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ZMC460 Motion Controller User Manual V1.5

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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 temperature exceeds

the range of -20° C-60° C

b)

places where the ambient humidity exceeds the range of 10%-

95% (non-condensing)

c)

places with corrosive gases and flammable gases

d)

places with many conductive powders such as dust and iron

powder, oil mist, salt, and organic solvents

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Summary of Contents for ZMC460

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: ...Power Input 11 3 1 1 Power Specification 11 3 2 RS485 CAN Communication Interface 12 3 2 1 RS485 CAN Communication Specification Wiring 12 3 2 2 Basic Usage Method 14 3 3 RS232 Serial Port 16 3 3 1 RS232 Communication Interface Specification Wiring 16 3 3 2 Basic Usage Method 18 3 4 IN Digital Input High Speed Latch Port Single ended Encoder 19 3 4 1 Digital Input Specification Wiring 20 3 4 2 Bas...

Page 6: ...n Wiring 33 3 10 2 Basic Usage Method 35 Chapter IV Expansion Module 38 4 1 CAN Bus Expansion 38 4 1 1 CAN Bus Expansion Wiring 38 4 1 2 CAN Bus Expansion Resource Mapping 40 4 2 EtherCAT Bus Expansion 44 4 2 1 EtherCAT Bus Expansion Wiring 44 4 2 2 EtherCAT Bus Expansion Resource Mapping 45 Chapter V Program Application 48 5 1 ZDevelop Software Usage 48 5 2 PC Upper Computer Program Application 5...

Page 7: ...ler 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 Motion control of up to 60 axes Pulse output mo...

Page 8: ...pport electronic cam electronic gear position latch synchronous follow virtual axis etc Support hardware comparison output HW_PSWITCH2 hardware timer precision output in motion Support pulse closed loop pitch compensation and other functions Multi file and multi task programming in ZBasic A variety of program encryption methods to protect the intellectual property rights of customers Support power...

Page 9: ...onals 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 Before installation please ensure that the product is powered off Do not disassemble the module otherwise the machine may be damaged Avoid direct sunlight installation In order to facilitate ventilation...

Page 10: ...troller in the following places a places where the surrounding ambient temperature exceeds the range of 20 C 60 C b places where the ambient humidity exceeds the range of 10 95 non condensing c places with corrosive gases and flammable gases d places with many conductive powders such as dust and iron powder oil mist salt and organic solvents ...

Page 11: ...ch pulse axis has 1 input and 1 output Max Extended IO 4096 inputs 4096 outputs PWM 12 AD DA 2 general ADs and 2 general DAs 0 10V Max Extended AD DA 1000 ADs 1000 DAs Pulse Bit 64 Encoder Bit 64 Speed Acceleration Bit 64 Pulse Max Frequency 10MHz Motion Axis Buffer 4096 Array Space 320000 Program Space 32MByte Flash Space 256MByte Power Supply Input 24V DC input Communication Interfaces RS232 RS4...

Page 12: ... continuous trajectory motion robotic car instructions ZMC430 30 axes point to point linear circular electronic cam continuous trajectory motion robotic car instructions Except for the axis resources in the function description in the form above the above models have the same resources so you can refer to this manual 2 3 Interface Definition ...

Page 13: ...erchanger the number of net port channels can be checked through port default IP address id 192 168 0 11 UDISK U disk interface 1 Insert U disk equipment E 24V Main power 1 24V DC power supplies for controller CAN CAN bus interface 1 Connect CAN expansion module and CAN equipment of other standards IN Digital IO input 24 Leakage type internal 24V supply power 12 high speed inputs IN0 3 have latch ...

Page 14: ...Humidity 10 95 non condensing Storage Temperature 40 80 not frozen Storage Humidity Below 90 RH no frost vibration Frequency 5 150Hz Displacement 3 5mm directly install 9Hz Acceleration 1g directly install 9Hz Direction 3 axial direction Shock collide 15g 11ms half sinusoid 3 axial direction Degree of Protection IP20 ...

Page 15: ... distance between two ports should be 3 81mm This 3Pin terminal is the power supply of the controller Terminal Definition Terminal Name Type Function EARTH Connect to ground Case Protection EGND Input Negative of DC input E 24V Input Positive of DC input 3 1 1 Power Specification Specification Item Description Voltage DC24V 10 10 The current to open 0 5A The current to work 0 4A Anti reverse conne...

Page 16: ...erential data 3 2 1 RS485 CAN Communication Specification Wiring The RS485 serial port supports the MODBUS_RTU protocol and custom communication mainly including 485A 485B and public end The CAN interface of the controller adopts the standard CAN communication protocol which mainly includes three ports CANL CANH and the public end And it can connect CAN expansion modules and other standard CAN dev...

Page 17: ...ies 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 communication both parties are connected together In CAN bus left and right sides connect a 120Ω resistor respectively please see below graphic Wiring Notes As above the daisy chain topology is used for wiring the star topology structure cannot be ...

Page 18: ... layer is fully grounded When on site wiring pay attention to make the distance between strong current and weak current it is recommended for the distance to be more than 20cm 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 Shielded Twisted Pair and th...

Page 19: ...uitively and refer to the ZBasic Programming Manual for details 5 According to their respectively instructions correctly set the relevant parameters of the third party equipment to match the parameters of each node 6 Correctly set the address 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 ...

Page 20: ...TXD Output RS232 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...

Page 21: ...als and it is recommended to use a double female head cross line when connecting to a computer Please 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 ...

Page 22: ...ut for hardware adapter head is needed 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 According 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 ca...

Page 23: ...nction 1 Function 2 Function 3 EGND External power ground EGND IN0 NPN leakage type high speed input Input0 High speed latch A EA6 IN1 Input1 High speed latch B EB6 IN2 Input2 High speed latch C EZ6 IN3 Input3 High speed latch D EA7 IN4 Input4 EB7 IN5 Input5 EZ7 IN6 Input6 EA8 IN7 Input7 EB8 EGND External power ground EGND IN8 NPN leakage type high speed input Input8 EZ8 IN9 Input9 EA9 IN10 Input1...

Page 24: ...nput Specification Wiring Specification Item High Speed Input IN0 11 Low Speed Input IN12 23 Input mode NPN leakage type the input is triggered when there is low electric level Frequency 100kHz 5kHz Impedance 3 3KΩ 4 7KΩ Voltage level DC24V DC24V 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 Isol...

Page 25: ...t the EGND port on the power supply to the COM terminal of the external input device If the signal area power supply of the external device and the power supply of the controller are in the same power supply system this connection also can be omitted 3 4 2 Basic Usage Method 1 Please follow the above wiring instructions for correct wiring 2 After power on please use any of the three interfaces ETH...

Page 26: ...ngle 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 are integrated in digital output signals Wiring Definition Terminal Name Type Function 1 Function 2 Function 3 Function 4 EGND External power ground E5V 5V power output max 300mA OUT0 NPN high Output0 PWM Output 0 Hardw...

Page 27: ...used for PWM or single ended axis common anode wiring It is not recommended for other purposes due to lower power OUT0 11 have the functions of PWM single ended pulse and hardware comparison output when PWM is off it is low speed output Single ended pulse axis 6 11 need to be configured as local axes compulsively through AXIS_ADDRESS when ATYPE 0 they are general output 3 5 1 Digital Output Specif...

Page 28: ...Reference Wiring Note The wiring principle of high speed digital output OUT 0 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 the input current does not exceed 300mA For the connection of the public end please connect the EGND port on the power supply to the negative pole of the DC power supply of ...

Page 29: ...lop 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 PWM_DUTY Please refer to ZBasic for details 5 Hardware comparison output can be set and opened through HW_PSWITCH2 Please refer to ZBasic for details 3 6 AD DA Analog Input Ou...

Page 30: ...End Analog public end 3 6 1 Analog Output Specification Wiring Specification Item DA 0 1 AD 0 1 Resolution 12 bit 12 bit Data range 0 4095 0 4095 Signal range 0 10V output 0 10V input Data refresh ratio 1KHz 1KHz Load impedance 1KΩ voltage output load 40KΩ voltage input impedance Wiring Reference Wiring Note The analog input output wiring method is as shown in the figure above and the external loa...

Page 31: ...asic 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 command also data of each channel can be checked through ZDevelop View AD DA P...

Page 32: ...a import and export and 3 file executions Its schematic diagram is shown in the figure below Specification Item USB2 0 Max Communication Ratio 12Mbps Max Output Current of 5V 500mA Whether Isolates No 3 8 ETHERNET ZMC460 motion controller has a 100M network port supports MODBUS_TCP protocol and custom communication and the default IP address is 192 168 0 11 The pin definition diagram is as follows...

Page 33: ... also be connected to the interchanger through an Ethernet cable and connected to other devices through the interchanger to realize multi point connection 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 diagra...

Page 34: ...r topology Transfer media Cable Transfer distance It is less than 100M between 2 nodes Process data Maximum 1486 bytes of one single frame Synchronization shaking of two slave stations 1us Refresh 1000 digital input and output about is 30us 16 servo axes is about 100us Communication Cable Requirements Both ETHERNET communication interface and EtherCAT communication interface adopt standard Etherne...

Page 35: ...l it makes a click sound kada In order to ensure 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 10 AXIS Differential Pulse Axi...

Page 36: ...V power of pulse encoder signal 8 Reserved Reserved 9 DIR Servo or step directional output differential signal 10 GND Negative pole of 5V power of pulse encoder signal 11 PUL Servo or step pulse output differential signal 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 differ...

Page 37: ...r places 3 10 1 AXIS Interface Signal Specification Wiring Specification Signal Item 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 l...

Page 38: ...ltage level DC24V Maximum current 50mA 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 39: ...w the above wiring instructions to wiring correctly 2 After powered on please use any one interface among the three interfaces 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 p...

Page 40: ...ller 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: ...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 42: ...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 1 1 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 independent power for IO Bo...

Page 43: ...re 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 real...

Page 44: ...invalid 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 45: ...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 46: ...ples 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 12...

Page 47: ...rtual 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 th...

Page 48: ...d in this way it supports IO remote expansion 4 2 1 EtherCAT Bus Expansion Wiring After the expansion wiring is completed each EIO expansion module does not need to develop again It only needs to manually configure the unique IO address and axis address in the EtherCAT master controller and it can be accessed after the configuration is completed The IO address number is set through the bus command...

Page 49: ...sequence of the devices on the bus You can view the total number of devices connected to the bus through the NODE_COUNT slot command Drive number The controller will automatically identify the drive on the slot and the number starts from 0 and the number is automatically numbered according to the connection sequence of the drive on the bus The drive number is different from the device number Only ...

Page 50: ... multiple of 8 Example NODE_IO 0 0 32 set the IO start number of slot 0 interface device 0 to 32 If device 0 is EIO16084 after configuration according to the above syntax the IO numbers corresponding to input IN0 15 are 32 47 in turn the general input port numbers in the axis interface are 48 55 and the drive alarm inputs of axes AXIS 0 3 are 48 51 respectively The IO numbers corresponding to the ...

Page 51: ...herCAT 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 52: ...ntroller 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 Ne...

Page 53: ...ZMC460 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 54: ...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 55: ...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 56: ...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 57: ...ows 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 58: ...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 59: ...n 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 60: ...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 am...

Page 61: ...ng 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 am...

Page 62: ...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 63: ...an 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 occupi...

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