Zmotion ZMIO300 Series User manual

ZMIO300 Series Hardware Manual Version 1.8
1
ZMIO300 Series Expansion Module
Hardware Manual
Version 1.8

ZMIO300 Series Hardware Manual Version 1.8
2
Copyright statement
This manual is copyrighted by Shenzhen Technology Co., Ltd.,
without the written permission of the Zmotion Technology, no person
shall reproduce, translate and copy any content in this manual.
ZMC controller software involved in details as well as the
introduction and routines of each instruction, please refer to 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!
Version is subject to the latest publishment of Zmotion Technology
website: www.zmotionglobal.com

ZMIO300 Series Hardware Manual Version 1.8
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Safety Information:
There are two levels, “Danger” and “Note”. Please take full care of safety and operate
correctly!
Danger: if not operate according to requirements, it will cause death or severe
wound.
Note: if not operate according to requirements, it will cause moderate damage
or minor wound, and equipment damage.
◆For different situations, even if the “Note” level, there might lead to serious
consequences. Please follow these two levels safety information, or it will break
products, relative machines and systems, even will cause death or severe wound,
Zmotion Technology has no obligation or responsibility for this kind of loss.
And please save this instruction, and send this manual to the end users.
Installation
Danger
The person who installs this product must be trained the
knowledge of electronic technology and equipment.
When removes the controller, external power supply must be
disconnected, then to operate, or will operate equipment
wrongly and damage equipment.
Don’t use in these places: 1. There are dusty, soot, conductive
dust, corrosive gas and flammable gas. 2. Expose in high-
temperature, condensation, wind and rain situation. 3. There
are vibration and shock occasions. 4. Electronic shock, fire and
wrong operation lead to product damage and deterioration.

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Note
Pay attention not make metal shavings and wire head fall into
the hardware wiring board, if falls into, there will cause fire,
malfunction, false operation.
Check if there is not foreign matter on the hardware wiring
board after installation. If it is, will cause operate abnormally,
then appear fire, malfunction and false operation.
The products must be installed with mounting bracket tightly
and firmly. If the controller is not installed well, it will cause
wrong motions, malfunction and fall off.
Wiring
Danger
The person who wires this product must be trained the
knowledge of electronic technology and equipment.
When wires, external power supply must be disconnected, then
to operate, or will cause electric shock, equipment malfunction
and wrong actions.
When conducts power and runs after wiring, attached
terminals must be installed. If this not did, there might be
electric shock.
Cable terminals should be well insulated. And make sure cable
is installed in the terminals, the insulation distance between
cables won’t decrease. Or will cause electric shock and
equipment damage.
Note
Pay attention not make metal shavings and wire head fall into
the hardware wiring board, if falls into, there will cause fire,

ZMIO300 Series Hardware Manual Version 1.8
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malfunction, false operation.
The specification and install methods of equipment external
wiring should obey local electric wiring regulations.
Firstly, determine the interface type to be connected, then link
with cable. If connect with wrong interface or false wiring, it
will cause module or external equipment malfunction.
Make sure the cable of press-in terminal is good contact. If the
cable is not pressed tightly, it will cause short circuit, fire or
false actions.
Don’t tie up control wire, communication cable and main
power circuit or power cord together, the trace distance should
exceed 100mm, or the noise will cause false actions.

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Content
ZMIO300 Series Expansion Module Hardware Manual...................................................................1
1Introduction...............................................................................................................................8
1.1 System Architecture ..................................................................................................8
1.1.1 EtherCAT Expansion.........................................................................................8
1.1.2 ZCAN Expansion..............................................................................................8
2Production Information.............................................................................................................9
2.1 Nameplate Information .............................................................................................9
2.2 Model Description.....................................................................................................9
3Production Description ...........................................................................................................11
3.1 Coupler Module ......................................................................................................11
3.1.1 ZMIO300-ECAT Communication Module .....................................................11
3.1.1.1 Interface Definition ..................................................................................11
3.1.1.2 Performance and Specification.................................................................12
3.1.1.3 Installation Size........................................................................................13
3.1.1.4 Interface Description................................................................................13
3.1.1.5 Terminal Definition..................................................................................14
3.1.1.6 Malfunction Indication and Solution........................................................15
3.1.2 ZMIO300-CAN Communication Module.......................................................16
3.1.2.1 Interface Definition ..................................................................................16
3.1.2.2 Performance and Specification.................................................................16
3.1.2.3 Installation Size........................................................................................17
3.1.2.4 Interface Description................................................................................18
3.1.2.5 Terminal Definition..................................................................................20
3.1.2.6 Wiring Method .........................................................................................21
3.1.2.7 Malfunction Indication and Solution........................................................21
3.2 Expansion submodule .............................................................................................22
3.2.1 ZMIO300-16DI Digital Input Module ............................................................22
3.2.1.1 Interface Definition ..................................................................................22
3.2.1.2 Performance and Specification.................................................................22
3.2.1.3 Installation Size........................................................................................23
3.2.1.4 Terminal Definition..................................................................................24
3.2.1.5 Wiring Mode ............................................................................................25
3.2.1.6 Malfunction Indication and Solution........................................................26
3.2.2 ZMIO300-16DO/DOP Digital Output Module ...............................................26
3.2.2.1 Interface Definition ..................................................................................27
3.2.2.2 Performance and Specification.................................................................27
3.2.2.3 Installation Size........................................................................................28
3.2.2.4 Terminal Definition..................................................................................28
3.2.2.5 Wiring Mode ............................................................................................30
3.2.2.6 Malfunction Indication and Solution........................................................31
3.2.3 ZMIO300-4AD Analog Input Module ............................................................31

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3.2.3.1 Interface Definition ..................................................................................31
3.2.3.2 Performance and Specification.................................................................32
3.2.3.3 Installation Size........................................................................................33
3.2.3.4 Terminal Definition..................................................................................33
3.2.3.5 Wiring Mode ............................................................................................35
3.2.3.6 Malfunction Indication and Solution........................................................35
3.2.4 ZMIO300-4DA Analog Output Module..........................................................36
3.2.4.1 Interface Definition ..................................................................................36
3.2.4.2 Performance and Specification.................................................................37
3.2.4.3 Installation Size........................................................................................37
3.2.4.4 Terminal Definition..................................................................................38
3.2.4.5 Wiring Mode ............................................................................................40
3.2.4.6 Malfunction Indication and Solution........................................................40
3.3 Wiring description...................................................................................................41
3.3.1 ECAT coupler + expansion submodule wiring reference................................41
3.3.2 ECAT coupler + expansion submodule wiring reference................................41
4Introductions for Use ..............................................................................................................42
4.1 Power Consumption Calculation Example..............................................................42
4.2 Start Number Configuration....................................................................................42
4.3 IO and Analog Monitor (watch)..............................................................................44
4.4 Expansion Address Description ..............................................................................44
4.5 Function Configuration ...........................................................................................45
5Data Dictionary Description ...................................................................................................49
5.1 Description Format..................................................................................................49
5.2 Specific Contents ....................................................................................................49
6Common problems..................................................................................................................56

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1Introduction
ZMIO300 Series expansion module is a kind of vertical fieldbus expansion
module, which supports EtherCAT and ZCAN fieldbus to expand IO, AD and DA.
When IO, AD and DA are not enough, a coupler module (ECAT or ZCAN
communication module) is matched with other modules (input/output/AD/DA module)
to expand.
This manual mainly describes ZMIO300 Series’ specification, property, usage, etc.
Please read this manual carefully for know more about the product and use more safely.
1.1 System Architecture
1.1.1 EtherCAT Expansion
1.1.2 ZCAN Expansion
Select suitable coupler module for ZMIO300 series expansion module to do
communication connection with the controller according to the fieldbus type supported

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by controller, then link a sub-expansion module to behind level interface to expand IO,
AD and DA.
2Production Information
2.1 Nameplate Information
(ZMIO300-ECAT is the example, other types are similar.)
➢Product Model: ZMIO300-ECAT
➢Size: 95*32mm
➢Power Supply: 24VDC, 2A
➢Manufacturer: Shenzhen Zmotion Technology Co.,Ltd
2.2 Model Description
ZMIO 300 - ECAT:
ZMIO → Vertical fieldbus expansion module (company product name)
300 → 300 series (series No.)
ECAT → ECAT communication module (module type)
◆Models (at present)
Product
name
In
Out
AD
DA
Communication
interface
Function description
ZMIO300-
-
EtherCAT
ECAT communication

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ECAT
module
ZMIO300-
CAN
-
CAN
CAN communication
module
ZMIO300-
16DI
16
-
Input module
(NPN/PNP)
ZMIO300-
16DO
-
16
-
Output module
(NPN)
ZMIO300-
16DOP
-
16
-
Output module
(PNP)
ZMIO300-
4AD
-
4
-
AD module
(16 Bit)
ZMIO300-
4DA
-
4
DA module
(16 Bit)

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3Production Description
3.1 Coupler Module
3.1.1 ZMIO300-ECAT Communication Module
3.1.1.1 Interface Definition
No.
Interface Name
Function Description
1
Status Indicator Light
POW
Power
indicator
green
It will light when
power is conducted.
RUN
Run
indicator
It will light when runs
normally.
ERR
Error
indicator
red
It will light when
communicate wrongly.
2
Ethernet communication
interface
EtherCAT
IN
EtherCAT input port is used to connect
with EtherCAT master/slave station
EtherCAT
OUT
EtherCAT output port is used to connect
with EtherCAT slave station
3
Local Expansion behind-
level Interface
Connect with sub-expansion module, doesn’t support
hot plug or discharge.
4
User’s terminal
Power terminal

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3.1.1.2 Performance and Specification
Item
Specification
Power Voltage
24V DC
Communication Protocol
EtherCAT Industrial Real-time Bus Protocol
Service
CoE (PDO, SDO)
Communication Cycle
250μs, 500μs, 1ms, 2ms, 4ms, etc.
Max Communication Speed
Ethernet 100Mbqs
Network Port
Standard Ethernet RJ45 interface
Transfer Medium
Super class5 twisted shielded pair cable
Transfer Distance
Two nodes are less than 100m
Continuation Sub Module Expansion
Up to16 input/output modules are expanded, or 8 AD/DA
modules, the total number can be up to 16, the actual
number depends on each module’s power.
Max IOs of Continuation Sub Module
256 inputs or 256 outputs
Max AIOs of Continuation Sub
Module
32 ADs or 32 DAs
Continuation slave station number
Up to 32
Power
1.6W
Internal power for behind level
8.4W

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3.1.1.3 Installation Size
Installation Step:
➢Please use 35mm standard DIN guide rail.
➢Open guide rail buckle of ECAT communication module, then embed ECAT
communication module in the DIN guide rail.
➢Press fit guide rail buckle of ECAT communication module, then fix ECAT
communication module in the DIN guide rail.
3.1.1.4 Interface Description
EtherCAT Communication Interface uses standard Ethernet RJ45 interface.
Network-port Wiring:
EtherCAT communication uses twisted pair cable with shield layer to transfer data
Pin No.
Signal
Description
1
TX+
Send signal (+)
2
TX-
Send signal (-)
3
RX+
Receive signal (+)
4
NC
Reserved
5
NC
Reserved
6
RX-
Receive signal (-)
7
NC
Reserved
8
NC
Reserved

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through net. Please use below cable specification.
Item
Specification
Cable type
Flexible crossover cable, category 5e
Conduct wire type
Double crossover cable
Line pair
4
Isolation
Cross skeleton
Junction
Crystal head with iron shell
Wire cable material
PVC material, injection
Wire cable length
Not exceed 100m
→ The usage method of RJ45 cable wiring:
➢Hold the crystal head with wire, then insert RJ45 interface, until there is a sound
“Kada”.
➢For the stability of communication, please fix wire cable with cable tie or others.
➢Please don’t mix EtherCAT IN and EtherCAT OUT interface. EtherCAT IN
interface is used to connect with EtherCAT network port of master station (the
controller) or EtherCAT OUT interface of front-level slave station (servo/ECAT
communication module), EtherCAT OUT interface is used to connect to EtherCAT
IN interface of behind level station (servo / ECAT / communication module).
3.1.1.5 Terminal Definition
Power terminal
Number
Identification
Type
Function
1
+24V
Power Positive Pole
24V power positive pole input
2
NC
-
Reserved
3
EARTH
-
Safety ground / Shield layer
4
NC
-
Reserved
5
GND
Power Negative Pole
24V power input negative pole

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Terminal Wiring
(Please use tubular pre-insulated terminals and wire cable that is suitable to wire path
to do user terminal wiring)
→Cable production steps:
➢Strip the cable insulation, the exposed copper part depends on the size of the tube-
type pre-insulated terminal.
➢Pass the conductor part of the cable into the tubular pre-insulated terminal and
crimp it with a crimping pliers.
→Wire cable connection steps:
➢Press the spring of the terminal to insert the cable with the tubular pre-insulated
terminal into the port.
➢Loosen the spring of the terminal, pull the cable lightly to check whether the cable
is firmly connected.
3.1.1.6 Malfunction Indication and Solution
Status Indication Light
Reason
Solution
POW
RUN
ERR
Light
twinkle alternately
and slowly
The communication of
EtherCAT master station and
coupler module breaks
Check if crystal head is
loosened or not
Check the net cable is
damaged or not
Restart the power.
Light
twinkle alternately
and rapidly
The pre-scanned sub module
and actual continuation sub
module are not totally
matched.
Check if the continuation
submodule is lost, or be in
malfunction
Check if appears hot plug
or discharger
Restart the power.

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3.1.2 ZMIO300-CAN Communication Module
3.1.2.1 Interface Definition
No.
Interface Name
Function Description
1
Status Indicator Light
POW
Power
indicator
green
It will light when
power is conducted.
RUN
Run
indicator
It will light when runs
normally.
ALM
Error
indicator
It will light when
communicate wrongly.
2
Dial code switch
8 dial codes, CAN address and CAN speed can be
selected to control the conduction of CAN 120Ω
ended-terminal resistor.
3
Local Expansion Behind-
level Interface
Connect with sub-expansion module, doesn’t support
hot plug or discharge.
4
User’s terminal
Power/CAN terminal
3.1.2.2 Performance and Specification
Item
Specification

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Power Voltage
24V DC
Communication Interface
CAN bus interface
The number can be connected
Up to 16 ZCAN slave station module
Transfer Distance
Less than 40m
Address Configuration
Dial code switch configuration
Continuation Submodule Expansion
Up to 6 input/output modules are expanded, or 3 AD/DA
modules, the total number can be up to 16, the actual
number depends on each module’s power.
Its Power
0.6W
Internal power for behind-level
7.9W
➢New version updates the module program, and coupler will alarm when submodule number
exceeds the limitation.
3.1.2.3 Installation Size
Installation Step:
➢Please use 35mm standard DIN guide rail.
➢Open guide rail buckle of ZCAN communication module, then embed ZCAN
communication module in the DIN guide rail.
➢Press fit guide rail buckle of ZCAN communication module, then fix ZCAN
communication module in the DIN guide rail.

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3.1.2.4 Interface Description
Dial code switch definition
8- bit dial code switch integrates a 120Ω ended-terminal resistance between CANH
and CANL, no need to connect externally. The first 6 bits are dialed OFF, the
relative value is 0, when they are dialed ON, the relative value is 1. When the code
8 is dialed ON, the resistor is conducted.
Address combination value = dial code 4 × 8 + dial code 3 × 4 + dial code 2 × 2 +
dial code 1 × 1. Speed combination value = dial code 6 × 2 + dial code 5 × 1.
The dial code switch must be configured before the power is on, it’s not valid to
dial after the power is on, it will take effect when power-on again.
Start number configuration
Dial code 1-4 are used to configure address combination value through dial switch,
then the controller set relative IO and AIO start number of expansion module
according to this address combination value.
Dial code
Name
Description
1
ID 0
CAN address dial code
2
ID 1
CAN address dial code
3
ID 2
CAN address dial code
4
ID 3
CAN address dial code
5
ID 4
CAN speed dial code
6
ID 5
CAN speed dial code
7
NC
Reserved
8
120Ω
CAN 120Ω resistor dial code
Address combination
value
Start IO
number
Start AD
number
Start DA
number
0
16
8
4

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Firstly, check the controller status and get the maximum IO and AIO number of the
controller itself, then configure dial code as 1-4. If IO and AIO number of
expansion module are coincided with IO and AIO number of the controller, only
one is valid, it is recommended to dial again to make them different.
Communication speed configuration
Dial code 5-6 are configured as the speed combination value through dial switch,
then the controller sets the relative communication speed of expansion module
according to this speed combination value.
1
32
16
8
2
48
24
12
3
64
32
16
4
80
40
20
5
96
48
24
6
112
56
28
7
128
64
32
8
144
72
36
9
160
80
40
10
176
88
44
11
192
96
48
12
208
104
52
13
224
112
56
14
240
120
60
15
256
128
64
Address combination value
Speed description
0
500 Kbps
1
250 Kbps
2
125 Kbps

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➢Please select CAN communication speed according to the actual application,
transfer distance, delay time, electromagnetism interference and others should be
considered. The default value of Baud rate is recommended to be 500K.
3.1.2.5 Terminal Definition
Power/CAN bus terminal
Number
Identification
Type
Function
1
+24V
Power Positive Pole
24V power positive pole input
2
CANH
CAN bus
CAN differential data H
3
EARTH
Safety ground
Safety ground / shielded layer
4
CANL
CAN bus
CAN differential data L
5
GND
Power ground
24V power negative pole input
➢When CAN expands, twisted shielded pair is recommended to use, and the shield
connects with the ground.
Terminal Wiring
(Please use tubular pre-insulated terminals and wire cable that is suitable to wire path
to do user terminal wiring)
→Cable production steps:
➢Strip the cable insulation, the exposed copper part depends on the size of the tube-
type pre-insulated terminal.
➢Pass the conductor part of the cable into the tubular pre-insulated terminal and
crimp it with a crimping pliers.
→Wire cable connection steps:
➢Press the spring of the terminal to insert the cable with the tubular pre-insulated
terminal into the port.
➢Loosen the spring of the terminal, pull the cable lightly to check whether the cable
is firmly connected.
3
1 MKbps