Zmotion ZMC004WEA, 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: ...AN 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 RS232A Serial Port 15 3 2 1 RS232 Communication Interface Specification Wiring 15 3 2 2 Basic Usage Method 16 3 3 RS232B RS485 Serial Port 17 3 3 1 RS232B RS485 Serial Port Communication Specification Wiring 18 3 3 2 Basic Usage 20 3 4 IN Digital Input Latch Po...

Page 6: ...sion Module 33 4 1 CAN Bus Expansion 33 4 1 1 CAN Bus Expansion Wiring 33 4 1 2 CAN Bus Expansion Resource Mapping 35 4 2 EtherCAT Bus Expansion 39 4 2 1 EtherCAT Bus Expansion Wiring 39 4 2 2 EtherCAT Bus Expansion Resource Mapping 40 Chapter V Program Applications 43 5 1 ZDevelop Software Usage 43 5 2 PC Upper Computer Program Application 48 Chapter VI Run and Maintain 51 6 1 Regular Inspection ...

Page 7: ... semiconductor equipment testing equipment assembly equipment locking equipment soldering machine dispensing equipment assembly line etc 1 2 Function Features 6 axes motion control at most Pulse output mode pulse direction or dual pulses The fastest refresh cycle of EtherCAT bus communication is 500us Support encoder position measurement which can be configured as handwheel input mode Maximum puls...

Page 8: ...osition 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 Support power failure detection and power failure storage 1 3 System Frame 1 4 Hardware Installment The ZMC004WEA motion controller is installed horizontally with screws and each co...

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

Page 10: ...ual V1 5 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: ...utputs Max Extended IO 512 inputs 512 outputs AD DA 2 general ADs and 2 general DAs 0 10V Max Extended AD DA 128 ADs and 64 DAs Motion Buffer of Each Axis 32 Pulse Bit 32 Encoder Bit 32 Speed and Acceleration Bit 32 Highest Pulse Frequency 500KHz Power Supply Input 24V DC input for main power 24V input for IO power Communication Interfaces RS232 RS485 Ethernet CAN EtherCAT Dimensions 177mm 122mm 2...

Page 12: ...nic cam linear circular continuous trajectory motion ZMC003BEA 3 axes point to point electronic cam linear circular continuous trajectory motion Note The controllers with the suffix W will have more and larger resources such as array space than the controllers with the B model Except for the different axis resources there is no difference in function 2 3 Interface Definition ...

Page 13: ... expansion module UDISK U disk interface 1 Insert U disk equipment 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 16 NPN type the power is supplied by internal 24V power supply There are 2 high speed inputs and IN0 1 have the latch function 0 15 have single...

Page 14: ...0 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: ...n power 24V input CANH Input output CAN differential data EARTH Earthing Grounding Protect CANL Input output CAN differential data GND Input Main power CAN public end Note please separately supply power for main power 24V and IO power 24V it is not recommended to use the same power supply or use one power supply that can provide 2 isolated 24V outputs Terminal Definition IO Power Terminal Name Typ...

Page 16: ...ic end And it supports connecting to expansion modules and other standard CAN devices Specification Item CAN Max Communication Rate 1M bps Terminal Resistor 120Ω Topology Daisy chain connection structure Nodes can be extended Up to 16 Communication Distance Longer communication distance lower communication rate max 100m is recommended Wiring Reference Connect the CANL and CANH of the standard CAN ...

Page 17: ...o 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 strong curre...

Page 18: ...n please use ETHERNET RS232 or RS485 to connect to ZDevelop 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 ...

Page 19: ...2A TXD Output RS232A port 0 send signal 5 EGND Output Negative pole output of 5V power and output for the public end 9 E5V Output 5V power output 3 2 1 RS232 Communication Interface Specification Wiring Specification Item RS232A port0 Maximum Communication Rate bps 115200 Terminal Resistor No Topology Structure Connect correspondingly 1 to 1 The number of nodes can be extended 1 Communication Dist...

Page 20: ...ss 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 3 2 2 Basic Usage Method 1 Please follow the above wiring instructio...

Page 21: ...OM 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 can start to do communicating 6 Communication data of RS232 RS485 can be directly viewed through ...

Page 22: ...n public end 9 485B Input output RS485 port 2 signal B 3 3 1 RS232B RS485 Serial Port Communication Specification Wiring Specification Item RS232B port 1 RS485 port 2 Max Communication Rate 115200 bps 115200 bps Terminal Resistor Topology Point to point Daisy chain connection structure Nodes can be extended 1 Up to 127 Communication Distance Longer communication distance lower communication rate m...

Page 23: ...eal and there are few nodes the branch structure can also be considered Please connect a 120Ω terminal resistor in parallel at the two ends of the CAN bus to match the circuit impedance and ensure communication stability when there are many slave stations Please be sure to connect the common terminal of each communication node to prevent the communication chip from burning out Please use twisted p...

Page 24: ... 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 can ...

Page 25: ... type pluggable terminals and the gap distance between terminals should be 5 08mm In addition the latch function is integrated in digital input signals Terminal Definition Terminal Name Type Function 1 Function 2 EGND IO Public end EGND IN0 NPN type low speed input Input 0 Latch IN1 Input 1 IN2 Input 2 IN3 Input 3 IN4 Input 4 IN5 Input 5 IN6 Input 6 IN7 Input 7 EGND IO Public end ...

Page 26: ...y are ordinary inputs 3 4 1 Digital Input Specification Wiring Specification Item High Speed Input IN14 15 Low Speed Input IN0 13 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 cur...

Page 27: ... IO 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 to wiring correctly 2 After powered on please select any one interface among the three interfaces...

Page 28: ...ntegrated in digital output signal Terminal Definition Terminal Name Type Function 1 Function 2 EGND E24V power ground IO public end E5V IO power input E24V OUT0 NPN Leakage type low speed 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 E5V power ground IO public end E5V E5V power ground max is 300mA OUT8 NPN Leakage type high ...

Page 29: ...akage type it is 0V when outputs Frequency 400kHz 8kHz Voltage level DC24V DC24V Max output current 300mA 300mA Max leakage current when off 25μA 25μA Respond time to conduct 1μs resistive load typical value 12μs Respond time to close 3μs 80μs Overcurrent protection Support Support Isolation method optoelectronic isolation Note The times in the form are typical based on the resistive load and may ...

Page 30: ... 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 Method 1 Please follow the above wiring instructions to wiring c...

Page 31: ...inition Terminal Name Type Function DA0 Output Analog output terminal AOUT 0 DA1 Analog output terminal AOUT 1 AGND Public End Analog public end AD0 Input Analog input terminal AIN 0 AD1 Analog input terminal AIN 1 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 ...

Page 32: ...ut impedance 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 Pair and the shielded cable is grounded ...

Page 33: ...ge 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 EtherCAT Bus Interface Ethernet ZMC004WEA motion controller has a 100M EtherCAT communication interface and it supports EtherCAT protocol In addition EtherCAT driver or EtherCAT expansion module can be connected Also it can be ethernet to communicate wit...

Page 34: ...lex Topology linear 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 Ethernet Wiring The Ethernet port of the controller can be connected to a computer HMI etc through an Ethernet c...

Page 35: ...ulti 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 interference and to prevent information from being eavesdropped As shown below ...

Page 36: ...nection method When installing hold the crystal head that is with the cable and insert it into the RJ45 interface until it makes a click sound kada 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 insulat...

Page 37: ...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 ZIO expansion module is powered by the dual power supply Except the main power supply an additional IO power supply is required to supply indep...

Page 38: ...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...

Page 39: ... 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 40: ...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 41: ...les 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 42: ...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 43: ...and 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 comma...

Page 44: ... 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 45: ...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 46: ...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 47: ...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 ...

Page 48: ...ZMC004WEA 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 49: ...t 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 50: ...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 51: ...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 52: ...ndows 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 need...

Page 53: ...n 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 54: ...ion 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 55: ...e 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 ...

Page 56: ...ning 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 ...

Page 57: ... 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 58: ... 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 occu...