CNC-Step Zero-3 User manual

Status: 14.03.2015
Operating Instructions
Zero-3 / 5-Channel Motor Controller
Article: 102100
Motor Power X/Y/Z: 3,5A
www.cnc-router.com

Operating Instructions
Zero-3 / 5-Channel Motor Controller
CNC-STEP e.K. ▪Siemensstrasse 13-15 ▪ 47608 Geldern ▪ Germany
Page 2
Support: +49 (0)2831/91021-50
12.10.2012
Zero-3 / 5-Channel Motor Controller
Brief description
The “Zero3“ controller contains all the electronic equipment required for operating the router with
up to four axes and up to five stepper motors. A PC with appropriate CNC controller software is
needed for commissioning. This User‘s Manual describes the installation, commissioning and
maintenance of the controller.

Operating Instructions
Zero-3 / 5-Channel Motor Controller
CNC-STEP e.K. ▪Siemensstrasse 13-15 ▪ 47608 Geldern ▪ Germany
Page 3
Support: +49 (0)2831/91021-50
12.10.2012
Contents
1GENERAL INFORMATION...........................................................................................5
1.1 Description of symbols.............................................................................................................5
2OVERVIEW OF FEATURES.........................................................................................6
3SAFETY MEASURES...................................................................................................7
3.1 Organizational safety measures..............................................................................................7
3.2 Personnel selection and qualification, general duties ...........................................................8
3.3 Safety warnings ........................................................................................................................8
3.4 Safety instructions for specific phases of operation..............................................................9
3.4.1 In normal operation .............................................................................................................9
3.4.2 During setup, maintenance, repair or disposal ..................................................................10
3.5 Precautions for special types of danger................................................................................11
3.5.1 Electrical power.................................................................................................................11
3.5.2 Hydraulic and pneumatic systems, steam..........................................................................12
3.5.3 Gas, dust, sparking.............................................................................................................12
3.5.4 Oil, grease, gases and other chemical substances..............................................................12
3.6 Safety devices..........................................................................................................................13
3.7 Possible risks to people ..........................................................................................................13
3.8 Duties of the system operator................................................................................................13
4COMMISSIONING.......................................................................................................14
4.1 Installation ..............................................................................................................................14
4.2 Power supply line ...................................................................................................................14
4.3 Connecting the machine.........................................................................................................14
4.3.1 Motor connectors (X1, X2, Y, Z)......................................................................................15
4.3.2 Control signals (ST)...........................................................................................................15
4.3.3 Rotating axis/tangential cutter (C).....................................................................................16
4.3.4 Status LEDs.......................................................................................................................17
4.3.5 LPT ports...........................................................................................................................18
4.3.6 External loads (power outlets)...........................................................................................19
4.3.7 Ground (GND)...................................................................................................................20
4.4 Commissioning .......................................................................................................................20
5CLEANING AND SERVICING ....................................................................................21

Operating Instructions
Zero-3 / 5-Channel Motor Controller
CNC-STEP e.K. ▪Siemensstrasse 13-15 ▪ 47608 Geldern ▪ Germany
Page 4
Support: +49 (0)2831/91021-50
12.10.2012
5.1 Work in the interior of the housing......................................................................................22
5.1.1 Opening the housing..........................................................................................................23
5.1.2 Changing fuses ..................................................................................................................23
5.1.3 DIP switch settings............................................................................................................24
5.1.4 Closing the housing ...........................................................................................................24
6TECHNICAL SPECIFICATIONS.................................................................................25
6.1 Absolute maximum ratings ...................................................................................................25
6.2 Electrical connection values ..................................................................................................25
6.3 Housing dimensions................................................................................................................26
7CUSTOMER SERVICE ...............................................................................................27

Operating Instructions
Zero-3 / 5-Channel Motor Controller
CNC-STEP e.K. ▪Siemensstrasse 13-15 ▪ 47608 Geldern ▪ Germany
Page 5
Support: +49 (0)2831/91021-50
12.10.2012
1General information
This stepper motor controller was designed according to all recognized guidelines in force at the
time of its development and subject to extensive and careful testing. Despite this, no guarantee of
trouble-free operation can be given. The developers guarantee that the Zero3 controller, when used
in connection with appropriate mechanical components, is generally appropriate for use for the
intended purpose in accordance with the description and User Manual.
No responsibility is accepted for consequential damages or damages resulting from lost profits,
interruption of operations, loss of information, etc. The Zero3 stepper motor controller is a
component that only runs when connected to an appropriate personal computer and appropriate
software. Under no circumstances is it an independent controller.
Because, despite every effort, malfunction can never be entirely avoided, we are grateful for all
feedback.
1.1 Description of symbols
NOTE: Special information on efficient operation of the machine
CAUTION: Special information on required or prohibited actions for avoiding
damage.
Information or requirements and prohibitions for preventing harm to persons or
extensive damage to property
Use by persons with a cardiac pacemaker prohibited
This symbol appears before sections describing activities which are
prohibited for persons with a pacemaker.
High voltage warning symbol
This sign warns of activities involving live components of the system.
Hot surface warning symbol
This symbol appears before sections describing activities where hot objects
are handled.

Operating Instructions
Zero-3 / 5-Channel Motor Controller
CNC-STEP e.K. ▪Siemensstrasse 13-15 ▪ 47608 Geldern ▪ Germany
Page 6
Support: +49 (0)2831/91021-50
12.10.2012
2Overview of features
Up to 4 axes or 5 stepper motors can be controlled. For one of the axes two motors can be used in
parallel (X1, X2).
The phase current for the motors of the X, Y and Z axes can be jointly set at 2.8 or 3.5A, as desired.
The phase current of the C axis can be set separately in four steps between 1.4 and 3.5A. When it is
not operating the motor current is automatically reduced to 66%.
For each axis the step resolution can be separately set at 1/5 or 1/10 of a full step. This corresponds
to 1,000 or 2,000 microsteps per revolution in the case of standard stepper motors (1.8° per full
step).
The 15-pin D-sub connection socket of the C axis has a 24V PWM output and a 12V power supply
for controlling the tangential cutting modules. (e.g. TCM-3 or ETO-2) with or without an oscillating
cutter. If an oscillating cutter is not used, the 24V output can alternatively be used for a brake.
The four reference or limit switches and an E-STOP button can be connected via a 9-pin D-sub
connector. A 0..10V analog signal for controlling the motor speed with an (external) frequency
inverter is available via a 25-pin D-sub port on the rear panel.
The power supply for external consumers can be switched on and off by the software at two power
outlets on the rear panel by means of two relays. They can each carry a load of 8A and have
separate fuses.
The current operating state of the controller can be read at any time using 12 LEDs on the front
panel.

Operating Instructions
Zero-3 / 5-Channel Motor Controller
CNC-STEP e.K. ▪Siemensstrasse 13-15 ▪ 47608 Geldern ▪ Germany
Page 7
Support: +49 (0)2831/91021-50
12.10.2012
3Safety measures
3.1 Organizational safety measures
The operating instructions must always be kept in an accessible position at the place where
the machine is being operated (in the toolbox or in a container specified for it)!
In addition to the user manual, the local general statutory or other binding regulations
governing accident prevention and environmental protection are to be observed. Pass
appropriate instructions on to operating personnel.
Instructions, including supervision and reporting responsibilities, which take account of
conditions specific to the factory, e.g. work organization, work procedures, and personnel,
must be added to the user manual.
If necessary or required by regulations, use personal protective equipment. Provide these for
operating personnel too!
At regular intervals check the safety and risk awareness of personnel and their compliance
with the operating manual!
Personnel must not wear long hair untied, loose clothing, or jewelry including rings. There
is a risk of injury, such as becoming caught in the machine.
Observe all safety and warning signs on the system at all times.
All safety and danger warning signs on the system must always be kept in a complete and
clearly legible condition.
Maintain cleanliness and good order in the area of the system!
If system operating behavior changes, switch it off immediately and report the fault to the
department or person responsible for it!
Do not make any changes, attachments or conversions to the system without permission.
Replacement parts must be in compliance with the manufacturer’s technical requirements.
Using genuine spare parts always ensures this.
Observe the schedule laid down or specified in the operating instructions for routine checks
and inspections!
Appropriate workshop equipment is essential for carrying out maintenance measures.
NOTE: The manufacturer’s documentation provided by suppliers must be
observed.
NOTE: Follow the special safety instructions in the individual chapters of this
user manual.

Operating Instructions
Zero-3 / 5-Channel Motor Controller
CNC-STEP e.K. ▪Siemensstrasse 13-15 ▪ 47608 Geldern ▪ Germany
Page 8
Support: +49 (0)2831/91021-50
12.10.2012
3.2 Personnel selection and qualification, general duties
Specify who is in charge of the system and authorize this person to refuse instructions from
third parties which are not in compliance with safety regulations.
Assign only trained or instructed personnel to the machine. Specify clearly the responsibility
of personnel for operation, setup, maintenance and repairs!
Work on/with the system may only be carried out by reliable personnel. (Observe the
statutory minimum age.)
Ensure that the system is only operated by personnel who are authorized to do so.
Allow personnel undergoing training, instruction or familiarization with the system or those
involved in general training to use the system only while under the uninterrupted
supervision of someone experienced with the machine.
All work on electrical system may only be carried out by personnel trained and qualified for
this.
3.3 Safety warnings
The Zero3 step motor controller is sometimes exposed to high thermal loads. All conversions and
alterations to the controller are carried out at the user’s risk and invalidate any warranty or warranty
claims.
The controller is equipped with forced air cooling. Under normal operating conditions the
components which become hot reach temperatures of more than 70°C. Make sure there is an
adequate air supply. In particular, the ventilation openings must not be closed, covered or clogged.
In addition, all valid VDE regulations and CE standards must be observed. Especially when the
power supply is being connected extreme caution is called for. Use separate and shielded cables
when connecting motors and limit switches/reference switches. For motor cables we suggest wire
gauge of at least 0.5 mm² (AWG 20).

Operating Instructions
Zero-3 / 5-Channel Motor Controller
CNC-STEP e.K. ▪Siemensstrasse 13-15 ▪ 47608 Geldern ▪ Germany
Page 9
Support: +49 (0)2831/91021-50
12.10.2012
3.4 Safety instructions for specific phases of operation
3.4.1 In normal operation
Before switching the machine on, ensure that only authorized persons are in the working
area of the system!
Refrain from operating the machine in a manner that would impair safety!
Initiate all measures to ensure that the machine is only operated in a safe and fully
functioning condition.
Do not operate the machine unless all guards and safety-related devices (e.g. detachable
safety devices, E-Stop equipment, exhaust devices) are in place and operational.
Check the system for any externally visible damage and defects at least once per shift!
Report any changes that have occurred to the responsible department or person! If required,
switch the system off immediately!
In case of a malfunction, switch the system off immediately! Have faults repaired
immediately!
Observe start-up/shut-down processes and control indicators as specified in the user manual.
NOTE: Follow the special safety instructions in the individual chapters of this user
manual.

Operating Instructions
Zero-3 / 5-Channel Motor Controller
CNC-STEP e.K. ▪Siemensstrasse 13-15 ▪ 47608 Geldern ▪ Germany
Page 10
Support: +49 (0)2831/91021-50
12.10.2012
3.4.2 During setup, maintenance, repair or disposal
Carry out the adjustment, maintenance and inspection activities specified in the operating
instructions at the specified intervals! These activities may only be carried out by qualified
personnel.
Inform operating personnel before starting special work and maintenance! Nominate a
supervisor!
When carrying out work, observe the start-up/shut-down processes as specified in the user
manual and the instructions for repair work!
Cordon off a wide area around the maintenance zone where necessary!
If the system has been completely shut down for service and repair work, it must be secured
against unexpected restarting. This can be done by locking the main switch or placing
warning sign on the main switch.
During installation work above body height use only climbing aids intended for this
purpose. Do not use parts of the system to assist in climbing! When carrying out
maintenance work at greater heights make use of fall arrest equipment!
Keep all handles, steps, railings, podiums, platforms and ladders free of dirt!
Ensure that any screw connections loosened during service and maintenance work are
always firmly retightened.
If it is necessary to remove safety devices when setting up, servicing and repairing the
machine, they must be reassembled immediately upon completion of the service and repair
work and their correct function checked.
Ensure that auxiliary and operating materials are disposed of in a safe and environmentally
friendly manner.
NOTE: Follow the special safety instructions in the individual chapters of this user
manual.