Operating instructions Zero 3 5-channel stepper motor - CNC-Step
Contents
1. Operating instructions sa tion Zero 3 HU 5 channel stepper motor controller 3 m o ub TI i NA m O pa CI www cnc router com O LLI 7 O pa O Created 12 10 2012 changed 27 09 2014 CNC Maschinenbau Operating instructions Zero3 5 channel stepper motor controller Zero 3 5 channel stepper 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 Siemensstrasse 13 15 Page 2 47608 Geldern Germany Phone 49 0 2831 91021 20 12 10 2012 CNC STEP Y CNC Maschinenbau F Operating instructions Zero3 5 channel stepper motor controller Contents 1 GENERAL INFORMATION 2na NGANGA NANLABAN AA 4 LL DESCNIDPUONOLSYMDONS pan O NAE EE Ei Ei 4 2 OVERVIEW OF FEAV URE Sivcccceccecsiccsancsutecdansesssccasceescecsssevatusatsewascedevuscsausevecseiveutensesewacswias 5 3 SAREE MEASURES eg dace ai tec NA NANG 6 3 1 Organizational safety measures Naa ANNA AA AA 6 3 2 Personnel selection and qualification general GUtICS ccscessecceseeceeecenecceeeceneecenecneeceneeenesensesenes T IF Wale Wan AB AA AN T 3 4 Safety instructions for specific phases of operation2. 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 Siemensstrasse 13 15 Page 8 47608 Geldern Germany Phone 49 0 2831 91021 20 12 10 2012 CNC Maschinenbau 7 Operating instructions Zero3 5 channel stepper motor controller 3 5 Precautions for special types of danger 3 5 1 Electrical power A A Work on the electrical systems or operating units may only be carried out by a qualified electrician or by an instructed person under the supervision of a qualified electrician in compliance with respective regulations for electrical equipment Persons with a pacemaker are not allowed to enter areas with a control cabinet System parts
3. cccsceesscsssceecceccceeeceecceeeuseeuseeueeeeeeeeeceeeueesuneeas T SAL Imong tc emcee AA E AA T 3 4 2 During setup maintenance repair or disposal 8 3 5 Precautions for special types of danger cccsscessecceseccsecceneccsecceneccenscuseecenseusescestsusescenseusessenseusessenes 9 ke eee ved FEC AA AA E ARIA 9 3 5 2 Hydraulic and PNEUMATIC systems SIAM aaa AA AA AGA 9 I9 Gas UIST SO NG AA AA 10 3 5 4 Oil grease gases and other chemical substances a 10 SA AA CA AA 10 3 7 Possible risks tO COD EG amp A NAN sete AGANE EO PANA DAGAN AA 10 3 8 Duties of the system operator sasivesisssiccssssccesccserassascassesssansedeaapaccansasncesawebencensenesiessapesaecesniasaneninareneees 10 4 COMMISSIONING AA 11 Al INSAN E E AA AA AA AA 11 AZ Se Ae AL NAA AN AA MA KANRAN 11 43 COMMECIME he Machine ssinisrissiisssoniosissiivnans inin riirii iania 11 ASA MOVOFCONMECIONS AL AZ AA MAA E AEN AA 12 EZ COMA SCS SA AA AA AA tenant 12 4 3 5 Rotating axis tangential cutter C Lam ATA NAYAN 13 7A WBS Or ee 2 0 oid Pg AN 14 AKOO LE PONG ATA ee ee ee ee ee eee 15 4 3 6 External loads power outlets neern neren nenne 16 AA LOISA AN AA AA 17 5 CLEANING AND SERVICING cvcisscrcucssivenaaswaveususncvanepassessxpsasaninapsessaneassenanvansaseannessaveavaswaenes 18 5 1 Work in the interior of the NOUSING siteseivnvssnndncscnonisnnteneuwnnseenennscssidennseowninnsesiseonsseunanmeesnsen
4. e 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 e Incase of a malfunction switch the system off immediately Have faults repaired immediately e Observe start up shut down processes and control indicators as specified in the user manual Siemensstrasse 13 15 Page 7 47608 Geldern Germany Phone 49 0 2831 91021 20 12 10 2012 CNC STEP Operating instructions Zero3 CNC Maschinenbau 4 Ka 5 channel stepper motor controller NOTE Follow the special safety instructions in the individual chapters of this user manual 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
5. Resolution X axis OFF 1 10 ON 1 5 microstep 2 Resolution Y axis OFF 1 10 ON 1 5 microstep 3 Resolution Z axis OFF 1 10 ON 1 5 microstep 4 Resolution C axis OFF 1 10 ON 1 5 microstep 5 Current of C motor 5 OFF 6 OFF 1 4A 5 ON 6 OFF 2 0A 5 OFF 6 ON 2 8A 5 ON 6 ON 3 5A Current of XYZ motors OFF 2 8A ON 3 5A Assignment of the 24V output OFF oscillation motor PWM controlled ON brake Caution The DIP switches are normally already set correctly at the factory for the supplied machine Changes are only required if the controller is to be operated with a different machine Never set the current higher than in the specifications for the stepper motors Doing so can lead to overheating of the motors or the cables and damage them Siemensstrasse 13 15 Page 20 47608 Geldern Germany Phone 49 0 2831 91021 20 12 10 2012 Operating instructions Zero3 CNC Maschinenbau yF 5 channel stepper motor controller 5 1 4 Closing the housing e Check whether all plug in connectors and lines that may have been removed are back in place especially the ground connections of the housing components green amber e Insert the housing cover in the profile on the right and screw the cover firmly onto the power supply unit e Insert the top left aluminum profile and screw it firmly to the front and rear panels Siemensstrasse 13 15 Page 21 47608 Geldern Germany Phone 49 0 2831 91021 20 12 10 2012 CNG Maschi
6. 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 PP OOP Siemensstrasse 13 15 Page 4 47608 Geldern Germany Phone 49 0 2831 91021 20 12 10 2012 CNC Maschinenbau 7 Operating instructions Zero3 5 channel stepper motor controller 2 Overview 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 bA as desired The phase current of the C axis can be set separately in four steps between 1 4 a
7. Af CNC Maschinenbau 7 Operating instructions Zero3 5 channel stepper motor controller 5 Cleaning and servicing The controller normally runs without wear and requires no maintenance In order to ensure correct function and safe operation it is necessary to regularly check that all connections are in good condition and that air supply to the ventilation openings of the housing is unhindered Procedure A A Siemensstrasse 13 15 Switch the controller off at the main switch and unplug the power plug Wait approximately 2 minutes to allow the energy stored in the capacitors can discharge Check the power supply the power supply cords of external consumers and all motor cables for visible signs of damage Damaged or cracked lines must be replaced at once Check the ventilation slots on the front and rear panels They must be free of swarf and accumulated dust If necessary clean the slots with a vacuum cleaner Avoid blowing them clean with compressed air under any circumstances This could lead to swarf being blown into the interior of the controller Swarf and small parts could break free and cause injuries Use a paintbrush or soft brush if there is stubborn soiling If necessary clean the surface of the housing with a slightly damp cloth Avoid using aggressive cleaning agents or solvents If liquid gets into the housing by mistake DO NOT start using the equipment again but have it checked by a specialist Pa
8. The limit switch can be an NC or NO normally open contact switched to ground The polarity can be selected in the software e g WinPCNC or Mach3 Pinno Siera 5 Estop switch closed OK open stop e Unused optional 12V sensor provision 7 Optional brake 24V 8 Optional brake for ground 9 lGrouna shield a A W N O ao N O Siemensstrasse 13 15 Page 12 47608 Geldern Germany Phone 49 0 2831 91021 20 12 10 2012 CNC Maschinenbau F Operating instructions Zero3 5 channel stepper motor controller 4 3 3 Rotating axis tangential cutter C The fifth axis can be used optionally either for a rotating axis dividing head or a tangential cutter So that this axis can be upgraded later without having to change existing wiring all the necessary additional signals are available on this connector 10 11 12 13 14 15 8 Oscillating motor 12 24V max 3A 6 Fan sensor 12V max 150mA oN OO KRW N a Stepper motor oscillating motor and 12V output are all short circuit proof Nonetheless because the 12V supply is also used internally malfunctions of the controller are possible in the event of a short circuit Pins 5 and 14 15 GND are connected internally but should be separately wired in order to prevent disruptions to the limit switch signals by the motor The limit switch can be a NC or a NO contact depending on ground The polarity can be selected in the software e g WinPCNC or Mach3 Sieme
9. acturer 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 Siemensstrasse 13 15 Page 6 47608 Geldern Germany Phone 49 0 2831 91021 20 12 10 2012 CNC Maschinenbau 7 Operating instructions Zero3 5 channel stepper motor controller 3 2 Personnel selection and qualification general duties e 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 e Assign only trained or instructed personnel to the machine Specify clearly the responsibility of personnel for operation setup maintenance and repairs e Work on with the system may only be carried out by reliable personnel Observe the statutory minimum age e Ensure that the system is only operated by personnel who are authorized to do so e 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 e All work on electri
10. ard motor 1 87 full step 200 full steps revolution Siemensstrasse 13 15 Page 22 47608 Geldern Germany Phone 49 0 2831 91021 20 12 10 2012 C N C S T E pP w CNC Maschinenbau Operating instructions Zero3 5 channel stepper motor controller 7 Customer service Our customer service is pleased to provide further technical information CNC STEP CNC Maschinenbau Frank Hylewicz Address Siemensstrafe 13 15 D 47608 Geldern Phone 49 0 2831 91021 50 Mo Fr 07 00am 3 00pm 49 152 22345755 Mobile In urgent cases Mo Thu 3 30pm 6 00pm Telefax 49 0 2831 91021 99 E Mail support cnc step de Internet www cnc router com Additionally our members of staff are permanently interested in receiving new information and experiences resulting from the use of our products which could be of great value for future improvements www cnc router com Siemensstrasse 13 15 Page 23 47608 Geldern Germany Phone 49 0 2831 91021 20 12 10 2012
11. as follows Pinna pesonpton Pinno eerie 1 Relay 1 Spindle Relay 2 cooling suction 2 Direction X1 and X2 Ref switch 4 Axis or tool ep pr X1 and X2 5 Cycle Y Direction Z Cycle Z Oez un Fstop low active ome switch 7 Reference switches X1 and X2 123 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Siemensstrasse 13 15 Page 15 47608 Geldern Germany Phone 49 0 2831 91021 20 12 10 2012 CNC Maschinenbau 7 Operating instructions Zero3 5 channel stepper motor controller A second LPT port is provided for controlling a tool changer and frequency inverter See the illustration at the top right The connector to the PC is male the one for the tool changer frequency inverter is female The pin LPT2 assignment is as follows description Motor on off open collector Looped through available O LOV Speed target Looped through available Signal ground 23 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 1 NI NO IM N NN IND EH iIe IR IB fe H Pin no 1 6 8 9 Pin no 1 is an open collector signal i e it is switched to ground whenever the spindle motor is switched on and can be used to control start stop input a frequency inverter max 30V 50mA Pin no 18 is the analog motor speed signal It is short circuit proof so that no damage is caused if a normal LPT cable Pin 18 ground is accidentally connected 4 3 6 External loads pow
12. cal 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 O 5 mm AWG 20 3 4 Safety instructions for specific phases of operation 3 4 1 In normal operation e Before switching the machine on ensure that only authorized persons are in the working area of the system e Refrain from operating the machine in a manner that would impair safety e Initiate all measures to ensure that the machine is only operated in a safe and fully functioning condition e 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
13. ccessible 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 manuf
14. e connections lead to the risk of damaging parts of the through this and safety functions which serve to protect life and limb can be disabled e Insert or remove connectors only with the controller switched off e Always lock connectors using the screws located on the connector housing The electronic equipment is protected against short circuits and interruption of the motor cable However unreliable contacts can lead to incorrect positioning and or arcing which can result in breakage of tools destruction of the workpiece or reduction of the service life of the system SS controller or destroying it e In addition the proper functioning of the system can be reduced Siemensstrasse 13 15 Page 11 47608 Geldern Germany Phone 49 0 2831 91021 20 12 10 2012 CNC Maschinenbau F Operating instructions Zero3 5 channel stepper motor controller For motors with 3A or higher current a wire gauge of at least 0 5mm AWG 20 must be used and both pins must always be connected for each wire For motors with lower current O 34mm and one pin are sufficient Shielding can be connected to either pin 5 or the sheet metal collar of the connector The motor outputs are short circuit proof interturn fault and short circuit O ao N O 4 3 2 Control signals ST The limiting switch and the E stop switch are connected at this connector All switches connect ground with the respective input The E stop switch must be NC normally closed
15. er outlets Two 230V external loads can be connected to the two power outlets on the rear panel The left hand power outlet looking at it from the rear is controlled by relay 1 and is normally used for the spindle motor The right hand power outlet is controlled by relay 2 and can be optionally used for a vacuum cleaner a coolant pump or other sub assemblies The maximum current consumption of each external load must not exceed 8A The total current consumption must not exceed 13 5A 16A minus the maximum current used by the machine itself Please note that the maximum current consumption can be higher than is to be expected from the rated performance of the device The maximum current consumption also taking account of start up and idling current is stated on the nameplate or in the manufacturer documentation Exceeding the maximum current leads to tripping of the fuses located in the interior of the housing Siemensstrasse 13 15 Page 16 47608 Geldern Germany Phone 49 0 2831 91021 20 12 10 2012 Operating instructions Zero3 CNC Maschinenbau 4 Ka 5 channel stepper motor controller 4 4 Commissioning Before final commissioning please check once again that all plug in connectors are correctly mounted and the locking screws are tight After this you can switch on the PC and install and launch the controller software Carry out the required setting of machine parameters according to the controller software user manual the
16. ge 18 47608 Geldern Germany Phone 49 0 2831 91021 20 12 10 2012 CNC Maschinenbau 7 Operating instructions Zero3 5 channel stepper motor controller 5 1 Work in the interior of the housing There is normally no maintenance required for the inside of the housing Repairs may only be carried out by the manufacturer or authorized workshops Exceptions are changing fuses and changing the factory settings with the help of the DIP switch In the case of all work which requires opening the housing be sure to pay attention to the following points A A Siemensstrasse 13 15 Switch the controller off at the main switch and unplug the power plug Wait approximately 2 minutes to allow the energy stored in the capacitors can discharge If these instructions are not followed there is the risk of serious or fatal injuries due to electric shock The controller can also be damaged if objects accidentally fall into it when opening the housing If the controller is opened directly after being in use the temperature of individual components in the controller may still be over 50 C There is danger of burning if these are touched We therefore recommend a cooling off period of 30 minutes Carefully save all screws and disassembled small parts When putting it back together be sure to reinstall all original parts in the places intended for them Screws that are too long can cause short circuits or damage components on the in
17. n many years experience and conforms to relevant regulations Nonetheless hazards arising from handling systems cannot be ruled out completely e Operating and service personnel need to be thoroughly familiar with remaining hazard points and always carry out work on the system with appropriate attention to these in order to avoid risks to life and limb of people or impairments of the machine and other real assets e Safety equipment or safety measures are only fully effective if the machine is used as specified Particular caution is necessary in operating modes where safety equipment is limited setup maintenance repairs 3 8 Duties of the system operator e System safety can only be achieved during regular operation if all measures required for such safety are adopted The operator of the system is responsible for planning these measures and checking that they are carried out e The system operator is required to maintain safety equipment on the system and in its periphery in the condition they were in at the time it commenced operating e The user must guarantee the cleanliness and neatness of the work space by means of appropriate instructions and checks In addition the operator should explain and teach operating personnel safety conscious behavior by means of internal application specific rules and protective measures Siemensstrasse 13 15 Page 10 47608 Geldern Germany Phone 49 0 2831 91021 20 12 10 2012 CNC Maschinenbau 7 O
18. ncsbucurndetunnnssiis 19 SLL OPS the NOUSING sisri E a EET ES AA 20 SL NANA AA AA AA AA AA 20 Balls IP SNN Na AA AA AA ANA AA a ee ete 20 5 1 4 Closing the PIOUS IIS AA AA AA 21 TECHNICAL SPECIFICATIONS masa NE NEN GAGANA NAKAKA NAA ANA ANA 22 6 1 Absolute maximum FAUNES sicccescccscccesisccensscescncssasstensictsdenwianacevssivecanevesnacuusaceonsivecuacteseienaacesuanceceasessans 22 6 2 Electrical connection VAIUECS cccsescssccceeccesecceeccuseeeneeuseecuseeuseeeuseeueeseuseecusseuseececeeuseesusesueessenssneeees 22 63 HOUSING UIMENSONS AA AA AA AA 22 7 CUSTOMER SERVICE NAA A 23 Siemensstrasse 13 15 Page 3 47608 Geldern Germany Phone 49 0 2831 91021 20 12 10 2012 CNC STEP CNC Maschinenbau 7 Operating instructions Zero3 5 channel stepper motor controller 1 General 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
19. nd 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 O 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 Siemensstrasse 13 15 Page 5 47608 Geldern Germany Phone 49 0 2831 91021 20 12 10 2012 CNC STEP 7 Operating instructions Zero3 CNC Maschinenbau 4 Ka 5 channel stepper motor controller 3 Safety measures 3 1 Organizational safety measures The operating instructions must always be kept in an a
20. nenbau Operating instructions Zero3 5 channel stepper motor controller 6 Technical specifications 6 1 Absolute maximum ratings In order to avoid equipment damage under no circumstances should the following parameters be exceeded Parameters Min Power supply o Z oZ o o F Y pG Vac Current consumption including external consumers 16 Aac Holes at LPT sial inputs and oopus 5 KB V V mo he C U Voltage at LPT2 pin 18 Storage temperature 155 y soo jv t85 C 6 2 Electrical connection values KC a ET Line frequency Current consumption with power supply unit Ambient temperature during operation o hao Level logical O for LPT signal inputs and outputs Input resistance for signal inputs 1 Pulse width for step signal 2 ae Step frequency 400 Delay time prior to automatic current reduction 0 5 Excess temperature response threshold C Precision of current control Number of microsteps per full step 510 fo Microsteps revolutions using a standard motor 1000 2000 Powersupply 10 15 45 yac Hz without ext consumers ae e Level logical 1 for signal inputs 25 HS A 2 oas Setup time for direction signal valid until stept O us o o too kHz 05 so c 6 3 Housing dimensions 260 mm Length without connection and operating elements 260 mm 1 Step is executed during rising edge i e transition from logical O to logical 1 rise of a pulse 2 Stand
21. nsstrasse 13 15 Page 13 47608 Geldern Germany Phone 49 0 2831 91021 20 12 10 2012 CNG Maschinenbau Operating instructions Zero3 5 channel stepper motor controller 4 3 4 Status LEDs Several LEDs for indicating the operating condition are mounted on the front plate numbered from left to right boni premono OO O Green PC Ready PC software ready toggle signal Cp mee i an Cp Ol A WI N a aa stop mushroom button or ext input Malfunction X4 axis OC X1 axis e e X2 axis Red Malfunction Y axis 10 Red AN Malfunction Z axis At Red Malfunction C axis 12 Red Malfunction oscillating motor or brake Some special conditions are indicated with flashing signals e Overheating LEDs 7 12 flash simultaneously e Excess voltage LEDs 1 and 7 12 flash simultaneously e Low voltage LED 1 flashes Siemensstrasse 13 15 Page 14 47608 Geldern Germany Phone 49 0 2831 91021 20 12 10 2012 CNC STEP 7 CNC Maschinenbau F Operating instructions Zero3 5 channel stepper motor controller 4 3 5 LPT ports The connection with the controller PC is by means of a 25 pin D sub connector LPT parallel port on the rear panel Most signals for basic functions phase direction spindle on off etc are available on the left connector The plug in connector on the controller is male i e to connect it with the PC a 1 1 extension cable with a male female plug is required The pins LPT1 are assigned
22. on which maintenance service and repair work is being carried out must be disconnected from the power supply if this is required First check that disconnected parts are free of voltage then ground and short circuit them and isolate live neighboring parts Use only original fuses with the electrical current for which they were designed Turn the system off immediately if encountering any faults in the power supply The system s electrical equipment must be inspected checked regularly Any faults such as loose connections damaged or cracked cable must be repaired immediately If it becomes necessary to carry out work on live components a second person must be called in who in an emergency can actuate the E Stop or the main switch equipped with a voltage tripping mechanism Cordon off the work area with a red and white safety chain and a warning sign Use only non conductive tools NOTE Follow the special safety instructions in the individual chapters of this user manual 3 5 2 Hydraulic and pneumatic systems steam Siemensstrasse 13 15 Only personnel with special knowledge and experience with hydraulic systems are permitted to carry out work on hydraulic equipment Check all lines hoses and screw couplings regularly for leaks and externally visible damage Repair any damage immediately Squirting oil can cause injury and is a fire hazard Before commencing repair work release pressure from the system sections and pressure line
23. perating instructions Zero3 5 channel stepper motor controller 4 Commissioning 4 1 Installation The controller should be installed in such a way that the controls on the front panel especially the E Stop switch are freely accessible at all times There should be free air flow to the ventilation openings on the housing Appropriate measures housing protective walls suction should be adopted to ensure that the controller remains free of shavings dust and liquids oil cooling water Metal swarf and cooling water can cause short circuits Dust can interfere with ventilation and thus cause overheating Both of these can lead to irreparable damage and risk of fire 4 2 Power supply line The controller is equipped with a universal AC adapter and can be operated without adjustment using line voltages from 115 to 240VAC If you are operating the equipment in a foreign country make sure that you use only appropriate and authorized power cord and power outlet adapters These must have a PE conductor and be designed for a load of up to 16A 4 3 Connecting the machine Connections for the positioning motors connectors X1 X2 Y and Z the rotating axis or tangential unit connector C if present and the end position switches and E stop switches connector ST are located on the front panel Before connecting the connector make sure that the assignment of individual contacts corresponds to the schematic shown below e Incompatibl
24. s hydraulic fluid compressed air coolants which are to be opened according to the unit specifications Move and mount hydraulic coolant and compressed air lines properly Connections must not be mixed up Fittings length and quality of hose lines must meet technical requirements Page 9 47608 Geldern Germany Phone 49 0 2831 91021 20 12 10 2012 Operating instructions Zero3 CNC Maschinenbau yF 5 channel stepper motor controller 3 5 3 Gas dust sparking e Carry out welding thermal cutting torch work and grinding operations on the system only when this is explicitly authorized There may for example be a risk of fire or explosion e Prior to welding burning and grinding clean the system and surrounding area of dust and combustible material and ensure there is sufficient ventilation risk of explosion e Inthe case of work in closed areas observe national regulations where these exist 3 5 4 Oil grease gases and other chemical substances e When handling oil grease gases and other chemical Substances follow the safety instructions applicable to the product e Exercise caution when handling hot auxiliary and operating materials risk of burning or scalding 3 6 Safety devices e Emergency stop device with E stop switches on the controller housing E stop chain as prescribed by applicable regulations 3 7 Possible risks to people Remaining hazard points e The safety equipment on the system is based o
25. side Metal housing parts must be connected to the PE conductor During reassembly be absolutely sure to reconnect all ground lines and to firmly tighten the screws Page 19 47608 Geldern Germany Phone 49 0 2831 91021 20 12 10 2012 CNG STEP J CNC Maschinenbau F Operating instructions Zero3 5 channel stepper motor controller 5 1 1 Opening the housing e Remove the aluminum profiles on the top left side by unscrewing one of the round head screws on the front and rear wall respectively e Loosen the screw of the housing cover and remove it e f possible leave the side elements the front panel and rear panel in place 5 1 2 Changing fuses The fuses are located in two plastic fuse holders green components on the right in the picture Start by removing the upper section of the fuse holder and check the fuse with a continuity tester Then replace the fuse if necessary and place the top part of the holder back in the PCB Caution Use only fuses with the same value slow blow 8A and rated for the voltage used 250V If the fuse trips frequently the connected external A consumer has excessive current N a N Schaiter consumption or is defective Never install fuses with higher amperage 5 1 3 DIP switch settings The switches are located on the edge of the PCB next to the fuses the blue component in the picture above They are numbered from 1 to 8 and the ON position is marked ON No Meaning 1
26. spindle motor and no workpiece or other objects on the work surface If necessary rotate the positioning drives into a safe position with sufficient distance to the final positions Close the covers or make sure that nobody is present within the hazardous area Prior to the first test run make sure that there are no tools in the collet of C Insert the power plug of the controller only now and switch the controller on at the main switch Start by checking that the end position switches and all E stop switches are functioning correctly Check that the stepper motors are rotating in the correct direction using manual travel jogging at slow speed e g 1mm s Check whether the displayed travel path corresponds with the path actually traversed adjustment steps MM In the event that anything fails to function as expected switch off the machine at once and check the connections as well as the software settings If all switches function as expected and the directions of movement and distances traversed are correct you can carry out a reference run homing The machine is ready for operation In order to familiarize yourself with operating the machine it is recommended that before the first rea processing operation you allow a CNC program to run in thin air i e without the tool material or workpiece Siemensstrasse 13 15 Page 17 47608 Geldern Germany Phone 49 0 2831 91021 20 12 10 2012 C N C S T E pP
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