Zmotion ZMC460 Manual
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Zmotion ZMC460 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

    ZMC460 Motion Controller User Manual V1.5 Content Chapter I Production Information..................3 1.1. Product Information ..................3 1.2. Function Features ....................3 1.3. System Frame ....................4 1.4. Hardware Installment ..................5 Chapter II Product Specification ..................7 2.1. Basic Specification .................... 7 2.2.
  • Page 6 ZMC460 Motion Controller User Manual V1.5 3.6. AD / DA: Analog Input / Output ............... 25 3.6.1. Analog Output Specification & Wiring ..........26 3.6.2. Basic Usage Method ................27 3.7. U Disk ......................28 3.8. ETHERNET ....................... 28 3.9.

  • Page 7: Chapter I Production Information

    ZMC460 Motion Controller User 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. ZMC4 series supports Zmotion XPLC function, and can be configured and displayed through the network.

  • Page 8: System Frame

    ZMC460 Motion Controller User Manual V1.5 directly drive some kinds of solenoid valves. ◆ Interfaces: EtherCAT, RS232, RS485, U Disk, Ethernet. ◆ Support linear interpolation, any circular interpolation, helical interpolation and spline interpolation of 60 axes at most. ◆ Support electronic cam, electronic gear, position latch, synchronous follow, virtual axis, etc.

  • Page 9: Hardware Installment

    ZMC460 Motion Controller User Manual V1.5 1.4. Hardware Installment The ZMC460 motion controller adopts the horizontal installation method of screw fixing, and each controller should be installed with 4 screws for fastening. → Unit: mm → Installment Hole Diameter: 4.5mm ⚫...
  • Page 10 ZMC460 Motion Controller User Manual V1.5 ⚫ Considering the convenient operation and maintenance of the controller, please do not install the controller in the following places: places where the surrounding ambient temperature exceeds the range of -20° C-60° C places where the ambient humidity exceeds the range of 10%-...

  • Page 11: Chapter Ii Product Specification

    ZMC460 Motion Controller User Manual V1.5 Chapter II Product Specification 2.1. Basic Specification Item Description Model ZMC460 ZMC430 Basic Axes Max Extended Axes Basic Axes Type EtherCAT/ Local pulse axes 24 inputs, 12 outputs, each pulse axis has 1 input and 1...

  • Page 12: Order Information

    ZMC460 Motion Controller User Manual V1.5 2.2. Order Information Model Description 60 axes, point to point, linear, circular, electronic cam, continuous ZMC460 trajectory motion, robotic car instructions. 30 axes, point to point, linear, circular, electronic cam, continuous ZMC430 trajectory motion, robotic car instructions.
  • Page 13 ZMC460 Motion Controller User Manual V1.5 → Interface Description Mark Interface Number Description Power indicator: it lights when power is conducted. Status Indication Light Run indicator: it lights when runs normally Error indicator: lights when runs abnormally RS232 RS232 serial port (port0)

  • Page 14: Work Environment

    ZMC460 Motion Controller User Manual V1.5 2.4. Work Environment Item Parameters Work Temperature -10℃-55℃ Work relative Humidity 10%-95% non-condensing Storage Temperature -40℃～80℃ (not frozen) Storage Humidity Below 90%RH (no frost) Frequency 5-150Hz Displacement 3.5mm(directly install)(<9Hz) vibration Acceleration 1g(directly install)(>9Hz) Direction...

  • Page 15: Chapter Iii Wiring And Communication Configuration

    ZMC460 Motion Controller User Manual V1.5 Chapter III Wiring and Communication Configuration 3.1. Power Input The power supply input adopts a 3Pin (there are all 3 terminals) screw-type pluggable wiring terminal, and the interval (means the gap distance between two ports) should be 3.81mm.

  • Page 16: Rs485, Can Communication Interface

    ZMC460 Motion Controller User Manual V1.5 3.2. RS485, CAN Communication Interface The communication interface adopts a 5Pin screw-type pluggable wiring terminal and the gap spacing between 2 terminals should be 3.81mm. For both RS485 communication and CAN communication, they can be used by connecting the corresponding interface.
  • Page 17 ZMC460 Motion Controller User Manual V1.5 lower communication rate is, and maximum of 100m is recommended. → Wiring Reference Connect 485A and 485B of RS485 to 485A and 485B of the controller correspondingly, and connect the public ends “EGND” of RS485 communication parties together.

  • Page 18: Basic Usage Method

    ZMC460 Motion Controller User 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 19 ZMC460 Motion Controller User Manual V1.5 (3) Please use the "ADDRESS" and "SETCOM" commands to set and view the protocol station number and configured parameters, see "ZBasic Programming Manual" for details. (4) Please use the "CANIO_ADDRESS" command to set the master's "address" and "speed"...

  • Page 20: Rs232 Serial Port

    ZMC460 Motion Controller User Manual V1.5 disordered. 3.3. RS232 Serial Port RS232 is in a standard DB9 male socket and supports MODBUS_RTU protocol and custom communication. → Interface Definition: Terminal Name Type Function 1、4、 Spare Reserved 6、7、8 Input RS232 signal, receive data...
  • Page 21 ZMC460 Motion Controller User Manual V1.5 maximum 10m is recommended. → Wiring Reference: → Wiring Notes: ⚫ The wiring of RS232 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 22: Basic Usage Method

    ZMC460 Motion Controller User Manual V1.5 3.3.2. Basic Usage Method (1) Please follow the above wiring instructions to wiring correctly. (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 23: In Digital Input & High-Speed Latch Port & Single-Ended Encoder

    ZMC460 Motion Controller User Manual V1.5 3.4. IN Digital Input & High-Speed Latch Port & Single- ended Encoder The digital input adopts 3 groups of 10Pin (there are 3 groups of 10 terminals) screw- type pluggable terminals, and the gap distance between terminals should be 3.81mm. In addition, the single-ended encoder and the high-speed latch functions are integrated in digital input signals.

  • Page 24: Digital Input Specification & Wiring

    ZMC460 Motion Controller User Manual V1.5 IN20 Input20 IN21 Input21 IN22 Input22 IN23 Input23 Note: IN0-3 have high-speed latch function, and IN0-11 have single-ended encoder function.  It is necessary to configure single-ended encoder axis 6-9 as local axes compulsively through ...

  • Page 25: Basic Usage Method

    ZMC460 Motion Controller User Manual V1.5 → Wiring Reference → Wiring Note: ⚫ The wiring principle of high-speed digital input IN (0-11) and low-speed digital input IN (12-23) is shown in the figure above. The external signal source can be an optocoupler, a key switch or a sensor, etc., all can be connected as long as the...

  • Page 26: Out: Digital Output, Pwm Terminal, Hardware Comparison Output, Single

    ZMC460 Motion Controller User Manual V1.5 (4) Latch function can be set and opened through “REGIST” instruction, in software, use REG_INPUTS to configure. Please refer to “ZBasic” for details. 3.5. OUT: Digital Output, PWM Terminal, Hardware Comparison Output, Single-ended Pulse The digital output adopts 2 sets of screw-type pluggable terminals with a spacing of 3.81mm, and the PWM, single-ended pulse and hardware comparison output functions...

  • Page 27: Digital Output Specification & Wiring

    ZMC460 Motion Controller User Manual V1.5 speed Output OUT2 Output2 PWM Output 2 PUL7 output External EGND power ground OUT3 Output4 PWM Output 3 DIR7 OUT4 Output5 PWM Output 4 PUL8 OUT5 Output6 PWM Output 5 DIR8 OUT6 Output7 PWM Output 6...
  • Page 28 ZMC460 Motion Controller User Manual V1.5 Respond time to 3μs 80μs 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.

  • Page 29: Basic Usage Method

    ZMC460 Motion Controller User Manual V1.5 provide an external 5V power input, the maximum current is 300mA. 3.5.2. Basic Usage Method (1) Please follow the above wiring instructions to wiring correctly. (2) After powered on, please use any one interface among the three interfaces ETHERNET, RS232 and RS485 to connect to ZDevelop.

  • Page 30: Analog Output Specification & Wiring

    ZMC460 Motion Controller User Manual V1.5 Terminal Name Type Function Analog input terminal AIN(0) Input Analog input terminal AIN(1) Analog output terminal: AOUT(0) Output Analog output terminal: AOUT(1) AGND Public End Analog public end 3.6.1. Analog Output Specification & Wiring →...

  • Page 31: Basic Usage Method

    ZMC460 Motion Controller User Manual V1.5 Please use STP cables, especially in harsh environments, and make sure the ⚫ shielding layer is fully grounded. → Cable Requirements: Shielded Twisted Pair, and the shielded cable is grounded. 3.6.2. Basic Usage Method (1) Please follow the above wiring instructions to wiring correctly.

  • Page 32: U Disk

    ZMC460 Motion Controller User Manual V1.5 3.7. U Disk The ZMC460 motion controller provides a USB communication interface to insert a U disk device, which is used for ZAR program upgrade, controller data import and export, and 3 file executions. Its schematic diagram is shown in the figure below: →...

  • Page 33: Ethercat Bus Interface

    The schematic diagram is as follows: 3.9. EtherCAT Bus Interface ZMC460 motion controller has a 100M EtherCAT communication interface, supports EtherCAT protocol, and connects to EtherCAT driver or EtherCAT expansion module. The pin definition diagram is as follows:...
  • Page 34 ZMC460 Motion Controller User 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 35: Axis Differential Pulse Axis Interface

    ZMC460 Motion Controller User Manual V1.5 reduce interference and to prevent information from being eavesdropped. As shown below: Item Specification Cable type Flexible crossover cable, Category 5e traverse twisted pair Line pairs Isolation cross skeleton Connector Crystal head with iron shell...
  • Page 36 ZMC460 Motion Controller User Manual V1.5 ATYPE parameter. → Interface Definition Interface Signal Description EGND Negative pole of IO 24V power IN24- Digital input, it is recommended to 29/ALM do drive alarm OUT12- Digital output, it is recommended 17ENABLE to do drive enable...

  • Page 37: Axis Interface Signal Specification & Wiring

    ZMC460 Motion Controller User Manual V1.5 Servo or step pulse output + PUL+ (differential signal+) Negative pole of 5V power of pulse/encoder signal Reserved Reserved Reserved Reserved Note:  ALM and ENABLE are recommended to be used as axis IO due to their small drive capacity.
  • Page 38 ZMC460 Motion Controller User Manual V1.5 Frequency ＜8kHz Voltage level DC24V Maximum current +50mA Overcurrent protection Isolation optoelectronic isolation +5V，GND Maximum output current for 5V 50mA EGND Maximum output current for 24V 50mA → Wiring Reference: Reference example of wiring with Panasonic A5/A6 servo driver:...

  • Page 39: Basic Usage Method

    ZMC460 Motion Controller User 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 connect carefully. ...
  • Page 40 ZMC460 Motion Controller User Manual V1.5 (5) Control corresponding motion through “View – Manual”. Refer to BASIC Routine: BASE(0,1) 'select axis 0 and axis 1 ATYPE = 1,1 'set axis 0 and axis as pulse axes UNITS = 1000,1000 'set pulse amount as 1000 pulses...
  • Page 41 ZMC460 Motion Controller User Manual V1.5 SPEED = 10,10 'set axis speed as 10/1000 pulse/s ACCEL = 1000,1000 ‘set axis acceleration as 1000*1000 pulse/s/s FWD_IN = -1,-1 'prohibit using axis positive hardware position limit REV_IN = -1,-1 'prohibit using axis negative hardware position limit...

  • Page 42: Chapter Iv Expansion Module

    ZMC460 Motion Controller User 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 43 ZMC460 Motion Controller User Manual V1.5 → Wiring Note: ZMC460 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 44: Can Bus Expansion Resource Mapping

    ZMC460 Motion Controller User 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 45 ZMC460 Motion Controller User Manual V1.5 command. There are also four speed parameters that can be selected. The communication speed must be consistent with the communication speed of the expansion module that corresponds to the combination value, then they can communicate with each other.
  • Page 46 ZMC460 Motion Controller User 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 47 ZMC460 Motion Controller User Manual V1.5 can be selected to expand two pulse axes. These two pulse axes need to be mapped and bound with the axis No., then access. Extended axes need to perform axis mapping operations, using the AXIS_ADDRESS command to map, and the mapping rules are as follows: AXIS_ADDRESS(axis No.)=(32*0)+ID...

  • Page 48: Ethercat Bus Expansion

    ZMC460 Motion Controller User 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 49: Ethercat Bus Expansion Resource Mapping

    ZMC460 Motion Controller User Manual V1.5 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 50 ZMC460 Motion Controller User Manual V1.5 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. When IO mapping, first check the maximum IO number of the controller itself (including the external IO interface and the interface in the pulse axis), and then use the command to set.
  • Page 51 ZMC460 Motion Controller User Manual V1.5 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...

  • Page 52: Chapter V Program & Application

    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 53 ZMC460 Motion Controller User 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 54 ZMC460 Motion Controller User 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 55 ZMC460 Motion Controller User 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 56 ZMC460 Motion Controller User 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 57: 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 58 ZMC460 Motion Controller User 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 59 ZMC460 Motion Controller User 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 60: Chapter Vi Run And Maintain

    ZMC460 Motion Controller User 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 61: Common Problems

    ZMC460 Motion Controller User 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 62 ZMC460 Motion Controller User 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 63 ZMC460 Motion Controller User 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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