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.

Operating Instructions
Zero-3 / 5-Channel Motor Controller
CNC-STEP e.K. ▪Siemensstrasse 13-15 ▪ 47608 Geldern ▪ Germany
Page 11
Support: +49 (0)2831/91021-50
12.10.2012
3.5 Precautions for special types of danger
3.5.1 Electrical power
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 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.

Operating Instructions
Zero-3 / 5-Channel Motor Controller
CNC-STEP e.K. ▪Siemensstrasse 13-15 ▪ 47608 Geldern ▪ Germany
Page 12
Support: +49 (0)2831/91021-50
12.10.2012
3.5.2 Hydraulic and pneumatic systems, steam
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 lines (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.
3.5.3 Gas, dust, sparking
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.
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)!
In the case of work in closed areas observe national regulations where these exist!
3.5.4 Oil, grease, gases and other chemical substances
When handling oil, grease, gases and other chemical substances, follow
the safety instructions applicable to the product!
Exercise caution when handling hot auxiliary and operating materials
(risk of burning or scalding)!

Operating Instructions
Zero-3 / 5-Channel Motor Controller
CNC-STEP e.K. ▪Siemensstrasse 13-15 ▪ 47608 Geldern ▪ Germany
Page 13
Support: +49 (0)2831/91021-50
12.10.2012
3.6 Safety devices
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
The safety equipment on the system is based on many years experience and conforms to
relevant regulations. Nonetheless, hazards arising from handling systems cannot be ruled out
completely.
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.
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
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.
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.
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.

Operating Instructions
Zero-3 / 5-Channel Motor Controller
CNC-STEP e.K. ▪Siemensstrasse 13-15 ▪ 47608 Geldern ▪ Germany
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Support: +49 (0)2831/91021-50
12.10.2012
4Commissioning
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.
Incompatible connections lead to the risk of damaging parts of the
controller or destroying it.
In addition, the proper functioning of the system can be reduced through
this and safety functions which serve to protect life and limb can be
disabled.
Insert or remove connectors only with the controller switched off!
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.

Operating Instructions
Zero-3 / 5-Channel Motor Controller
CNC-STEP e.K. ▪Siemensstrasse 13-15 ▪ 47608 Geldern ▪ Germany
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Support: +49 (0)2831/91021-50
12.10.2012
4.3.1 Motor connectors (X1, X2, Y, Z)
Pin no.
Signal
1+6
Motor winding A+
2+7
Motor winding A-
3+8
Motor winding B+
4+9
Motor winding B-
5
Ground, shield
For motors with 3A or higher current a wire gauge of at least 0.5mm² (AWG 20) must be used and
both pins must always be connected for each wire. For motors with lower current, 0.34mm² 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).
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). 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).
Pin no.
Signal
1
Limit switch C or tool probe
2
Limit switch X
3
Limit switch Y
4
Limit switch Z
5
E-stop switch (closed = OK, open = stop)
6
Unused (optional 12V sensor provision)
7
Optional brake +24V
8
Optional brake for ground
9
Ground, shield

Operating Instructions
Zero-3 / 5-Channel Motor Controller
CNC-STEP e.K. ▪Siemensstrasse 13-15 ▪ 47608 Geldern ▪ Germany
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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.
Pin no.
Signal
1+9
Stepper motor winding A+
2+10
Stepper motor winding A-
3+11
Stepper motor winding B+
4+12
Stepper motor winding B-
7+8
Oscillating motor +12..24V (max. 3A)
14+15
Oscillating motor GND
13
Limit switch C
5
Signal ground, shielding
6
Fan, sensor +12V max. 150mA
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).

Operating Instructions
Zero-3 / 5-Channel Motor Controller
CNC-STEP e.K. ▪Siemensstrasse 13-15 ▪ 47608 Geldern ▪ Germany
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Support: +49 (0)2831/91021-50
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4.3.4 Status LEDs
Several LEDs for indicating the operating condition are mounted on the front plate (numbered from
left to right).
Some special conditions are indicated with flashing signals:
Overheating: LEDs 7-12 flash simultaneously
Excess voltage: LEDs 1 and 7-12 flash simultaneously
Low voltage: LED 1 flashes
LED
no.
Color
Symbol
Meaning
1
Green
Power (controller switched on)
2
Green
Ready (PC software ready, toggle signal)
3
Yellow
Running (current reduction when off)
4
Yellow
Relay 1 (spindle on)
5
Yellow
Relay 2 (cooling, suction)
6
Red
Emergency stop (mushroom button or ext. input)
7
Red
Malfunction X1 axis
8
Red
Malfunction X2 axis
9
Red
Malfunction Y axis
10
Red
Malfunction Z axis
11
Red
Malfunction C axis
12
Red
Malfunction oscillating motor or brake
PC
!

Operating Instructions
Zero-3 / 5-Channel Motor Controller
CNC-STEP e.K. ▪Siemensstrasse 13-15 ▪ 47608 Geldern ▪ Germany
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Support: +49 (0)2831/91021-50
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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 as follows:
Pin no.
description
Pin no.
description
1
Relay 1 (spindle)
14
Relay 2 (cooling/suction)
2
Direction X1 and X2
15
Ref. switch 4. Axis or tool
probe
3
Cycle X1 and X2
16
Watchdog (toggle/charge
pump)
4
Direction Y
17
Spindle speed PWM
5
Cycle Y
18
Signal ground
6
Direction Z
19
7
Cycle Z
20
8
Direction 4th axis (C)
21
9
Cycle 5th axis
22
10
Reference switch Z
23
11
E-Stop (low active)
24
12
Reference switch Y
25
13
Reference switches X1 and
X2

Operating Instructions
Zero-3 / 5-Channel Motor Controller
CNC-STEP e.K. ▪Siemensstrasse 13-15 ▪ 47608 Geldern ▪ Germany
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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:
Pin no.
description
Pin no.
description
1
Motor on/off (open
collector)
14
2
Looped through,
available
15
Looped through,
available
3
16
4
17
5
18
0..10V Speed target value
6
19
Signal ground
7
20
8
21
9
22
10
23
11
24
12
25
13
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 (power 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.

Operating Instructions
Zero-3 / 5-Channel Motor Controller
CNC-STEP e.K. ▪Siemensstrasse 13-15 ▪ 47608 Geldern ▪ Germany
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Support: +49 (0)2831/91021-50
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4.3.7 Ground (GND)
For machines with ground connection.
Example: High-Z Series > 03/2015
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.
Prior to the first test run make sure that there are no tools in the collet of the
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.
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 “real” processing operation you allow a CNC program to run “in
thin air,“ i.e., without the tool, material or workpiece.