Zmotion XPLC108E, Manual

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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: ...1 3 1 Power Input CAN Communication Interface 11 3 1 1 Power Specification 12 3 1 2 CAN Communication Specification Wiring 12 3 1 3 Basic Usage Method 14 3 2 RS485 Serial Port 15 3 2 1 RS485 CAN Communication Specification Wiring 15 3 2 2 Basic Usage Method 17 3 3 RS232 Serial Port 18 3 3 1 RS232 Communication Interface Specification Wiring 18 3 3 2 Basic Usage Method 19 3 4 IN Digital Input Latch...

Page 6: ...pansion Module 34 4 1 CAN Bus Expansion 34 4 1 1 CAN Bus Expansion Wiring 34 4 1 2 CAN Bus Expansion Resource Mapping 36 4 2 EtherCAT Bus Expansion 40 4 2 1 EtherCAT Bus Expansion Wiring 40 4 2 2 EtherCAT Bus Expansion Resource Mapping 41 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 Inspecti...

Page 7: ...omical multi axis motion controllers can be applied in 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 8 12 axes motion control The fastest perio...

Page 8: ...232 RS485 Ethernet Support 12 axes linear interpolation Support electronic cam electronic gear position latch synchronous follow virtual axis 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 1 3 System Frame 1 4 Hardware Installment The XPLC108E motion controller is installed...

Page 9: ... 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 upper and lower parts of the controller and the installation environment and surrounding components Considering the convenient operation and maintenance of the controller plea...

Page 10: ...XPLC108E Motion Controller User Manual V1 5 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: ...tputs AD DA 2 general DAs 2 general DAs 0 10V Max Extended AD DA 128 ADs 64 DAs Pulse Bit 32 Encoder Bit 32 Speed and Acceleration Bit 32 Max Pulse Frequency 500kHz Motion Buffer of Each Axis 512 Array Space 320000 Program Space 2MByte Flash Space 6MByte Power Supply Input 24V DC main power input 24V DC IO power input Communication Interfaces RS232 RS485 Ethernet CAN EtherCAT Dimensions 219 135mm ...

Page 12: ...rol it doesn t support circular interpolation helical interpolation and continuous interpolation 2 3 Interface Definition Interface Description Mark Interface Number Description IO POWER The led that indicates the current state 1 IO power state it lights when IO power is conducted POWER 1 Power state it lights when power is ...

Page 13: ... command default IP address is 192 168 0 11 24V Main power supply 1 24V DC power it supplies the power for controller CAN CAN bus interface 1 Connect CAN expansion modules and CAN equipment of other standards IN Digital IO input port 32 NPN leakage type power is supplied by IO 24V power IN0 1 have the latch function IN26 31 can be configured as 24V encoder OUT Digital IO output port 32 NPN leakage...

Page 14: ...ser Manual V1 5 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: ...finition Terminal Name Type Function 24V Input Power 24V input CANH Input output CAN differential data EARTH Grounding Shield CANL Input output CAN differential data GND Input Power ground Note please supply internal 24V power and external 24V IO power separately it is not recommended to use one same power supply or use one power that provides 2 isolated 24V IO Power Terminal Definition Terminal N...

Page 16: ...ch mainly includes three ports CANL CANH and the public end And it can connect CAN expansion modules and other standard CAN devices Specification Item CAN Maximum Communication Rate bps 1M Terminal Resistor 120Ω Topological Structure Daisy Chain Topology The number of nodes can be extended Up to 16 Communication Distance The longer communication distance is the lower communication rate is and maxi...

Page 17: ...f the CAN bus for matching the circuit impedance and ensuring communication stability Please be sure to connect the public ends of each node on the CAN bus to prevent the CAN chip from burning out Please use STP Shielded Twisted Pair especially in bad environments and make sure the shielding layer is fully grounded When on site wiring pay attention to make the distance between strong current and w...

Page 18: ...Develop 3 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 view the CAN status intuitively and refer to the ZBasic Programming Manual for details 4 Correctly set the address and speed of the...

Page 19: ...pts a 5Pin there are all 5 terminals screw type pluggable wiring terminal and the interval means the gap distance between two ports should be 3 81mm RS485 communication and CAN communication can be achieved through connecting to corresponding interfaces of this terminal Terminal Definition Terminal Name Function GND 485 communication public end A 485 B 485 3 2 1 RS485 CAN Communication Specificati...

Page 20: ...hain topology is used for wiring 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 use STP Shielded Twisted Pair especially in bad environments and make sure the shielding layer is fully grounded When on site wiring pay attention to make the distance between strong current and weak current it is rec...

Page 21: ...wiring instructions to wiring correctly 2 After powered on please use ETHERNET or RS232 or 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 Build the communication between controller according to Baud rate and other serial parameters ...

Page 22: ...end 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 Distance...

Page 23: ... 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 Method 1 Please follow the above wiring instructions to wiring correctly 2 After powered on please use...

Page 24: ...ng 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 Latch Single ended Encoder The digital input adopts 4...

Page 25: ...ut 7 EGND IO power ground IO public end EGND IN8 NPN type digital 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 power ground IO public end EGND IN16 NPN type digital input Input 16 IN17 Input 17 IN18 Input 18 IN19 Input 19 IN20 Input 20 IN21 Input 21 IN22 Input 22 IN23 Input 23 EGND IO power ground IO public end EGND IN24 NPN ...

Page 26: ...4 1 Digital Input Specification Wiring Specification Item Digital Input IN0 31 Input mode NPN type trigger input when in low electricity Frequency 5kHz Impedance 4 7KΩ Voltage level DC24V The voltage to open 14 5V The voltage to close 14 7V Minimal current 1 8mA negative Max current 6mA negative Isolation mode Photoelectric isolation Note the above parameters are standard values when the voltage o...

Page 27: ...rminal of the external input device If the signal area power supply of the external device and the IO 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 to wiring correctly 2 After powered on please select any one interface among the three interfaces ETHERNET RS232 and RS485 t...

Page 28: ...ower input DC24V OUT0 NPN Leakage digital output Output 0 OUT1 Output 1 OUT2 Output 2 OUT3 Output 3 OUT4 Output 4 OUT5 Output 5 OUT6 Output 6 OUT7 Output 7 EGND IO power ground IO public end NC Spare OUT8 NPN Leakage digital output Output 8 OUT9 Output 9 OUT10 Output 10 OUT11 Output 11 OUT12 Output 12 OUT13 Output 13 OUT14 Output 14 OUT15 Output 15 EGND IO power ground IO public end E5V 5V power o...

Page 29: ...UT27 Output 27 PUL2 OUT28 Output 28 DIR1 OUT29 Output 29 PUL1 OUT30 Output 30 DIR0 OUT31 Output 31 PUL0 Note Pulse ports can use E5V common anode output or E24V common anode output OUT16 31 can be configured as pulse axis interfaces when ATYPE 0 they are general outputs The max output current of OUT28 31 is 500mA the max current of OUT0 27 is 300mA 3 5 1 Digital Output Specification Wiring Specifi...

Page 30: ...ue to the leak type output the shutdown of the output 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 digital output OUT 0 31 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...

Page 31: ... 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 3 6 AD DA Analog Input Output The analog port adopts a set of 5Pin screw type pluggable terminals with a spacing of 3 81mm Terminal Definition Terminal Name Type Function DA0 Output Analog output terminal AOUT 0 DA1 Analog...

Page 32: ...1KHz Voltage input impedance output load 300KΩ voltage input impedance 33KΩ voltage output load Wiring Reference Wiring Note The analog input output wiring method is as shown in the figure above and the external load signal range must match with this signal range Please use STP especially in bad environments and make sure the shielding layer is fully grounded Cable Requirements Shielded Twisted Pa...

Page 33: ...nnect 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 Please refer to ZBasic for details 3 7 ETHERNET XPLC108E motion controller has a 100M network port and it supports MODBUS_TCP protocol and custom communication the default IP address is 192 ...

Page 34: ...through an Ethernet cable and using point to point connection method The schematic diagram is as follows The controller can also be connected to the interchanger 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 ...

Page 35: ...1 5 3 8 EtherCAT Bus Interface XPLC108E motion controller has a 100M EtherCAT communication interface and it supports EtherCAT protocol In addition EtherCAT driver or EtherCAT expansion module can be connected The pin definition is as follows ...

Page 36: ...s 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 Ethernet RJ45 interface The network cable adopts Category 5e STP and the crystal head has a metal sh...

Page 37: ...d that is with the cable and insert it into the RJ45 interface until 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 diame...

Page 38: ...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 1 1 CAN Bus Expansion Wiring The IO expansion module is powered by the dual power supply Except the main power supply an additional IO power supply is required to supply indepe...

Page 39: ...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 40: ... 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 ...

Page 41: ...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 ...

Page 42: ...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...

Page 43: ...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...

Page 44: ...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...

Page 45: ... 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 46: ...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...

Page 47: ...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 ...

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: ...XPLC108E 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: ...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 ...

Page 52: ...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 ...

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 co...

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...