning the Router Motor
Using a vacuum or a soft brush, clean and dust and debris away from the top and
bottom of the machine head plate.

Carefully remove any dust and debris from all air passages and vents using a
vacuum cleaner or soft brush. DO NOT use compressed air for this purpose.
Pay particular attention to any dust or debris that may have been drawn into
the motor. Remove any buildup of grime resulting from working with green or
sappy timber. This practice with extend the life of your motor and its brushes.
Maintenance procedures for the router motor are outlined on the next page.

7: Cleaning the Microswitches

The X,Y Z axis all have microswitches
Using a soft bristled brush, carefully clean dust and debris away from the
microswitch, to an area where it can be removed using a vacuum cleaner.

Z axis
microswitch.

Denford Compact 1000 - User manual Page 30

7: Maintenance of the Router Motor
Warning - x Failure to Start.
Should the motor fail to start, check that the prongs on the mains
Caution.
power cord plug are making good contact inside the machine back
panel socket. Check the on/off switch on the router motor is set
Wear safety glasses and
a suitable respiratory to the “on” position. Check for any blown fuses (referring to the
mask when cleaning the electrical diagrams delivered separately with your machine), replace
machine. them and rectify the cause.
Lubrication.
Warning - x The router motor has been lubricated with a sufficient amount of
high grade lubricant for the life of the unit under normal operating
Never open the safety conditions. No further lubrication is necessary.
guard door and enter
the working area when Brush Inspection.
the spindle or machine At approximately 100 hours of use, Denford recommends you
axes are moving.
take or send your motor to your nearest authorised router motor
service station or Denford agent to be thoroughly cleaned and
Warning - x inspected; worn parts replaced, where necessary; recharged with
fresh lubricant, if required; reassembled with new brushes; and
performance tested.
Caution.
Any loss of power before the above maintenance check may
If the cutting tool has
been recently used, it indicate the need for immediate servicing of your router motor. Do
may still be HOT. not continue to operate the motor under these conditions.

Denford Compact 1000 - User manual Page 31

7: Lubrication

Notes on use of Swansil Lubricant on Denford Routing Machines

1. Clean down machine with brush and vacuum - do not use compressed
air.
2. Position the Machine in mid-travel.
3. Open the guard.
4. Isolate machine from power supply.
5. Spray each lead screw and guide rail with a 2-3 second burst.
6. Leave 2-3 minutes for silicone to dry before operating the machine.

Item 1 to carried out daily or between components.

Items 2 – 6 to be carried out weekly.

Always adhere to general instructions and warnings on Swansil can.

For full Health and Safety information visit

http://www.swantek.com/html/msds/136.htm

Do not spray into confined areas.

Any excessive over spray to be dried off with a dry, clean, lint-free cloth before operating the
machine.

Denford Compact 1000 - User manual Page 32

8: Maintenance Log
Date of Name of personnel Details of
maintenance carrying out the maintenance work
work. maintenance. completed.

Denford Compact 1000 - User manual Page 33

8: Maintenance Log
Date of Name of personnel Details of
maintenance carrying out the maintenance work
work. maintenance. completed.

Denford Compact 1000 - User manual Page 34

9: Technical Support

Denford Limited provides unlimited telephone and e-mail Technical Support

on this CNC machine to registered users. On-site visits by our engineers may
be chargeable. Please refer to the information held in your separate Warranty
pack, for specific details.
Before contacting Denford for support, please read your hardware and software
manuals and check the Denford websites for support.
Internet (access technical support and FAQ sections):
Denford UK: http://www.denford.co.uk
Denford USA: http://www.denford.com
When you request support, please be at your CNC machine, with your hardware
and software documentation to hand. To minimise delay, please be prepared to
provide the following information:

• CNC Machine Serial Number (from the machine ID panel).

• Registered user's name / company name.
• The CNC machine control software name and version number (from the
“Help|About” menu option).
• The wording of any error messages that appear on your computer screen, if
applicable.
• A list of the steps that were taken to lead up to the problem.
• A list of any maintenance work that has been carried out on the CNC
machine.

Contact Details:
Denford Limited,
Birds Royd, Brighouse, West Yorkshire, HD6 1NB, UK.
Telephone: 01484 728000
Fax: 01484 728100
ISDN: 01484401157:01484401161
E-mail: [email protected]
Technical Support: Monday to Friday 8.30am - 4.30pm GMT
For international dialling: +44 and remove first 0 in each city code.

Denford Compact 1000 - User manual Page 35

9: Troubleshooting - Cutting Problems
The part is being cut at an incorrect depth :
Check the validity of the following:
1) The Z value entered in the tool length offset.
2) The Z value entered in the workpiece offset file.
3) The number (size) used for defining the depth of cut used in your CNC program.
4) The sign (+ or -) used for defining the depth of cut used in your CNC program. If your
workpiece datum is aligned with the upper surface of your billet, any Z values cutting into
this billet will have a minus sign.
The machine begins cutting the part at the wrong location :
Check the following:
1) The workpiece and tool offset files have been configured and applied successfully. If
no offsets have been configured, the CNC machine will use the machine datum as the
starting point for any machining co-ordinates read.
2) The X and Y values entered in the workpiece offset file are correct.
Poor surface finishes are obtained :
Check the following:
1) The correct feedrates and spindle speeds are being used, appropriate for the cutting tool
profile and type of material being machined. Recommended feed and speed values should
be available from your tool and material supplier. Note that running incorrect feeds and
speeds can severely shorten the life expectancy of your tools.
2) The billet being machined is securely clamped.
3) The correct tool profile, appropriate to the finish required, is being used. Check that the
cutting edges are sharp and undamaged.
4) Any machine drive belts are correctly tensioned and not slipping.
5) The tool profile is held securely in the tool holder or collet, which in turn is held securely
in the machine spindle.
When using double sided tape, the billet keeps lifting from the sub-table (sheet of
MDF) :
Check the surface of the sub-table is clean and smooth before attempting to add the billet.
Routinely clean tape adhesive residue from the sub-table. Check tape adequately covers
all parts of the billet. Check the sequence in which the various parts of your design are
machined. For example, machine any small or etched surfaces before cutting pieces
completely out from the billet. If you keep the largest solid area of the billet attached to
the sub-table for as long as possible, you reduce the likelihood of the billet moving during
machining.

Denford Compact 1000 - User manual Page 36

9: Troubleshooting - VR CNC Milling Software
1) Your computer communicates with your Router using the Denford
Machine Link cable. Check the Denford Machine Link cable
(RS232 or USB) is securely plugged into a valid COM/USB port
on the computer. Note that COM ports are sometimes labelled
as serial ports. Identify whether the COM port being used is
labelled as COM1 or COM2. The opposite end of this cable is
securely plugged into the RS232/USB port, located on the right
end panel of the machine cabinet.
2) Check all mains power connections are correctly fitted and
secure. Power up the Router, using the red on/off switch, If no
power is present, switch off the mains supply, then wait at least 5
minutes before attempting to access the Router electronics. The
Router electrical panel is mounted on the left side of the machine
cabinet. Check the condition of the on/off switch and any fuses.
For more information.
3) Start the VR CNC Milling software (from the default installation,
Note - x click “Start | Programs | Denford | VR Milling”). The name of CNC
machine that can be directly controlled by the VR CNC Milling
The password used to
access the "Machine
software is displayed on the main program titlebar. From the
Properties" window can main menubar at the top of the VR CNC Milling software screen,
be changed by the user. click “Setup | Setup Machine Parameters”. You may be required
Remember that the to enter a password. The default password is “denny”. Type
default password the password and click [OK]. The “Machine Properties” window
listed here will not be will open. You can configure the type (name) of CNC machine
recognised if you have
attached to your pc and any COM port settings from this window.
changed it.
If you change any 4) The “Machine Properties” window will open with the name of the
passwords, we current (active) machine highlighted and its listing expanded.
recommend you make The name of the active machine in the software must match the
a note of them in the name and version of your real CNC machine - this information is
Notes section in either
printed on the CE identification panel, usually applied to one of
this or your CNC Control
Software manual. the machine cabinet end panels. If the correct machine name
is NOT listed as the active machine, right click over the required
machine name title to display a pop-up menu. Click “Make
Active”, then click [OK] and restart the VR CNC Milling software.
Reopen the "Machine Properties" window to check that the
changes have been applied.

Denford Compact 1000 - User manual Page 37

9: Troubleshooting - VR CNC Milling Software
Note - x 5) Check the LED display status on the NextStep Motion Control
Board, referring to the descriptive list to determine the condition
Any optional equipment
of the board. A problem with this card can cause problems with
fitted to your Microrouter
Compact can be communications. The board is located in the top, left corner
configured using the of the electrical panel. Call Denford Customer Services for
options available in the assistance.
“Machine Properties” Warning - Risk of electric shock. Note that in order to check
window.
the readout, the CNC machine must be powered up with the
electrical panel exposed. Exercise extreme caution - do not
touch any live electrical components since damage may occur to
the hardware or technician inspecting the equipment. Remember
to shutdown the CNC machine, then replace the electrical panel
cover plate, on completion of this step.
6) Check the COM port on your computer is functioning correctly.
Consult your IT person or Computer Support Centre for help
with these issues. Check the COM port settings in Windows by
accessing the Device Manager. Check the com ports enabled
and labelled properly in the computer BIOS. Check the physical
COM port itself functional. For example, Windows and the BIOS
may show that the COM ports are fine, but the port is not seen by
any external devices.
7) When all else fails...
Thoroughly check the condition of the Denford Machine Link
cable. If the cable is bad, communication will not occur. Try
using a different computer to connect to the machine. Check for
help on the technical support, FAQ and download sections of the
Denford websites and/or contact Denford Customer Services for
further assistance.

Denford Compact 1000 - User manual Page 38

9: Troubleshooting - Mechanical Problems
The safety guard door cannot be opened :
In most cases, this is because the interlock guard switch has locked the door in the closed
position. The interlock guard switch is mounted behind the front, lower machine panel,
accessible from beneath the front of the machine.
Check the following:
1) Mains power is reaching the CNC machine. Check the mains plug is fitted to an available
power socket and the socket is switched on. Check the Router on/off keyswitch,
mounted on the right end panel of the machine cabinet, has been turned to the on “I”
position.
2) The emergency stop button is not pressed in. To release, push and turn the button
clockwise until it springs back out to its ready position.
3) No CNC program is running. Wait for all machining operations to finish, then switch the
software to operate in jog mode.

Denford Compact 1000 - User manual Page 39

10: Specification of the Compact 1000
Safety Features:
• Manual operation, totally enclosed, interlocked, safety guard door.
• Emergency stop button.
• Toolpath graphics to verify part programs prior to machining.

Mechanical Details:
• Travel X axis 400mm (15.7”).
• Travel Y axis 240mm (9.05”).
• Travel Z axis 110mm (4.3”).

Dimensions:
• Machine Length 845mm (33”).
• Machine height 675mm (26.5”).
• Machine depth - door closed 750mm (29.5”).

Weights:
• Machine weight 90 KG (198 lb).

Electrical Details:
• Mains supply required:
220/240Volts, 50Hz, 8 Amps.
• Spindle motor: 1.3 kW
• Spindle Speeds: 0 - 23,000RPM.
• Axis stepper motors

Performance:
• Rapid traverse rate up to 5000 mm/min (197 in./min)
• Max Feed traverse rate up to 5000 mm/min (197 in./min)

Denford Compact 1000 - User manual Page 40

10 : EC Declaration of Conformity
The responsible person........................Mr P T Harkness

Business Name ....................................Denford Limited.

Address ................................................Birds Royd,

Brighouse,
West Yorkshire,
HD6 1NB,
United Kingdom.

Declares that the machinery described:

Manufacturer ........................................Denford Limited.

Model Name .........................................Compact 1000 Series CNC Machine.

Serial Number.......................................(please refer to warranty card and/or machine

casing).

conforms to the following directives:.....The Machinery directive 98/37/EC

The LVD Directive 73/23/EEC
The EMC directive 89/336/EEC

and the following standards............................................................................................

(where applicable) ..........................................................................................................

and complies with the relevant .......................................................................................

health and safety requirements. .....................................................................................

Signature ..............................................

Position within company.......................Senior Design Engineer.

Signed at ..............................................Denford Limited,

Birds Royd,
Brighouse,
West Yorkshire,
Document: DC-RC 1-01. HD6 1NB,

Denford Compact 1000 - User manual Page 41

10 : Compact 1000 Series Noise Level Test Results
Test Report No.: NL-FR1-01

Machinery Manufacturer: Denford Limited

Machinery Type/ Model: Compact 1000 Router

The Compact 1000 can be supplied with a dust extraction system.
The test was carried out with and without this option, using a
‘Yorkleen Woodvac” WY1 for this purpose.

Equipment
Meter ref; ‘Realistic’ 42-3019
Compact 1000 Router
Yorkleen Woodvac WY1
C

B D
EX

FRONT
A
A, B, C & D are measurement positions 1 metre from the machine
Ex: Vacuum for dust extraction.
Test Conditions:

Spindle speed 23,000rpm.

Axis speed 900mm/min.
Ambient background noise <60 dB(A)

Test Results
Condition A B C D
Spindle + Drives + Extractor 78 76 78 76
Spindle + Drives + NO Extractor 76 75 77 75
Extractor Only 68 70 73 76

Denford Compact 1000 - User manual Page 42

11: Glossary
BILLET ................................. A small, usually rectangular, bar of wood or metal in an intermediate stage of
manufacture.
CAD ......................................Computer Aided Design - the use of a wide range of computer based tools that assist
engineesrs, architects and other design professionals in their design of “real world”
objects.
CAM......................................Computer Aided Manufacture - software that is capable of creating tool cutter paths in
a number of different axes for different CNC systems. Usually taking the design input
from CAD system.
CNC.......................................Computer Numerical Control - a computerised system of hardware and software,
which controls the movement of a machine tool.
DRIVE ................................. The controller unit for a disk system.
DRY RUN ........................... An operation used to test how a CNC program will function without driving the
machine itself.
DWELL ............................... A programmed time delay.
EDIT ................................... The mode used for altering the content of a CNC program via the Desktop Tutor or
qwerty keyboard.
END OF BLOCK SIGNAL ... The symbol or indicator ( ; )that defines the end of a block of data. The equivalent of
the pc [return] key.
ERROR................................. The deviation of an attained value from a desired value.
G-CODE ............................. The programming language understood by the machine controller.
FEEDRATE ......................... The rate, in mm/min or in/min at which the cutting tool is advanced into the workpiece.
For milling and drilling, the feedrate applies to the reference point on the end of the
axis of the tool.
FILE .................................... An arrangement of instructions or information, usually referring to work or control
settings.
FORMAT ............................. The pattern or way that data is organised.
FNC .................................... FANUC Miller file, extension ".fnc". Contains G and M codes describing the machine
and cutting operations.
G CODE ............................. A preparatory code function in a CNC program that determines the control mode.
HARDWARE ....................... Equipment such as the machine tool, the controller, or the computer.
HOME ................................. Operation to send the axes of the CNC machine to their extreme limits of movement.
Defines the co-ordinate based grid system of the CNC machine. Commonly referred
to as homing the machine, or sending the machine to its home position.
INCREMENTAL .................. Incremental programming uses co-ordinate movements that are related from the
previous programmed position. Signs are used to indicate the direction of movement.
INPUT ................................. The transfer of external information (data) into a control system.
INTERFACE ....................... The medium through which the control/computer directs the machine tool.

Denford Compact 1000 - User manual Page 43

11: Glossary
JOG CONTROL.................... Manual movement mode for the machine axes, using very small pre-defined
movements, called jog steps. One stepped movement is applied per movementusing
the machine offset facility. key/button press.
M CODE ............................. A miscellaneous code function in a CNC program used to indicate an auxiliary
function (ie, coolant on, tool change etc.).
MACHINE DATUM ............. A fixed zero reference point set by the machine manufacturer. The machine datum is
used to define the co-ordinate based grid system of the CNC machine. All machining
co-ordinates originate from this point. However, this point can be temporarily moved
MACHINE OFFSET.............. The workpiece offset file used with VR and real CNC machines.
MDI ..................................... Manual Data Input - A method used for manually inserting data into the control system
(ie, Desktop Tutor, qwerty keyboard etc.).
MODAL ............................... Modal codes entered into the controller by a CNC program are retained until changed
by a code from the same modal group or cancelled.
NC ...................................... Numerical control.
OFFSET ............................. Combination of two types of file, the workpiece offset and the tool offset. Used to
describe the workpiece datum, a zero reference used on the CNC machine to ensure
machining occurs in the correct place on the billet. Offsets are used to shift parts of
the three dimensional co-ordinate based grid system, used by the CNC machine.
PART DATUM ..................... Used as a zero reference point in a CNC file. All machining co-ordinates originate
from this point.
PART PROGRAM................. A list of coded instructions which describes how the designed part, or component, will
be manufactured. The part program is also referred to as the CNC file, program, or G
and M code program.
PC ....................................... Personal computer.
POST PROCESSOR............ A file or setting that contains instructions for a CAM system, detailing how to create
CNC code that can be understood by a particular CNC system (e.g. VR CNC Milling).
PROGRAM ......................... A systematic arrangements of instructions or information to suit a piece of equipment.
RAPID TRAVERSE .............. Fast movement of the cutting tool through the 3 machine axes between cutting
settings.
REFERENCE POINTS......... The machine has 3 reference points used in setting the limits of movement for its
slides (axes).
REMOVEABLE MEDIA.........A computerised storage medium that is not permanently attached to the system, e.g.
Floppy Disk, Flash Memory Card, USB Memory Key, CD/DVD disc.
ROUTER MOTOR ................ The removable cutting head (motor). Also referred to as the machine head.
RPM...................................... Revolutions per minute (rev/min) - a measure of spindle speed.
SLIDES................................. The 3 machine axes - see axis.
SPINDLE SPEED ............... The rate of rotation (velocity) of the machine head / cutting tool, measured in RPM.
SOFTWARE ....................... Programs, tool lists, sequence of instructions etc...

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11: Glossary
TOOL OFFSET ................... When machining, allowances must be made for the size of tools being used, since
they all differ in length. The tool offset is the amount the Z value must be moved (or
offset), so that all the different cutting tool tips used line up with each other, so they
can all be used by one CNC file. See OFFSET.
TRAVERSE ........................ Movement of the cutting tool through the 3 machine axes between cutting settings.
TXT ..................................... Standard Windows text only file, extension ".txt".
WORK (WORKPIECE) ....... The actual material being machined. The work is sometimes referred to as the billet
or stock.
WORKPIECE DATUM ........ Used as a zero reference point on the real billet. All machining co-ordinates originate
from this point, when offset files are used.
WORKPIECE OFFSET ........ A file containing X, Y and Z values that can shift the entire three dimensional co-
ordinate based grid system, used by the CNC machine. See OFFSET.
WORD ................................ A combination of a letter address and digits, used in a CNC program (ie, G42, M04
etc.).
VIRTUAL REALITY............... A fully interactive, three dimensional, computer based simulation of a real world object
or event.
Z TOOL OFFSET ................ See Tool Offset

Denford Compact 1000 - User manual Page 45

12: Notes
Use this page to make a note of any parts of the software you have changed or configured,
for example, common tooling set-ups, machine parameters, changes to installation paths or
passwords etc.

Denford Compact 1000 - User manual Page 46

Contact Details (UK):
Denford Limited,
Birds Royd, Brighouse,
West Yorkshire, HD6 1NB,
UK.

For General Enquiries (UK):

Telephone: 01484 728000
Fax: 01484 728100
E-mail: [email protected]

For Sales Enquiries (UK):

Telephone: 01484 728000
Fax: 01484 728100
E-mail: [email protected]

For Customer Services and Technical Support (UK):

Telephone: 01484 728000
Fax: 01484 728100
ISDN: 01484401157:01484401161
E-mail: [email protected]
Technical Support: Monday to Friday 8.30am - 4.30pm GMT
For international dialling from outside the UK: Add “44” to the
number and remove the first “0” from each city code.

Contact Details (USA):

Denford Inc.
815 West Liberty Street,
Medina, Ohio 44256,
USA.

For Customer Services and Technical Support (USA):

Telephone: 330 7253497
Fax: 330 7253297
E-mail: [email protected]
Technical Support: Monday to Friday 8.30am - 4.30pm Eastern

Disclaimer:
Please note that due to nature of hardware and software developments, the
specifications and features of this product can change without notice. The
information contained in this guide is correct at the date of printing only - March,
2006. If in doubt, please refer to your order and delivery invoices. No liability can
be accepted by Denford Limited for loss, damage or injury caused by any errors
in, or omissions from, the information supplied in this manual. Denford Limited
reserves the right to alter any specifications and documentation without prior notice.
No part of this manual or its accompanying documents may be reproduced or
transmitted in any form or by any means, electronic or mechanical, for any purpose,
without the express written permission of Denford Limited. All brands and products
are trademarks or registered trademarks of their respective companies. Copyright
Denford Limited - Version 1.04.03. All rights reserved.

Language:
This manual is written using European English.

Questions and Comments:

Any questions and comments regarding this guide should be referred to the
following e-mail address: [email protected]
Alternatively, telephone Denford Customer Services on 01484 728000 and ask to
speak to a member of our Technical Authoring Team.

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