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ZMC306X Motion Controller User Manual V1.5

directly drive some kinds of solenoid valves.

◆

Interfaces: RS232, RS485, U Disk, EtherNET.

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Support up to 12 axes linear interpolation, arbitrary circular interpolation, helical

interpolation and spline interpolation.

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Support electronic cam, electronic gear, position latch, synchronous follow, virtual

axis and other functions.

◆

Support pulse closed loop, pitch compensation and other functions.

◆

Support multi-file and multi-task programming in ZBasic.

◆

A variety of program encryption methods to protect the intellectual property rights of

customers.

◆

Support power failure detection and power failure storage. (It can detect and save

when power-off)

1.3.

System Frame

Summary of Contents for ZMC306X

Page 1: ......

Page 2: ...he ZMC controller software and the introduction and routine of each command please refer to the ZBASIC software manual Information contained in this manual is only for reference Due to improvements in design and functions and other aspects Zmotion Technology reserves the final interpretation Subject to change without notice Pay attention to safety when debugging the machine Please be sure to desig...

Page 3: ...ided into Danger and Caution Failure to operate as required may result in moderate injury minor injury or equipment damage Please keep this guide in a safe place for reading when needed and be sure to hand this manual to the end user Install Danger When the controller is disassembled all external power supplies used by the system should be disconnected before operation otherwise it may cause misop...

Page 4: ...at the insulation distance between cables will not be reduced after the cables are installed on the terminal block Notice Avoid metal shavings and wire ends falling into the hardware circuit board during installation The cable connection should be carried out correctly on the basis of confirming the type of the connected interface It should be confirmed that the cables pressed into the terminals a...

Page 5: ...onfiguration 11 3 1 Power Input 11 3 1 1 Power Specification 11 3 2 RS485 RS422 CAN Communication Interfaces 12 3 2 1 RS485 RS422 CAN Specification Wiring 12 3 2 2 Basic Usage Method 15 3 3 RS232 Serial Port 17 3 3 1 RS232 Communication Interface Specification Wiring 17 3 3 2 Basic Usage 18 3 4 IN Digital Input High Speed Latch Port 19 3 4 1 Digital Input Specification Wiring 21 3 4 2 Basic Usage ...

Page 6: ...Interface Signal Specification Wiring 32 3 9 2 Basic Usage Method 35 Chapter IV Expansion Module 37 4 1 CAN Bus Expansion 37 4 2 CAN Bus Expansion Wiring 37 4 3 CAN Bus Expansion Resource Mapping 39 Chapter V Program Applications 44 5 1 ZDevelop Software Usage 44 5 2 PC Upper Computer Program Application 49 Chapter VI Run and Maintain 52 6 1 Regular Inspection and Maintenance 52 6 2 Common Problem...

Page 7: ...n controllers can be applied in robots SCARA Delta 6 joints electronic semiconductor equipment testing equipment assembly equipment locking equipment soldering machine dispensing equipment non standard equipment printing and packaging equipment textile and garment equipment stage entertainment equipment medical equipment assembly line etc 1 2 Function Features The controller supports 12 axes motio...

Page 8: ...olation Support electronic cam electronic gear position latch synchronous follow virtual axis and other functions Support pulse closed loop pitch compensation and other functions Support multi file and multi task programming in ZBasic A variety of program encryption methods to protect the intellectual property rights of customers Support power failure detection and power failure storage It can det...

Page 9: ... Installment The ZMC306X motion controller is installed horizontally with screws and each controller should be fastened with 4 screws Unit mm Mounting Hole Diameter 4 5mm ZMC304X motion controller has 4 basic axes the installation method is same as ZMC306X ...

Page 10: ...Avoid direct sunlight installation In order to facilitate ventilation and controller replacement 2 3cm should be left between the upper and lower parts of the controller and the installation environment and surrounding components Considering the convenient operation and maintenance of the controller please do not install the controller in the following places a places where the surrounding ambient...

Page 11: ...here are 1 input and 1 output in each one pulse axis Max Extended IO 512 inputs and 512 outputs PWM 2 AD DA 2 general ADs and 2 general DAs 0 10V Max Extended AD DA 128 ADs 64 DAs Pulse Bit 32 Encoder Bit 32 Speed and Acceleration Bit 32 Highest Pulse Frequency 10MHz Motion Buffer of Each Axis 128 Array Space 300000 Program Space 300KByte Flash Space 128MByte Power Supply Input 24V DC input Commun...

Page 12: ...ronic cam ZMC304X 2 4 axes point to point linear electronic cam ZMC304XR ZMC304X full functions Delta robotic arm instructions ZMC306X 6 axes point to point linear circular electronic cam continuous trajectory motion robot structure ZMC306XR ZMC306X full functions 6 joint robotic arm instructions Note ZMC304X has HW version ZMC304 HW and it supports hardware comparison output function please refer...

Page 13: ...lights when power is conducted RUN 1 Run state it lights when runs normally ALM 1 Error state it lights when runs incorrectly RS232 RS232 serial port port0 1 Use MODBUS_RTU protocol RS485 RS485 serial port port1 1 Use MODBUS_RTU protocol RS422 RS422 serial port port2 1 Use MODBUS_RTU protocol ETHERNET Network port 1 Use MODBUS_TCP protocol expand the number of network ports through the ...

Page 14: ... Digital IO output port 12 NPN Leakage type the power is supplied by internal 24V power supply There are 2 high speed outputs OUT0 1 have PWM function AD Analog input port 2 12 bit resolution 0 10V DA Analog output port 2 12 bit resolution 0 10V AXIS Pulse axis interface 6 It includes differential pulse output and differential encoder input 2 4 Work Environment Item Parameters Work Temperature 10 ...

Page 15: ... E 24V and EGND should be 3 81mm This 3Pin terminal is the power supply of the controller Terminal Definition Terminal Name Type Function E 24V Input Positive terminal of DC power input connect positive of power to positive of controller EGND Input Negative terminal of power input FG Earthing Grounding Protect 3 1 1 Power Specification Specification Item Description Voltage DC24V 10 10 The current...

Page 16: ...ential data CANH CAN differential data EGND Communication public end 422TX RS422 send 422TX RS422 send 422RX RS422 receive 422RX RS422 receive 3 2 1 RS485 RS422 CAN Specification Wiring The RS485 serial port supports the MODBUS_RTU protocol and custom communication mainly including 485A 485B and public end The RS422 serial port supports the MODBUS_RTU protocol and custom communication mainly inclu...

Page 17: ...tion distance is the 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 Connect the CANL and CANH of the standard CAN module to the CANL and CANH of the other side correspondingly And public ends of the CAN bus commu...

Page 18: ...point to point connection the star topology structure cannot be used When the use environment is ideal and there are no many nodes 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...

Page 19: ...rounded 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 RS485 to connect to ZDevelop 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_AD...

Page 20: ...ress and speed of the slave station expansion module according to the manual of the slave station 7 After all the settings are completed restart the power supply of all stations to establish communication 8 Note that the speed settings of each node on the CAN bus must be consistent and the address settings cannot cause conflicts otherwise the ALM alarm light will be on and the communication establ...

Page 21: ...signal send data 5 EGND Output Negative pole output of 5V power and output for the public end 9 E5V Output Positive pole output of 5V power maximum is 300mA 3 3 1 RS232 Communication Interface Specification Wiring Specification Item RS232 Maximum Communication Rate bps 115200 Terminal Resistor No Topology Structure Connect correspondingly 1 to 1 The number of nodes can be extended 1 Communication ...

Page 22: ...ease be sure to connect the public ends of each communication node to prevent the communication chip from burning out Please use STP especially in bad environments and make sure the shielding layer is fully grounded Cable Requirements Shielded Twisted Pair and the shielded cable is grounded 3 3 2 Basic Usage 1 Please follow the above wiring instructions to wiring correctly 2 After powered on pleas...

Page 23: ...to their respectively instructions correctly set the relevant parameters of the third party equipment to match the parameters of each node 5 When all is configured it can start to do communicating 6 Communication data of RS232 RS485 can be directly viewed through ZDevelop Controller State the Controller CommunicationInfo 3 4 IN Digital Input High Speed Latch Port The digital input adopts 3 groups ...

Page 24: ... speed input Input 2 IN3 Input 3 IN4 Input 4 IN5 Input 5 IN6 Input 6 IN7 Input 7 EGND IO public end EGND IO public end IN8 NPN type low speed input Input 8 IN9 Input 9 IN10 Input 10 IN11 Input 11 IN12 Input 12 IN13 Input 13 IN14 Input 14 IN15 Input 15 EGND IO public end EGND IO public end IN16 NPN type low speed input Input 16 IN17 Input 17 IN18 Input 18 IN19 Input 19 IN20 Input 20 IN21 Input 21 I...

Page 25: ... 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 Wiring Reference Wiring Note The wiring principle of high speed digital input IN 0 1 and low speed digital input IN 2 23 is shown in the figure above The external si...

Page 26: ...tly 2 After powered on please select any one interface among the three interfaces ETHERNET RS232 and RS485 to connect to ZDevelop 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 Pl...

Page 27: ... end OUT8 NPN Leakage type low speed output Output 8 OUT9 Output 9 OUT10 Output 10 OUT11 Output 11 Note The E5V power output port is used for PWM or common anode wiring of single ended axis It is not recommended for other purposes due to lower power OUT0 1 have the function of PWM When PWM is off it is general output 3 5 1 Digital Output Specification Wiring Specification Item High Speed Output OU...

Page 28: ...will be obviously affected by the external load circuit and the output frequency should not be set too high in the application Wiring Reference Wiring Note The wiring principle of high speed digital output OUT 0 1 and low speed digital output OUT 2 11 is shown in the figure above The external signal receiving end can be an optocoupler or a relay or solenoid valve all can be connected as long as th...

Page 29: ...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 3 Open or close output port directly through OP command also it can be opened or closed through ZDevelop View Op Please refer to ZBasic for details 4 The PWM function set the frequency and duty cycle through PWM_FREQ and...

Page 30: ...lic end of this analog AD0 Input Analog input terminal AIN 0 AD1 Analog input terminal AIN 1 3 6 1 Analog Output Specification Wiring Specification Item AD 0 1 DA 0 1 Resolution 12 bit 12 bit Data range 0 4095 0 4095 Signal range 0V 10V input 0V 10V output Data refresh 1kHz 1kHz Voltage input impedance output load 300KΩ voltage input impedance 10KΩ voltage output load Wiring Reference ...

Page 31: ...rements 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 2 After powered on please use any one interface among the three interfaces ETHERNET RS232 and RS485 to connect to ZDevelop 3 Analog input voltage can be read through AIN command and corresponding analog voltage can be output through AOUT comman...

Page 32: ...data importing and exporting file 3 executing etc Its schematic diagram is shown in the figure below Specification Item USB2 0 Highest Communication Ratio 12Mbps Max Output Current of 5V 500mA Whether Isolates No 3 8 ETHERNET ZMC306X motion controller has a 100M network port and it supports MODBUS_TCP protocol and custom communication the default IP address is 192 168 0 11 The pin definition is as...

Page 33: ...er through an Ethernet cable and then use interchanger to connect to other devices then multi point connection can be achieved The schematic diagram is as follows 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 ...

Page 34: ...the stability of communication please fix the cables with cable ties When disassembling press the tail mechanism of the crystal head and pull out the connector and the module in a horizontal direction Please use tube type pre insulated terminals and cables with appropriate wire diameters to connect the user terminals 3 9 AXIS Differential Pulse Axis Interface This product provides 6 local differen...

Page 35: ...DIR Servo or step direction output 10 GND Negative pole of 5V power of pulse encoder signal 11 PUL Servo or step pulse output 12 Reserved Reserved 13 GND Negative pole of 5V power of pulse encoder signal 14 OVCC Positive pole of IO 24V power 15 Reserved Reserved 16 Reserved Reserved 17 EA Encoder differential input signal A 18 EB Encoder differential input signal B 19 EZ Encoder differential input...

Page 36: ...em Description PUL DIR Signal type Differential output signal Voltage range 0 5V Maximum frequency 10MHz EA EB EZ Signal type Differential input signal Voltage range 0 5V Maximum frequency 5MHz IN24 29 Input method NPN leak type it is triggered when low electric level is input Frequency 5kHz Impedance 6 8KΩ Voltage level DC24V The voltage to open 10 5V The voltage to close 10 7V Minimal current 1 ...

Page 37: ...anual V1 5 Overcurrent protection No 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 38: ...troller 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 39: ...ces ETHERNET RS232 default parameter it can be connected directly and RS485 default parameters it can be connected directly but for hardware adapter head is needed to connect to ZDevelop 3 Set axis parameters such as ATYPE UNITS SPEED ACCEL FWD_IN REV_IN etc 4 There are many parameters related to pulse axis they can be set and checked through relative instructions please see axis parameter and axi...

Page 40: ...s 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 FWD_IN 1 1 prohibit using axis positive hardware position limit REV_IN 1 1 prohibit using axis negative hardware position limit MOVE 10 AXIS 0 axis 0 moves distance of 10 1000 pulses in positive MOVE 20 AXIS 0 axis 0 moves distance of 20 1000 pulses in negative ...

Page 41: ...ds to connect one 120 ohm resistor externally When connecting multiple CAN expansion modules you only need to dial ON for the eighth digit of the last expansion module which means please do not dial bit 8 of other modules 4 2 CAN Bus Expansion Wiring The ZIO expansion module is powered by the dual power supply Except the main power supply an additional IO power supply is required to supply indepen...

Page 42: ...are 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 When connecting multiple ZIO expansion modules on the CAN bus a 120 ohm resistor needs to be connected in parallel between the CANL and CANH terminals for the ZIO expansion module that is with 8 digit dialing codes the terminal resistor can be rea...

Page 43: ...nvalid It needs to be powered on again to take effect Dial 1 4 to select the CAN address and the controller sets the IO number range of the corresponding expansion module according to the CAN DIP address When each is dialed as OFF the corresponding value is 0 when it is ON it corresponds to a value of 1 and the address combination value dial 4 8 dial code 3 4 dial code 2 2 dial code 1 Dial code 5 ...

Page 44: ...t number in IN and OP must include IO point in the axis interface use the bit 1 4 to set the ID so as to determine the number range of IO to be expanded If the controller itself contains 28 INs and 16 OPs then the starting address set by the first extended board should exceed the maximum value of 28 According to below rule the dial code should be set to the combination value 1 binary combination v...

Page 45: ...es of 4 The allocation of digital IO numbers corresponding to different dial code IDs is as follows DIP 1 4 combination value Starting AD number End AD number Starting DA number End DA number 0 8 15 4 7 1 16 23 8 11 2 24 31 12 15 3 32 39 16 19 4 40 47 20 23 5 48 55 24 27 6 56 63 28 31 7 64 71 32 35 8 72 79 36 39 9 80 87 40 43 10 88 95 44 47 11 96 103 48 51 12 104 111 52 55 13 112 119 56 59 14 120 ...

Page 46: ...tual axis AXIS_ADDRESS 6 1 32 0 ZCAN expansion module ID 1 axis 0 is mapped to axis 6 ATYPE 6 8 ZCAN extended axis type pulse direction stepping or servo UNITS 6 100 0 pulse equivalent 1000 SPEED 6 100 speed 100uits s ACCEL 6 1000 acceleration 1000units s 2 MOVE 100 AXIS 6 extended axis movement 100units Extended resource viewing According to the CAN connection after the power is turned on and the...

Page 47: ...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 48: ...ontroller 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 ZBasic ZPLC and ZHMI can run multi tasks and ZBasic can run multi tasks and can be mixed with ZPLC and ZHMI Step Operations Display Interface 1 Open ZDevelop click File N...

Page 49: ...ZMC306X Motion Controller User Manual V1 5 2 Click File New File select file type to build here select Basic click OK 3 Double click AutoRun enter task number 0 ...

Page 50: ... basic file will be saved under zpj project automatically Save all means all files under this project will be saved 5 Click controller connect if no controller select connect to simulator Then connect to controller window will pop up you can select serial port or net port to connect select matched serial port ...

Page 51: ...m download RAM download ROM if it is successful there is print indication at the same time program is downloaded into controller and runs automatically RAM it will not save when power off ROM it will save data when power off and when the program is connected to controller again running according to task number ...

Page 52: ...ent 8 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 When the project is not created only the Bas file cannot be downloaded to the controller The number 0 in automatic operation represents the task number and the program ...

Page 53: ...dows linux 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 The dll library needs...

Page 54: ... basic box click next or finish 4 Find C function library provided by manufacturer Routine is below 64 bit library 5 Copy all DLL related library files under the above path to the newly created project 6 Add a static library and related header files to the project Static library zauxdll lib 1 Right click the header file first and then select Add Existing ...

Page 55: ...on lib Related header files zauxdll2 h zmotion h Item 2 Add static libraries and related header files in sequence in the pop up window 7 Declare the relevant header files and define the controller connection handle so far the project is newly created ...

Page 56: ... of the device can be appropriately adjusted according to the surrounding environment to make it work within the specified standard environment Check item Check content Inspection standards power supply Check whether the voltage is rated DC 24 V 10 10 surroundings Whether the ambient temperature is within the specified range when installed in the cabinet the temperature inside the cabinet is the a...

Page 57: ...ing Whether the cable is damaged aged cracked The cable must not have any abnormal appearance 6 2 Common Problems Problems Suggestions Motor does not rotate 1 Check whether the ATYPE of the controller is correct 2 Check whether hardware position limit software position limit alarm signal work and whether axis states are normal 3 Check whether motor is enabled successfully 4 Confirm whether pulse a...

Page 58: ...IO board POWER led is ON RUN led is OFF 1 Check whether the power of the power supply is sufficient At this time it is best to supply power to the controller alone and restart the controller after adjustment 2 Check whether the ALM light flickers regularly hardware problem RUN led is ON ALM led is ON 1 Program running error please check ZDevelop error code and check application program Fail to con...

Page 59: ...can be checked and captured after connection through serial port 3 When net port led is off please check wiring 4 Check whether controller power led POWER and running indicator led RUN are ON normally 5 Check whether the cable is good quality change one better cable to try again 6 Check whether controller IP conflicts with other devices 7 Check whether controller net port channel ETH are all occup...

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