CNC-Step Zero-4 Bedienungsanleitung
Operating Instructions
Zero-4 / 5-Channel Stepper Controller
CNC-STEP GmbH & Co. KG ▪ Siemensstrasse 13-15 ▪ 47608 Geldern ▪ Germany
Page 2
Support: +49 (0)2831/91021-50
6/16/2021
Zero-4 / 5-Channel Stepper Controller
Brief description
The "Zero-4" control is a further development of the well-known "Zero-3" control.
It contains the complete electronics required to operate a milling machine with up to 4 axes and up
to 5 stepper motors. The hardware interface "CncPod" and the control software KinetiC-NC are
already included.
The connection to the PC takes place directly via the network interface (LAN). This manual
describes the installation, commissioning, and maintenance of the controller.
Operating Instructions
Zero-4 / 5-Channel Stepper Controller
CNC-STEP GmbH & Co. KG ▪ Siemensstrasse 13-15 ▪ 47608 Geldern ▪ Germany
Page 3
Support: +49 (0)2831/91021-50
6/16/2021
List of contents
1GENERAL.....................................................................................................................5
1.1 Symbol description...................................................................................................................5
2FEATURES...................................................................................................................6
3SECURITY MEASURES...............................................................................................7
3.1 Organizational measures for security ....................................................................................7
3.2 Personnel selection and qualification, basic obligations.......................................................8
3.3 Safety.........................................................................................................................................8
3.4 Safety instructions for specific operating phases ..................................................................9
3.4.1 in normal operation..............................................................................................................9
3.4.2 for set-up, maintenance, repair, disposal...........................................................................10
3.5 Indications of special dangers ...............................................................................................11
3.5.1 electrical energy.................................................................................................................11
3.5.2 Gas, dust, sparking.............................................................................................................11
3.5.3 Hydraulics, pneumatics, steam..........................................................................................12
3.5.4 Oils, fats, gases, and other chemical substances................................................................12
3.6 Safety.......................................................................................................................................12
3.7 Possible hazards to people.....................................................................................................13
3.8 Obligations of the plant operator..........................................................................................13
4COMMISSIONING.......................................................................................................14
4.1 list.............................................................................................................................................14
4.2 mains connection....................................................................................................................14
4.3 Connection of the machine (front)........................................................................................14
.........................................................................................................................................................15
4.3.1 Motor connector (X1, X2, Y, Z)........................................................................................15
4.3.2 Control signals (ST)...........................................................................................................16
4.3.3 Axis of rotation / tangential knife (C) ...............................................................................17
4.3.4 Status LEDs.......................................................................................................................18
4.4 Connections back (PC and accessories) ...............................................................................19
4.4.1 External consumers (sockets)............................................................................................19
4.4.2 External emergency stop ...................................................................................................19
4.4.3 Grounding connection .......................................................................................................20
4.4.4 Other connections..............................................................................................................20
Operating Instructions
Zero-4 / 5-Channel Stepper Controller
CNC-STEP GmbH & Co. KG ▪ Siemensstrasse 13-15 ▪ 47608 Geldern ▪ Germany
Page 4
Support: +49 (0)2831/91021-50
6/16/2021
4.4.4.1 Sensor inputs XLR 1-5................................................................................................20
4.4.4.2 PC connection (LAN) .................................................................................................21
4.4.4.3 Connection frequency converter (FU) for RF spindles...............................................21
4.4.4.4 In / Out........................................................................................................................22
4.5 commissioning.........................................................................................................................23
5CLEANING AND MAINTENANCE..............................................................................24
5.1 Working inside the housing...................................................................................................25
5.1.1 Open the chassis ................................................................................................................26
5.1.2 Replacement of fuses.........................................................................................................26
5.1.3 Setting the DIP switches....................................................................................................27
5.1.4 Closing the chassis.............................................................................................................27
6TECHNICAL DATA.....................................................................................................28
6.1 Absolute limits........................................................................................................................28
6.2 Electrical connection values ..................................................................................................28
6.3 Housing dimensions................................................................................................................29
7CUSTOMER SERVICE ...............................................................................................30
Operating Instructions
Zero-4 / 5-Channel Stepper Controller
CNC-STEP GmbH & Co. KG ▪ Siemensstrasse 13-15 ▪ 47608 Geldern ▪ Germany
Page 5
Support: +49 (0)2831/91021-50
6/16/2021
1General
The present stepper motor control was designed based on all common and known guidelines at the
time of development and tested very elaborately and carefully. Nevertheless, a guarantee for error-
free function cannot be given. The developers guarantee that the Control Zero-4 in conjunction with
suitable mechanical components in the sense of the description and user manual is basically suitable
for the intended purpose.
Any liability for consequential damages or damages resulting from loss of profit, business
interruption, loss of information, etc. is excluded. The stepper motor control Zero-4 is a component
that can only run in conjunction with a suitable personal computer and software. It is by no means
an independent control.
Since mistakes, despite all efforts, can never be completely avoided, we are grateful for every hint.
1.1 Symbol description
NOTE: Information concerning the economic use of the installation
ATTENTION: Special information or rules and prohibitions for damage prevention.
Information or rules and prohibitions for the prevention of personal injury or extensive
property damage.
Ban on people with pacemakers
This sign faces activities in areas that are prohibited for people with pacemakers.
Warning of dangerous electrical voltage
This sign presalts activities on voltage-carrying system components.
Warning of hot surface
This sign presalens activities in dealing with hot objects.
Operating Instructions
Zero-4 / 5-Channel Stepper Controller
CNC-STEP GmbH & Co. KG ▪ Siemensstrasse 13-15 ▪ 47608 Geldern ▪ Germany
Page 6
Support: +49 (0)2831/91021-50
6/16/2021
2Features
Up to 4 axes or up to 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 set together to either 2.8 or 3.5A.
The phase current of the C-axis can be set separately in 4 steps between 1.4 and 3.5A. At a
standstill, the motor current is automatically lowered to 66%.
The step resolution can be selected for each axis separately between 1/5 and 1/10 micro step. This
corresponds to 1000 or 2000 steps per revolution for standard stepper motors (1.8° full step).
The 15-pin Sub-D connector of the C-axis has a 24V PWM output and a 12V power supply for
controlling tangential cutting modules. (z.B.TCM-4 or ETO-3) with or without oscillating knives.
If no oscillating knife is used, alternative a holding brake can be connected to the ST plug. By
switching the corresponding DIP switch, the 24V output on the ST connector is activated.
Both together is not possible!
Via a 9-pin Sub-D socket, the 4 reference or limit switches, as well as an emergency stop switch can
be connected. On a 25-pin Sub-D socket at the back, a 0...10V analog signal is available for speed
control with an (external) frequency converter.
Via two relays, the mains voltage for external consumers can be switched on and off by the software
at two sockets on the back. The sockets can each be loaded with 8A and are secured separately.
Via 12 LEDs on the front panel, the current operating status of the controller can be recognized at
any time.
Operating Instructions
Zero-4 / 5-Channel Stepper Controller
CNC-STEP GmbH & Co. KG ▪ Siemensstrasse 13-15 ▪ 47608 Geldern ▪ Germany
Page 7
Support: +49 (0)2831/91021-50
6/16/2021
3Security measures
3.1 Organizational measures for security
•Keep the operating instructions constantly at hand at the place of use of the system (in the
tool compartment or the container provided for this purpose)!
•Observe the generally valid legal and other binding regulations for accident prevention and
environmental protection in addition to the operating instructions! Provide appropriate
instructions to the operator.
•Supplement the operating instructions with instructions including supervisory and reporting
obligations to consider operational peculiarities, e.g., regarding work organization, work
processes, personnel employed.
•Use personal protective equipment as required or required by regulations. Make them
available to the operating staff!
•Regularly check the safety- and hazard-conscious work of the staff in compliance with the
operating instructions!
•Staff are not allowed to wear open long hair, loose clothing, or jewelry, including rings.
There is a risk of injury for example by getting stuck.
•Always observe all safety and hazard instructions on the system!
•Always keep all safety and hazard information on the system in complete readable
condition!
•Ensure cleanliness and order at the plant!
•Shut down the system immediately in the event of changes in its operating behavior and
report the fault to the competent body or person!
•Do not make any changes, additions, and conversions to the plant, without permission!
•Spare parts must comply with the technical requirements laid down by the manufacturer.
This is always guaranteed with original spare parts.
•Comply with prescribed deadlines or deadlines specified in the operating instructions for
recurring inspections and maintenance!
•To carry out maintenance measures, workshop equipment appropriate to the task is
necessary.
Operating Instructions
Zero-4 / 5-Channel Stepper Controller
CNC-STEP GmbH & Co. KG ▪ Siemensstrasse 13-15 ▪ 47608 Geldern ▪ Germany
Page 8
Support: +49 (0)2831/91021-50
6/16/2021
NOTE: Please pay attention to the manufacturer documentation of the supplier
companies.
NOTE: Please note the special safety instructions in the individual chapters!
3.2 Personnel selection and qualification, basic obligations
•Define the plant operator responsibility also regarding traffic regulations and enable him to
refuse safety-violating instructions from third parties!
•Use only trained or instructed personnel. Clearly define the responsibilities of the staff for
operation, set-up, maintenance, and repair!
•Work on / with the plant may only be carried out by reliable personnel. (Observe the legally
permissible minimum age!)
•Make sure that only personnel commissioned for this purpose will work at the plant!
•Allow personnel to be trained, to be trained, to be instructed or in the context of a general
training only under the constant supervision of an experienced person at the plant!
•All work on the electrical system may only be carried out by the trained and qualified
personnel for this purpose.
3.3 Safety
The stepper motor control Zero-4 is partially exposed to high thermal loads. Any modifications and
changes to the control system are made at the risk of the operator and lead to the loss of any
warranty and warranty claims.
The controller is provided with a forced ventilation. The heat-developing components reach
temperatures of over 70°C in the normal operating state. Pay attention to adequate air supply. In
particular, the ventilation openings must not be closed, covered, or penetrated.
Furthermore, all applicable electrical regulations and CE standards must be complied with.
Especially when connecting the supply voltage, extreme caution is appropriate. For the connection
of motors and end/reference switches, use separate and shielded cables. For motor cables, we
recommend a cable cross-section of at least 0.5 mm².
Operating Instructions
Zero-4 / 5-Channel Stepper Controller
CNC-STEP GmbH & Co. KG ▪ Siemensstrasse 13-15 ▪ 47608 Geldern ▪ Germany
Page 9
Support: +49 (0)2831/91021-50
6/16/2021
3.4 Safety instructions for specific operating phases
3.4.1 in normal operation
•Before switching on the system, make sure that only authorized persons are in the work area
of the system!
•Refrain from any safety-related way of working!
•Take all measures to ensure that the system is only operated in safe and functional
condition!
•Operate the system only if all protective devices and safety-related devices, e.g., detachable
protective devices, emergency stop devices, extraction devices, are available and functional!
•Check the system at least once per shift for externally recognizable damage and defects!
Report any changes that have occurred immediately to the competent authority or person! If
necessary, shut down the system immediately!
•Shut down the system immediately in case of malfunctions! Have faults eliminated
immediately!
•Observe the control indicators during the switching on and off processes according to the
operating instructions!
NOTE: Please note the special safety instructions in the individual chapters!
Operating Instructions
Zero-4 / 5-Channel Stepper Controller
CNC-STEP GmbH & Co. KG ▪ Siemensstrasse 13-15 ▪ 47608 Geldern ▪ Germany
Page 10
Support: +49 (0)2831/91021-50
6/16/2021
3.4.2 for set-up, maintenance, repair, disposal
•Comply with the setting, maintenance and inspection activities and dates prescribed in the
operating instructions! These activities may only be carried out by qualified personnel.
•Inform the operating staff before the start of the execution of special and maintenance work!
Appoint a supervisor!
•For all work, observe the switching on and off processes in accordance with the operating
instructions and the instructions for maintenance work!
•Secure the maintenance area, if necessary, over a wide area!
•If the system is completely switched off during maintenance and repair work, it must be
secured against unexpected reactivating. For example, by locking the main switch or
attaching a
•Warning sign on the main switch.
•For assembly work above body height, use only safety-related ascent aids. Do not use plant
parts as ascent aids! For maintenance work at a higher altitude, use fall protection devices!
•Keep all handles, kicks, railings, pedestals, stages, and ladders free of pollution!
•During maintenance and repair work, tighten loosened screw connections again and again!
•If the disassembly of safety devices is required during set-up, maintenance and repair, the
reassembly and inspection of the safety devices must take place immediately after
completion of the maintenance and repair work.
•Ensure safe and environmentally friendly disposal of operating and auxiliary materials as
well as replacement parts!
NOTE: Please note the special safety instructions in the individual chapters!
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