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Zmotion ZMC004WEA-V2 User Manual
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Zmotion ZMC004WEA-V2 User Manual

Pulse + ethercat motion controller
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Summary of Contents for Zmotion ZMC004WEA-V2

  • 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: Safety Statement

    ⚫ 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

    ZMC004WEA-V2 Motion Controller User Manual V1.6.0 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 ..................6 Chapter II Product Specification ..................8 2.1. Basic Specification .................... 8 2.2.
  • Page 6 ZMC004WEA-V2 Motion Controller User Manual V1.6.0 Chapter IV Expansion Module ................... 35 4.1. CAN Bus Expansion ..................35 4.1.1. CAN Bus Expansion Wiring..............35 4.1.2. CAN Bus Expansion Resource Mapping ..........37 4.2. EtherCAT Bus Expansion ................. 41 4.2.1. EtherCAT Bus Expansion Wiring ............41 4.2.2.

  • Page 7: Chapter I Production Information

    4 axes, but 6 axes can be expanded to achieve some simple trajectory control requirements, such as, linear interpolation, circular interpolation, helical interpolation, etc. ZMC004WEA-V2 economical multi-axis motion controllers can be applied in pulse applications within 6 axes, electronic semiconductor equipment (testing equipment, assembly equipment, locking equipment, soldering machine), dispensing equipment, assembly line, etc.
  • Page 8 ZMC004WEA-V2 Motion Controller User Manual V1.6.0 ◆ Interfaces: EtherCAT, RS232, RS485. ◆ Support up to 6 axes linear interpolation, arbitrary circular interpolation, helical interpolation, and spline interpolation. ◆ Support electronic cam, electronic gear, position latch, synchronous follow, virtual axis, and other functions.

  • Page 9: System Frame

    ZMC004WEA-V2 Motion Controller User Manual V1.6.0 1.3. System Frame --Connect EtherCAT to bus drive-- --Connect EtherCAT (as EtherNET) to bus drive--...

  • Page 10: Hardware Installment

    ZMC004WEA-V2 Motion Controller User Manual V1.6.0 1.4. Hardware Installment The ZMC004WEA-V2 motion controller is installed horizontally with screws, and each controller should be fastened with 4 screws. → Unit: mm → Mounting Hole Diameter 4.5mm Non-professionals are strictly prohibited to operate. Specifically, ⚫...
  • Page 11 ZMC004WEA-V2 Motion Controller User Manual V1.6.0 ⚫ 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 -10° C- 55° C...

  • Page 12: Chapter Ii Product Specification

    ZMC004WEA-V2 Motion Controller User Manual V1.6.0 Chapter II Product Specification 2.1. Basic Specification Item Description Model ZMC004WEA-V2 ZMC004BEA-V2 Basic Axes Max Extended Axes Array space 16000 2400 Flash space 8MByte 2MByte Type of Basic Axes EtherCAT/local pulse axes/encoder axes Digital IO There are 16 inputs and 16 outputs.

  • Page 13: Interface Definition

    ZMC004WEA-V2 Motion Controller User Manual V1.6.0 interpolation motion. 3 axes, point to point, electronic cam, linear, circular, continuous ZMC003WEA-V2 interpolation motion. 4 axes, point to point, electronic cam, linear, circular, continuous ZMC004BEA-V2 interpolation motion. 3 axes, point to point, electronic cam, linear, circular, continuous ZMC003BEA-V2 interpolation motion.
  • Page 14 ZMC004WEA-V2 Motion Controller User Manual V1.6.0 → Interface Description Mark Interface Number Description Power state: it lights when power is conducted. The led that indicates the current state. Run state: it lights when runs normally Error state: it lights when runs incorrectly...

  • Page 15: Work Environment

    ZMC004WEA-V2 Motion Controller User Manual V1.6.0 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 16: Chapter Iii Wiring, Communication Configuration

    ZMC004WEA-V2 Motion Controller User Manual V1.6.0 Chapter Wiring, Communication Configuration 3.1. Power Input, CAN Communication Interface The power supply input adopts a 5Pin (there are all 5 terminals) screw-type pluggable wiring terminal, and the interval (means the gap distance between two ports) should be 5.08mm.

  • Page 17: Power Specification

    ZMC004WEA-V2 Motion Controller User Manual V1.6.0 recommended to use the same power supply, or use one power supply that can provide 2 isolated 24V outputs. And please note that main power and IO power correspond to different indication led, when the LED is ON, it can be used normally, when it is off, please check the power wiring.

  • Page 18: Wiring Reference

    ZMC004WEA-V2 Motion Controller User Manual V1.6.0 → Wiring Reference Connect the CANL and CANH of the standard CAN module to the CANL and CANH of the other side correspondingly (CANL to CAHL, CANH to CANH). And public ends of the CAN bus communication both parties are connected together.

  • Page 19: Cable Requirements

    ZMC004WEA-V2 Motion Controller User Manual V1.6.0 It should be noted that the equipment grounding (chassis) on the entire line must be ⚫ good, and the grounding of the chassis should be connected to the standard factory ground pile. → Cable Requirements: Twisted pair shielded wire, and shielded cable grounded.

  • Page 20: Rs232A Serial Port

    ZMC004WEA-V2 Motion Controller User Manual V1.6.0 3.2. RS232A Serial Port RS232A is in one standard DB9 male socket and supports MODBUS_RTU protocol and custom communication. → Interface Definition: Terminal Name Type Function 1, 4, 6, 7, 8 Spare Reserved 232A-RXD...
  • Page 21 ZMC004WEA-V2 Motion Controller User Manual V1.6.0 Maximum Communication Rate (bps) 115200 Terminal Resistor Topology Structure Connect correspondingly (1 to 1) The number of nodes can be extended The Longer communication distance is, Communication Distance the lower communication rate is, maximum 5m is recommended.

  • Page 22: Basic Usage Method

    ZMC004WEA-V2 Motion Controller User Manual V1.6.0 3.2.2. 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 are default parameters, then it can be connected directly) and RS485 (there are default parameters, then it can be connected directly, but for hardware, adapter head is needed) to connect to ZDevelop.

  • Page 23: Rs232B/Rs485 Serial Port

    ZMC004WEA-V2 Motion Controller User Manual V1.6.0 3.3. RS232B/RS485 Serial Port RS232B and RS485 are in a standard DB9 male socket and support MODBUS_RTU protocol and custom communication. → Interface Definition: Terminal Name Type Function 1, 6, 8, 9 Spare Reserved...

  • Page 24: Rs232B/Rs485 Serial Port Communication Specification & Wiring

    ZMC004WEA-V2 Motion Controller User Manual V1.6.0 3.3.1. RS232B/RS485 Serial Port Communication Specification & Wiring → Specification Item RS232B (port 1) RS485 (port 2) Max Communication Rate 115200 (bps) 115200 (bps) Terminal Resistor Connect correspondingly Daisy chain connection Topology (one to one)

  • Page 25: Basic Usage Method

    ZMC004WEA-V2 Motion Controller User Manual V1.6.0 connecting to a computer. As above, the daisy chain topology is used for RS485 (port 2) wiring, so the star ⚫ topology cannot be used. When the use environment is ideal and there are few nodes, the branch structure can also be considered.

  • Page 26: In Digital Input & Latch Port & Single-Ended Encoder

    ZMC004WEA-V2 Motion Controller User Manual V1.6.0 (3) Please use the "ADDRESS" and "SETCOM" commands to set and view the protocol station No. and configured parameters, see "ZBasic Programming Manual" for details. (4) According to their respectively instructions, correctly set the relevant parameters of the third-party equipment to match the parameters of each node.

  • Page 27: Digital Input Specification & Wiring

    ZMC004WEA-V2 Motion Controller User Manual V1.6.0 Input 0 Latch Input 1 Input 2 Input 3 NPN type, low- Input 4 speed input Input 5 Input 6 Input 7 EGND IO Public end EGND Input 8 Input 9 IN10 NPN type, low-...

  • Page 28: Encoder Wiring

    ZMC004WEA-V2 Motion Controller User Manual V1.6.0 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 IO power supply (E24V port) is 24V.

  • Page 29: Basic Usage Method

    ZMC004WEA-V2 Motion Controller User Manual V1.6.0 → Wiring Note: The wiring principle of high-speed digital input IN (14-15) and low-speed digital input ⚫ IN (0-13) 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 requirements on output of electric level can be achieved.

  • Page 30: Digital Output Specification & Wiring

    ZMC004WEA-V2 Motion Controller User Manual V1.6.0 → Terminal Definition Terminal Name Type Function 1 Function 2 E24V power ground / IO EGND public end E24V IO power input, E24V OUT0 Output 0 OUT1 Output 1 OUT2 Output 2 NPN Leakage...
  • Page 31 ZMC004WEA-V2 Motion Controller User Manual V1.6.0 Item High Speed Out (OUT8-15) Low Speed Out (OUT0-7) Output mode NPN leakage type, it is 0V when outputs Frequency ＜400kHz ＜8kHz Voltage level DC24V DC24V Max output current +300mA +300mA Max leakage 25μA 25μA...

  • Page 32: Basic Usage Method

    ZMC004WEA-V2 Motion Controller User Manual V1.6.0 → Pulse Wiring Here, use OUT14 and OUT15 to connect to driver, it only supports single-ended wiring, differential connection is invalid. → Wiring Note: The wiring principle of high-speed digital output OUT (8-15) and low-speed digital ⚫...

  • Page 33: Ad/Da Analog Input/Output

    ZMC004WEA-V2 Motion Controller User Manual V1.6.0 (2) After powered on, please use any one interface among the three interfaces ETHERNET, RS232 and RS485 to connect to ZDevelop. (3) Open or close output port directly through “OP” command, also, it can be opened or closed through “ZDevelop/View/Op”.

  • Page 34: Basic Usage Method

    ZMC004WEA-V2 Motion Controller User Manual V1.6.0 Signal range 0-10V output 0-10V input Data refresh ratio 1KHz 1KHz Voltage input impedance / >10KΩ (voltage output 300KΩ (voltage input output load load) impedance) → Wiring Reference → Wiring Note: The analog input/output wiring method is as shown in the figure above, and the ⚫...

  • Page 35: Ethercat Bus Interface / Ethernet

    “ZDevelop/View/AD/DA”. Please refer to “ZBasic” for details. 3.7. EtherCAT Bus Interface / Ethernet ZMC004WEA-V2 motion controller has a 100M EtherCAT communication interface, and it supports EtherCAT protocol. In addition, EtherCAT driver or EtherCAT expansion module can be connected. Also, it can be ethernet to communicate with host computer, and supports MODBUS_TCP protocol and custom communication.

  • Page 36: Ethernet Wiring

    ZMC004WEA-V2 Motion Controller User Manual V1.6.0 → 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 37 ZMC004WEA-V2 Motion Controller User Manual V1.6.0 → Communication Cable Requirements Both ETHERNET communication interface and EtherCAT communication interface adopt standard Ethernet RJ45 interface. The network cable adopts Category 5e STP, and the crystal head has a metal shell to reduce interference and to prevent information from being eavesdropped. As shown below:...
  • Page 38 ZMC004WEA-V2 Motion Controller User Manual V1.6.0 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 ⚫ interface until it makes a "click" sound (kada).

  • Page 39: Chapter Iv Expansion Module

    ZMC004WEA-V2 Motion Controller User Manual V1.6.0 Chapter IV Expansion Module The controller can expand digital IO, analog IO, pulse axis and other resources through CAN bus or EtherCAT bus. That is, it can use together with ZIO series CAN expansion modules, EIO series EtherCAT expansion modules, or ZMIO310 series vertical expansion modules.
  • Page 40 ZMC004WEA-V2 Motion Controller User Manual V1.6.0 → Wiring Note: ZMC004WEA-V2 controller uses the dual power, and ZIO expansion module also  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 41: Can Bus Expansion Resource Mapping

    ZMC004WEA-V2 Motion Controller User Manual V1.6.0 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 42 ZMC004WEA-V2 Motion Controller User Manual V1.6.0 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. The factory default communication speed is 500 KBPS on both sides, there is no need to set this, unless you need to change the speed.
  • Page 43 ZMC004WEA-V2 Motion Controller User Manual V1.6.0 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 44 ZMC004WEA-V2 Motion Controller User Manual V1.6.0 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 'the local axis interface of the expansion module AXIS 0 AXIS_ADDRESS(axis No.)=(32*1)+ID...

  • Page 45: Ethercat Bus Expansion

    ZMC004WEA-V2 Motion Controller User Manual V1.6.0 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. 4.2. EtherCAT Bus Expansion The EIO expansion modules and ZMIO310-ECAT are expansion modules used by the EtherCAT bus controller.
  • Page 46 ZMC004WEA-V2 Motion Controller User Manual V1.6.0 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 47: Ethercat Bus Expansion Resource Mapping

    ZMC004WEA-V2 Motion Controller User Manual V1.6.0 4.2.2. EtherCAT Bus Expansion Resource Mapping → IO Mapping: 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 48 ZMC004WEA-V2 Motion Controller User Manual V1.6.0 command to map the axis number, and the axis mapping also needs to pay attention to the axis number of the entire system cannot be repeated. The mapping syntax of the EIO series extended axis is the same as that of the bus driver.

  • Page 49: 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 50 ZMC004WEA-V2 Motion Controller User Manual V1.6.0 Click “File” – “New File”, select file type to build, here select Basic, click “OK”. Double click “AutoRun”, enter task number 0.
  • Page 51 ZMC004WEA-V2 Motion Controller User Manual V1.6.0 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 52 ZMC004WEA-V2 Motion Controller User Manual V1.6.0 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 53 ZMC004WEA-V2 Motion Controller User Manual V1.6.0 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 54: 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 55 ZMC004WEA-V2 Motion Controller User Manual V1.6.0 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 56 ZMC004WEA-V2 Motion Controller User Manual V1.6.0 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 57: Chapter Vi Run And Maintain

    ZMC004WEA-V2 Motion Controller User Manual V1.6.0 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 58: Common Problems

    ZMC004WEA-V2 Motion Controller User Manual V1.6.0 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 59 ZMC004WEA-V2 Motion Controller User Manual V1.6.0 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 60 ZMC004WEA-V2 Motion Controller User Manual V1.6.0 expansion modules with the same ID. Use twisted-pair cables, ground the shielding layer, and use dual power supplies for severe interference (the main power supply of the expansion module and the IO power supply are separately powered) Check IP address of PC, it needs to be at the same segment with controller IP address.

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