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ZMC416BE 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.

ZMC416BE high-performance multi-axis motion controller is a stand-alone motion

controller compatible with EtherCAT bus and pulse type. The controller itself supports 16

axes at most, but it can be extended to 32 axes for complex continuous trajectory control

requirements.

ZMC4 series high-performance multi-axis motion controller 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 32 axes.

◆

Pulse output mode: pulse / direction or dual pulses.

◆

Maximum pulse frequency output of each axis: 10MHZ.

◆

4096 isolation inputs and 4096 isolation outputs can be extended at most through

ZCAN bus.

◆

Axis position limit signal / origin signal port can be configured as any input at will.

◆

The maximum output current of general digital outputs can reach 300mA, which can

directly drive some kinds of solenoid valves.

Содержание ZMC416BE

Страница 1: ......

Страница 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...

Страница 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...

Страница 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...

Страница 5: ...ion 11 3 1 Power Input 11 3 1 1 Power Specification 11 3 2 RS485 RS422 CAN Communication Interface 11 3 2 1 RS485 RS422 CAN Communication Specification Wiring 12 3 2 2 Basic Usage 15 3 3 RS232 Serial Port 16 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 20 3 4 2 Basic Usage 21 ...

Страница 6: ...ce Signal Specification Wiring 34 3 11 2 Basic Usage 36 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 and Applications 48 5 1 ZDevelop Software Usage 48 5 2 PC Upper Computer P...

Страница 7: ...ARA 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 32 axes Pulse output mode pulse direction or dual puls...

Страница 8: ...polation of 32 axes at most Support electronic cam electronic gear position latch synchronous follow virtual axis etc 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 Power failure detection and power failure storage 1 3 System Frame ...

Страница 9: ...aster 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 and controller replacement 2 3cm should be left between the upp...

Страница 10: ...bient 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 ...

Страница 11: ...herCAT local pulse axis encoder axis Digital IO 24 15 inputs 8 15 outputs Max Extended IO 4096 inputs 4096 outputs PWM 4 AD DA 2 general AD 0 10V 2 general DA 0 10V Max Extended AD DA 512 ADs 512 DAs Pulse Bit 64 Encoder Bit 64 Speed Acceleration Bit 64 Pulse Max Frequency 10MHz Motion Axis Buffer 4096 Array Space 320000 Program Space 2MByte Flash Space 240MByte Power Supply Input 24V DC input Com...

Страница 12: ...xes point to point linear circular electronic cam continuous trajectory motion robotic car instructions ZMC416BE 1 16 axes point to point electronic cam ZMC416BE 2 16 axes point to point linear electronic cam ZMC416BE 6 16 axes point to point linear circular electronic cam 2 3 Interface Definition ...

Страница 13: ...ERNET Ethernet 1 Use MODBUS_TCP protocol expand Ethernet through interchanger 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 to CAN expansion module or controller IN Digital IO input 24 15 Leakage type internal 24V ...

Страница 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 ...

Страница 15: ...input negative pole FG Connect to ground Case Protection Ground 3 1 1 Power Specification Specification Item Description Input Voltage DC24V 10 10 Opening Current 0 5A Work Current 0 4A Anti reverse connection Valid Overcurrent Protection Valid 3 2 RS485 RS422 CAN Communication Interface The communication interface adopts a screw type pluggable wiring terminal with a 10Pin spacing of 3 81mm And th...

Страница 16: ...serial port supports the MODBUS_RTU protocol and custom communication mainly including 485A 485B and common port The CAN interface of the controller adopts the standard CAN communication protocol which mainly includes three ports CANL CANH and the common port And it supports connecting CAN expansion modules and other standard CAN devices RS422 serial port supports MODBUS_RTU protocol and custom co...

Страница 17: ... Reference Connect 485A and 485B of RS485 to 485A and 485B of the controller correspondingly and connect the common terminal EGND of both parties of RS485 communication 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 c...

Страница 18: ...t the two ends of the CAN bus to match the circuit impedance and ensure communication stability Please be sure to connect the common terminal of each node on the CAN bus to prevent the CAN chip from burning out Please use twisted pair shielded wires especially in harsh environments make sure the shielding layer is fully grounded On site wiring should also pay attention to the distance between stro...

Страница 19: ... and SETCOM commands to set and view the protocol station number and configuration parameters see ZBasic Programming Manual for details 4 Please use the CANIO_ADDRESS command to set the master s address and speed according to the needs and use the CANIO_ENABLE command to enable or disable the internal CAN master function or through ZDevelop Controller State the Controller Communication Info to vie...

Страница 20: ...h 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 establishment will fail or the communication will be 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 PIN Name Type Function 1 4 6 7 8 NC...

Страница 21: ... lower communication rate max 10m is recommended Wiring Reference Wiring Notes The wiring of RS232 is as above the sending and receiving signals need to be cross connected and it is recommended to use a double female cross line when connecting to a computer Please be sure to connect the common terminal of each communication node to prevent the communication chip from burning out Please use twisted...

Страница 22: ... one adapter is needed for hardware to connect to ZDevelop 3 Please use the ADDRESS and SETCOM commands to set and view the protocol station number and configuration parameters see ZBasic Programming Manual for details 4 Correctly set the relevant parameters of the third party equipment according to their respective instructions to match the parameters of each node 5 When all is configured it can ...

Страница 23: ...ing Definition Terminal Name Type Function 1 Function 2 Function 3 EGND External power ground EGND IN0 NPN leakage type high speed input Switch Input 0 High Speed Latch EA3 IN1 Switch Input 1 EB3 IN2 NPN leakage type low speed input Switch Input 2 EZ3 IN3 Switch Input 3 IN4 Switch Input 4 IN5 Switch Input 5 IN6 Switch Input 6 IN7 Switch Input 7 EGND External power ground EGND IN8 NPN leakage type ...

Страница 24: ... 23 Note Input 0 and input 1 both have latch input A and latch input B function at the same time Encoder 3 is reserved for 24V encoder which supports 24V handwheel When ATYPE 0 it is general output 3 4 1 Digital Input Specification Wiring Specification Item High Speed Input IN0 1 Low Speed Input IN2 23 Input mode NPN leakage type low level input trigger Input frequency 100kHz 5kHz Input impedance ...

Страница 25: ... meets the requirements For the common terminal please select the EGND port on the power supply terminal to connect to the COM terminal of the external input device If the power supply of the signal area of the external device and the power supply of the controller are in the same power supply system this connection can also be omitted 3 4 2 Basic Usage 1 Please follow the above wiring instruction...

Страница 26: ...e digital output signal is integrated with PWM single ended pulse and hardware comparison output functions 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 speed output Switch Output 0 PWM Output 0 Hardware Comparison Output OUT1 Switch Output 1 PWM Output 1 OUT2 Switch Output 2 PWM Output 2 PUL1...

Страница 27: ... type 0V when outputs Output frequency 400kHz 8kHz Output voltage level DC24V DC24V Max output current 300mA 300mA Max leakage current when OFF 25μA 25μA Conduction respond time 1μs resistive load typical value 12μs Respond time when OFF 3μs 80μs Overcurrent protection Support Support Isolation method Optical isolation Optical isolation Note The times in the table are typical based on the resistiv...

Страница 28: ... supply of the external input device If the DC power supply of the external device and the controller power supply are in the same power supply system this connection can also be omitted The E5V port is a 5V power output port which can be used when some loads need to provide an external 5V power input the maximum current is 300mA 3 5 2 Basic Usage 1 Please follow the above wiring instructions for ...

Страница 29: ...is 15 as pulse axis type UNITS 1000 set axis 15 pulse amount as 1000 pulses per unit SPEED 10 set axis speed as 10 1000 pulse s ACCEL 1000 set axis acceleration as 1000 1000 pulse s s DECEL 1000 set axis deceleration as 1000 1000 pulse s s MOVE 100 axis 15 moves 100 1000 pulses 3 6 AD DA Analog Input Output The analog port adopts a set of 6Pin screw type pluggable terminals with a pitch of 3 81mm ...

Страница 30: ...al AIN 1 AGND Common terminal Analog common terminal 3 6 1 Analog Input 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 Voltage input impedance output load 10KΩ voltage output load 44KΩ voltage input impedance Wiring Reference ...

Страница 31: ...ounded Cable Requirements Twisted pair shielded wire and shielded cable grounded 3 6 2 Basic Usage 1 Please follow the above wiring instructions for correct wiring 2 After power on please use any of 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...

Страница 32: ...ta 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 ZMC416BE motion controller has a 100M Ethernet port supports MODBUS_TCP protocol and custom communication and the default IP address is 192 168 0 11 The pin definition diagram is as fol...

Страница 33: ... to point with a computer HMI etc through an Ethernet cable The schematic diagram is as follows The controller can 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 ...

Страница 34: ...nual V1 5 3 9 EtherCAT Bus Interface ZMC416BE 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 ...

Страница 35: ...ss data Max 1486 bytes of single frame Synchronization shaking of two slave stations 1us Refresh 1000 digital input and output about 30us 16 servo axes about 100us Communication Cable Requirements Both ETHERNET communication interface and EtherCAT communication interface adopt standard Ethernet RJ45 interface The network cable adopts Category 5e shielded twisted pair and the crystal head has a met...

Страница 36: ...tor 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 ENCODER Interface ZMC416BE provides 3 encoder interfaces and each interface is standard DB9 male socket Interface Definition Interface Pin Signal Description 1 EA Encoder differential input signal A 2 EA Encoder differential input s...

Страница 37: ...l Signal voltage range 0 5V Signal max frequency 5MHz 5V GND 5V power max output current 50mA Wiring Reference Reference example of wiring with Panasonic A5 A6 servo driver 3 11 AXIS Differential Pulse Axis Interface This product provides 15 local differential pulse axis interfaces each interface is a standard DB9 female socket Interface Definition Interface Pin Signal Description 1 PUL Servo step...

Страница 38: ...recommended to be used as axis IO due to their small drive capacity 5V is only used for communication between the controller and the servo driver please do not use it as power supply for other places The last axis is controlled by PWM interface 3 11 1 AXIS Interface Signal Specification Wiring Specification Signal Item Description PUL DIR Signal type Differential output signal Signal voltage range...

Страница 39: ...nt protection No Isolation Optical isolation 5V GND 5V power max output current 50mA EGND 24V power max output current 50mA Wiring Reference Reference example of wiring with Panasonic A5 A6 servo driver 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 ...

Страница 40: ... three interfaces ETHERNET RS232 default parameter it can be connected directly and RS485 default parameter can be connected directly one adapter is needed for hardware 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 an...

Страница 41: ... 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 ...

Страница 42: ...s 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 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 indepe...

Страница 43: ...hare 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 re...

Страница 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 ...

Страница 45: ...st 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 ...

Страница 46: ...iples 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 1...

Страница 47: ...irtual 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 t...

Страница 48: ...nd 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 comman...

Страница 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...

Страница 50: ...a 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...

Страница 51: ...therCAT 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 ...

Страница 52: ... 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 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...

Страница 53: ...ZMC416BE 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 ...

Страница 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 ...

Страница 55: ...om 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 ...

Страница 56: ...rent 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 ...

Страница 57: ...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...

Страница 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 ...

Страница 59: ...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 ...

Страница 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 a...

Страница 61: ...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...

Страница 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 co...

Страница 63: ...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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