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Zmotion ZMC408CE Manual

Pulse+bus motion controller
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  • Page 2 This manual is copyrighted by Shenzhen Technology Co., Ltd., without the written permission of the Zmotion Technology, no person shall reproduce, translate and copy any content in this manual. The above-mentioned actions will constitute an infringement of the copyright of the company's manual, and Zmotion will investigate legal responsibility according to law.
  • Page 3 ⚫ Zmotion will not take any legal responsibility for personal safety accidents and property losses caused by failure to comply with the contents of this manual or illegal operation of products. Safety Level Definition According to the level, it can be divided into "...
  • Page 4 ◆ Improper installation of the controller may result in misoperation, failure and fire. Wiring ◆ The specifications and installation methods of the external wiring of the equipment shall comply with the requirements of local power distribution regulations. ◆ When wiring, all external power supplies used by the system should be disconnected before operation.

  • Page 5: Table Of Contents

    ZMC408CE Motion Controller Hardware Manual V1.5 Content Chapter I Production Information..................3 1.1. Product Information ..................3 1.2. Function Features ....................3 1.3. System Frame ....................5 1.4. Hardware Installment ..................5 Chapter II Product Specification ..................7 2.1. Basic Specification .................... 7 2.2.
  • Page 6 ZMC408CE Motion Controller Hardware Manual V1.5 3.5.2. Basic Usage ..................24 3.6. ETHERNET ....................... 26 3.7. EtherCAT Bus Interface ................... 27 3.8. AXIS Differential Pulse Axis Interface ............. 29 3.8.1. AXIS Interface Signal Specification & Wiring ........31 3.8.2. Basic Usage Method ................33 3.9.

  • Page 7: Chapter I Production Information

    ZMC408CE Motion Controller Hardware Manual V1.5 Chapter I Production Information 1.1. Product Information ZMC is the abbreviation of the network motion controller model launched by Zmotion Technology. ZMC408CE high-performance multi-axis motion controller is a stand-alone motion controller that is compatible with EtherCAT bus and pulse type. The controller itself supports 8 axes, but 32 axes can be expanded at most to achieve complex continuous trajectory control requirements.
  • Page 8 ZMC408CE Motion Controller Hardware Manual V1.5 ◆ Axis position limit signal / origin signal port can be configured as any input at will. ◆ The maximum output current of general digital outputs can reach 300mA, which can directly drive some kinds of solenoid valves.

  • Page 9: System Frame

    ZMC408CE Motion Controller Hardware Manual V1.5 1.3. System Frame 1.4. Hardware Installment The ZMC408CE motion controller is installed horizontally with screws, and each controller should be fastened with 4 screws. → Unit: mm → Mounting Hole Diameter 4.5mm...
  • Page 10 ZMC408CE Motion Controller Hardware Manual V1.5 ⚫ Non-professionals are strictly prohibited to operate. Specifically, professionals who had been trained related electrical equipment, or who master electrical knowledge. Please be sure to read the product instruction manual and safety ⚫ precautions carefully before installation.

  • Page 11: Chapter Ii Product Specification

    ZMC408CE Motion Controller Hardware Manual V1.5 Chapter II Product Specification 2.1. Basic Specification Item Description Model ZMC408CE Basic Axes Max Extended Axes Type of Basic Axes Pulse axis / encoder axis / ECAT bus axis 24 inputs and 16 outputs, and each Axis axis has 2 Digital IO additional inputs and 2 additional outputs.

  • Page 12: Interface Definition

    ZMC408CE Motion Controller Hardware Manual V1.5 8 axes, point to point, linear, circular, electronic cam, continuous ZMC408CE trajectory motion, robot structure. 16 axes, point to point, linear, circular, electronic cam, continuous ZMC408CE-16 trajectory motion, robot structure. 2.3. Interface Definition → Interface Description...

  • Page 13: Work Environment

    ZMC408CE Motion Controller Hardware Manual V1.5 Run state: it lights when runs normally Error state: it lights when runs incorrectly RS232 RS232 serial port Use MODBUS_RTU protocol RS485 RS485 serial port Use MODBUS_RTU protocol EtherCAT bus interface, connect to EtherCAT...
  • Page 14 ZMC408CE Motion Controller Hardware Manual V1.5 Work Temperature -10℃-55℃ Work relative Humidity 10%-95% non-condensing -40℃～80℃ (not frozen) Storage Temperature Storage Humidity Below 90%RH (no frost) Frequency 5-150Hz Displacement 3.5mm(directly install)(<9Hz) vibration Acceleration 1g(directly install)(>9Hz) Direction 3 axial direction Shock (collide)

  • Page 15: Chapter Iii Wiring & Communication

    ZMC408CE Motion Controller Hardware Manual V1.5 Chapter III Wiring & Communication 3.1. Power Input, CAN Communication Interface The power supply input adopts a 5Pin screw-type pluggable wiring terminal, and the interval (means the gap distance between two ports) should be 3.81mm. This 5Pin terminal is the power supply of the controller.
  • Page 16 ZMC408CE Motion Controller Hardware Manual V1.5 protocol, which mainly includes three ports, CANL, CANH and the public end. And it can connect CAN expansion modules and other standard CAN devices. → Specification Item Maximum Communication Rate (bps) Terminal Resistor 120Ω...

  • Page 17: Basic Usage Method

    ZMC408CE Motion Controller Hardware Manual V1.5 the branch structure also can be used. Please connect a 120Ω terminal resistor in parallel to each end of the CAN bus for ⚫ matching the circuit impedance and ensuring communication stability. ⚫ Please be sure to connect the public ends of each node on the CAN bus to prevent the CAN chip from burning out.

  • Page 18: In Digital Input & High-Speed Latch Port

    ZMC408CE Motion Controller Hardware Manual V1.5 "speed" according to the needs, and use the "CANIO_ENABLE" command to enable or disable the internal CAN master function, or through "ZDevelop/Controller/State the Controller/Communication Info” to view the CAN status intuitively, and refer to the “ZBasic Programming Manual”...

  • Page 19: Digital Input Specification & Wiring

    ZMC408CE Motion Controller Hardware Manual V1.5 → Terminal Definition Terminal Name Type Function 1 Function 2 Input 0 Input 1 NPN leakage type, High Speed high-speed input Latch Input 2 Input 3 Input 4 Input 5 NPN leakage type, low-speed input...

  • Page 20: Basic Usage Method

    ZMC408CE Motion Controller Hardware Manual V1.5 The voltage to open <15V <14.5V The voltage to close >15.1V >14.7V Minimal current -2.3mA (negative) -1.8mA (negative) Max current -7.5mA (negative) -6mA (negative) Isolation mode optoelectronic isolation Note: the above parameters are standard values when the voltage of controller power supply (E+24V port) is 24V.

  • Page 21: Out Digital Output & Pwm Terminal

    ZMC408CE Motion Controller Hardware Manual V1.5 (3) State values of relative input ports can be read directly through “IN” command, also, it can be read through “ZDevelop/View/In”. Please refer to “ZBasic” for details. (4) Latch function can be set and triggered through “REGIST” instruction, in software, use REG_INPUTS to configure.

  • Page 22: Digital Output Specification & Wiring

    ZMC408CE Motion Controller Hardware Manual V1.5 OUT2 type, Output 2 PWM 2 Hardware Comparison Out 2 high- OUT3 Output 3 PWM 3 Hardware Comparison Out 3 speed OUT4 Output 4 PWM 4 Hardware Comparison Out 4 output OUT5 Output 5...
  • Page 23 ZMC408CE Motion Controller Hardware Manual V1.5 close Overcurrent Support Support protection Isolation method optoelectronic isolation Note: The times in the form are typical based on the resistive load, and may change  when the load circuit changes.  Due to the leak-type output, the shutdown of the output will be obviously affected by the external load circuit, and the output frequency should not be set too high in the application.

  • Page 24: Basic Usage Method

    ZMC408CE Motion Controller Hardware Manual V1.5 same power supply system, this connection can also be omitted. The E5V port is a 5V power output port, which can be used when some loads need to ⚫ provide an external 5V power input, the maximum current is 300mA.

  • Page 25: Ad/Da Analog Input/Output Specification & Wiring

    ZMC408CE Motion Controller Hardware Manual V1.5 → Terminal Definition Terminal Name Type Function Analog output terminal: AOUT(0) Output Analog output terminal: AOUT(1) AGND Public End Unique public end of this analog Analog input terminal: AIN(0) Input Analog input terminal: AIN(1) 3.4.1.

  • Page 26: Basic Usage Method

    ZMC408CE Motion Controller Hardware Manual V1.5 Please use STP, especially in bad environments, and make sure the shielding layer is ⚫ fully grounded. 3.4.2. Basic Usage Method (1) Please follow the above wiring instructions to wiring correctly. (2) After powered on, please use EtherNET or RS232 o connect to ZDevelop.

  • Page 27: Rs232/Rs485 Communication Interface Specification & Wiring

    ZMC408CE Motion Controller Hardware Manual V1.5 RS232 (port 0) signal, 232RXD Input receive data RS232 (port 0) signal, send 232TXD Output data 485A/+ Input/Output RS485 (port1) signal A/+ Negative pole output of 5V EGND Output power, and output for the...

  • Page 28: Basic Usage

    ZMC408CE Motion Controller Hardware Manual V1.5 → Wiring Reference: → Wiring Notes: ⚫ The wiring of RS232 (port0) is as above, it needs to cross-wiring for sending and receiving signals, and it is recommended to use a double-female head cross line when connecting to a computer.
  • Page 29 ZMC408CE Motion Controller Hardware Manual V1.5 (2) After powered on, please use any one interface among the three interfaces ETHERNET, RS232 (there is default parameter, which can be connected directly) and RS485 (there is default parameter, which can be connected directly, but for hardware, adapter head is needed) to connect to ZDevelop.

  • Page 30: Ethernet

    ZMC408CE Motion Controller Hardware Manual V1.5 3.6. ETHERNET ZMC408CE motion controller has one ethernet port, and it supports MODBUS_TCP protocol and custom communication, the default IP address is 192.168.0.11. The pin definition is as follows: The Ethernet port of the controller can be connected to a computer, HMI, etc. through an Ethernet cable, and using point to point connection method.

  • Page 31: Ethercat Bus Interface

    ZMC408CE Motion Controller Hardware Manual V1.5 3.7. EtherCAT Bus Interface ZMC408CE motion controller has a 100M EtherCAT communication interface, and it supports EtherCAT protocol. In addition, EtherCAT driver or EtherCAT expansion module can be connected. The pin definition is as follows:...
  • Page 32 ZMC408CE Motion Controller Hardware Manual V1.5 → Specification Item Specification Communication protocol EtherCAT protocol Valid service CoE(PDO, SDO), FoE IO adopts input and output synchronization / DC- Synchronization method distributed clock Physical level 100BASE-TX Duplex mode Full duplex Topology linear topology...

  • Page 33: Axis Differential Pulse Axis Interface

    ZMC408CE Motion Controller Hardware Manual V1.5 Isolation cross skeleton Connector Crystal head with iron shell Cable material Cable length Less than 100m Use RJ45 network cable connection method: When installing, hold the crystal head that is with the cable and insert it into the RJ45 ⚫...
  • Page 34 ZMC408CE Motion Controller Hardware Manual V1.5 pulse/encoder signal Reserved Reserved Servo or step directional output DIR+ (differential signal) + Negative pole of 5V power of pulse/encoder signal Servo or step pulse output PUL- (differential signal) - Reserved Reserved Negative pole of 5V power of...

  • Page 35: Axis Interface Signal Specification & Wiring

    ZMC408CE Motion Controller Hardware Manual V1.5 3.8.1. AXIS Interface Signal Specification & Wiring → Specification: Signal Item Description Signal type Differential output signal PUL/DIR Voltage range 0-5V Maximum frequency 10MHz Signal type Differential input signal EA/EB/EZ Voltage range 0-5V Maximum frequency...
  • Page 36 ZMC408CE Motion Controller Hardware Manual V1.5 → Wiring Note: The wiring principle of the differential pulse axis interface is shown in the figure  above, and the wiring methods of different types of drivers are different, please...

  • Page 37: Basic Usage Method

    ZMC408CE Motion Controller Hardware Manual V1.5 connect carefully. When speed is met, use low-speed differential pulse preferentially. When high-speed  differential pulse interface is used, please make sure controller internal digital ground is connected to driver high-speed pulse reference ground.
  • Page 38 ZMC408CE Motion Controller Hardware Manual V1.5 (5) Control corresponding motion through “View – Manual”. Refer to BASIC Routine:...

  • Page 39: Mpg Handwheel Interface

    ZMC408CE Motion Controller Hardware Manual V1.5 BASE(0,1) 'select axis 0 and axis 1 ATYPE = 1,1 'set axis 0 and axis 1 as pulse axes UNITS = 1000,1000 'set pulse amount as 1000 pulses SPEED = 10,10 'set axis speed as 10*1000 pulse/s ACCEL = 1000,1000 ‘set axis acceleration as 1000*1000 pulse/s/s...

  • Page 40: Mpg Handwheel Interface Specification & Wiring

    ZMC408CE Motion Controller Hardware Manual V1.5 Note: ➢ 5V power supply only supplies for handwheel, don’t supply power for others. ➢ All signals of this interface are digital input signals, number is IN (40-51). 3.9.1. MPG Handwheel Interface Specification & Wiring →...
  • Page 41 ZMC408CE Motion Controller Hardware Manual V1.5 → Wiring Note The wiring principle of handwheel encoder axis interface is shown above, please ⚫ connect carefully due to diversified handwheel designs. ⚫ Please use STP, especially in bad environments, and make sure the shielding layer is...

  • Page 42: Basic Usage Method

    ZMC408CE Motion Controller Hardware Manual V1.5 3.9.2. Basic Usage Method Refer to above handwheel wiring graphic, correctly connect the handwheel and controller. After powered on, please select ETHERNET or RS232 or RS485 to connect to ZDevelop. Configure axis No., if there is no default AXIS axis No. (axis 10, 11, 12, 13 are recommended) of controller handwheel interface, remapped must be done.

  • Page 43: Chapter Iv Expansion Module

    ZMC408CE Motion Controller Hardware Manual V1.5 Chapter IV Expansion Module The controller can expand digital IO, analog IO, pulse axis and other resources through CAN bus (ZIO series expansion modules). For details, please refer to "ZIO Expansion Card Hardware Manual". Also, through EtherCAT bus (EIO series expansion cards) expansion of these resources also can be achieved, please refer to each EIO hardware manual for details.
  • Page 44 ZMC408CE Motion Controller Hardware Manual V1.5 → Wiring Note: ZMC408CE controller uses the single power, and ZIO expansion module uses dual-  power. When using, main power supply of expansion module and main power supply of controller can share one power. When they use different power supplies, controller power EGND needs to connect to expansion module power GND, otherwise CAN may be burnt out.

  • Page 45: Can Bus Expansion Resource Mapping

    ZMC408CE Motion Controller Hardware Manual V1.5 4.1.2. CAN Bus Expansion Resource Mapping The ZCAN expansion module generally has an 8-bit DIP switch, dial ON to take effect, and the meaning of the DIP is as follows: 1-4: they are used for ZCAN expansion module IO address mapping, the corresponding value is 0-15.
  • Page 46 The initial digital IO mapping number starts from 16 and increases in multiples of 16. The distribution of digital IO numbers corresponding to different dial IDs is as follows (ZMC408CE motion controller expansion board’s DIP ID starts from 3 at least, so starting IO No. starts from 64 at...
  • Page 47 ZMC408CE Motion Controller Hardware Manual V1.5 The initial IO mapping number of the analog AD starts from 8 and increases in multiples of 8. The initial IO mapping number of the analog DA starts from 4 and increases in multiples of 4. The allocation of digital IO numbers corresponding to different dial code...
  • Page 48 ZMC408CE Motion Controller Hardware Manual V1.5 When the CAN bus expansion mode is used to expand the pulse axis, ZIO16082M can be selected to expand two pulse axes. These two pulse axes need to be mapped and bound with the axis No., then access.

  • Page 49: Ethercat Bus Expansion

    ZMC408CE Motion Controller Hardware Manual V1.5 ALMRM indicator light is on, please check whether the wiring, resistor and dial setting are correct, and whether the CANIO_ADDRESS command of the controller is set as the master end (32), and whether the CAN communication speed is consistent.

  • Page 50: Ethercat Bus Expansion Resource Mapping

    ZMC408CE Motion Controller Hardware Manual V1.5 EIO expansion module wiring reference example (take ZMC408SCAN as an example): Involved number concepts in above figure are as follows: the bus-related command parameters will use the following numbers: Slot number (slot): The slot number refers to the number of the bus interface on the controller, and the slot number of the EtherCAT bus is 0.
  • Page 51 ZMC408CE Motion Controller Hardware Manual V1.5 The program on the controller can access the resources on the expansion module only through the IO number. The IO number of the EtherCAT bus expansion module is set through the bus command NODE_IO, and the input and output are configured at the same time.
  • Page 52 ZMC408CE Motion Controller Hardware Manual V1.5 AXIS_ADDRESS( axis number )=(slot number<<16)+driver number+1 Example: AXIS_ADDRESS(0)=(0<<16)+0+1 'the first drive on the EtherCAT bus, drive number 0, bound as axis 0 AXIS_ADDRESS(1)=(0<<16)+1+1 'the second drive on the EtherCAT bus, drive number 1, bound as axis 1 If the first node is EIO16084, and EIO16084 is connected to drive, then driver 0 here is the first pulse driver connected to EIO16084, otherwise it is the EtherCAT driver.

  • Page 53: Chapter V Program & Applications

    5.1. ZDevelop Software Usage ZDevelop is a PC-side program development, debugging and diagnostic software for the ZMoiton series motion controllers of Zmotion Technology. Through it, users can easily edit and configure the controller program, quickly develop applications, diagnose system operating parameters in real time, and watch the motion controller. The running program is debugged in real time and supports Chinese and English bilingual environments.
  • Page 54 ZMC408CE Motion Controller Hardware Manual V1.5 Click “File” – “New File”, select file type to build, here select Basic, click “OK”. Double click “AutoRun”, enter task number 0.
  • Page 55 ZMC408CE Motion Controller Hardware Manual V1.5 Edit program program editing window, click “save”, built basic file will be saved under “zpj.” project automatically. “Save all” means all files under this project will be saved. Click “controller – connect”, if no...
  • Page 56 ZMC408CE Motion Controller Hardware Manual V1.5 parameters port address, then click “connect”. Click “Ram/Rom” – “download RAM download ROM”, if it is successful, there is print indication, the same time, program downloaded into controller runs automatically. RAM: it will not...
  • Page 57 ZMC408CE Motion Controller Hardware Manual V1.5 Click “Debug” – “Start/Stop Debug” to call “Task” “Watch” window, because it was downloaded before, here select “Attach the current”. Click “View” – “Scope” to open oscilloscope. Note: ⚫ When opening an project, choose to open the zpj file of the project. If only the Bas file is opened, the program cannot be downloaded to the controller.

  • Page 58: Pc Upper-Computer Program Application

    Mac, Android, and wince, and provides dll libraries in various environments such as vc, c#, vb.net, and labview, as shown in the figure below. PC software programming refers to "ZMotion PC Function Library Programming Manual". The program developed using the PC software cannot be downloaded to the controller, and it is connected to the controller through the dll dynamic library.
  • Page 59 ZMC408CE Motion Controller Hardware Manual V1.5 Select development language “Visual C++” and the select program type “MFC application type”. Select “Based on basic box”, click “next” or “finish” Find function library provided manufacturer. Routine below (64-bit library) Copy all DLL related library files under the above path to the newly created project.
  • Page 60 ZMC408CE Motion Controller Hardware Manual V1.5 zmotion.lib Item". Related header 2) Add static files: libraries and zauxdll2.h, related zmotion.h header files in sequence in the pop-up window. Declare relevant header files and define controller connection handle, so far the project is...

  • Page 61: Chapter Vi Run And Maintain

    ZMC408CE Motion Controller Hardware Manual V1.5 Chapter VI Run and Maintain The correct operation and maintenance of the device can not only guarantee and extend the life cycle of the equipment itself, but also take technical management measures according to the pre-specified plan or the corresponding technical conditions to prevent equipment performance degradation or reduce the probability of equipment failure.

  • Page 62: Common Problems

    ZMC408CE Motion Controller Hardware Manual V1.5 Should be within the range of Whether the device is subjected to vibration resistance vibration or shock impact resistance Keep good ventilation and Is the heat dissipation good heat dissipation The mounting screws should...
  • Page 63 ZMC408CE Motion Controller Hardware Manual V1.5 invalid. and whether the "input" view can watch the signal change of the limit sensor. Check whether the mapping of the limit switch is correct. Check whether the limit sensor is connected to the common terminal of the controller.
  • Page 64 ZMC408CE Motion Controller Hardware Manual V1.5 Check master-slave configuration, communication speed configuration, etc. Check the DIP switch to see if there are multiple expansion modules with the same ID. Use twisted-pair cables, ground the shielding layer, and use dual power supplies for severe interference...

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