Zmotion EIO1616 User manual

Foreword
The motion controller provides rich interface, and it has excellent motion control performance, which
can meet the expansion requirements of various projects.
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. The
above-mentioned actions will constitute an infringement of the copyright of the company's manual, and
Zmotion will investigate legal responsibility according to law.
For details about the 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 design an effective safety protection device in the machine, and add an error
handling program in the software, otherwise Zmotion has no obligation or responsibility for the loss
caused.
In order to ensure the safe, normal and effective use of the product, please be sure to read this
product manual carefully before installing and using the product.

Safety Statement
⚫This chapter describes the safety precautions required for the correct use of this product. Before
using this product, please read the instructions for use and correctly understand the relevant
information on safety precautions.
⚫This product should be used in an environment that meets the design specifications, otherwise
it may cause equipment damage or personal injury, and malfunctions or component damage
caused by failure to comply with relevant regulations are not within the scope of product quality
assurance.
⚫Zmotion will not take any legal responsibility for personal safety accidents and property losses
caused by failure to comply with the contents of this manual or illegal operation of products.
Safety Level Definition
According to the level, it can be divided 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
misoperation or damage to the equipment.
◆It is forbidden to use in the following places: places with dust, oil fume, conductive
dust, corrosive gas and flammable gas; places exposed to high temperature,
condensation, wind and rain; places with vibration and shock. Electric shock, fire
and misuse can cause product damage and deterioration.
Notice
◆Avoid metal shavings and wire ends falling into the hardware circuit board during
installation.
◆After installation, ensure that there are no foreign objects on the hardware circuit
board.
◆When installing, make it tightly and firmly with the mounting frame.

◆Improper installation of the controller may result in misoperation, failure and fire.
Wiring
Danger
◆The specifications and installation methods of the external wiring of the
equipment shall comply with the requirements of local power distribution
regulations.
◆When wiring, all external power supplies used by the system should be
disconnected before operation.
◆When powering on and running after the wiring work is completed, the terminals
attached to the product must be installed.
◆Cable terminals should be well insulated to ensure that 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 are in good
contact.
◆Do not bundle the control wires and communication cables with the main circuit
or power supply wires, etc., and the distance between the wires should be more
than 100 mm, otherwise noise may cause malfunction.
◆If the controller is not installed properly, it may cause electric shock or equipment
failure or malfunction.

EIO1616 Bus Expansion Module User Manual V1.5
Content
Chapter I Production Information........................................................................................2
1.1. Product Information ..........................................................................................2
1.2. Function Features..............................................................................................2
1.3. System Frame ...................................................................................................2
1.4. Hardware Installment........................................................................................2
Chapter II Product Specification .........................................................................................5
2.1. Interface Definition............................................................................................5
2.2. Order Information..............................................................................................6
2.3. Work Environment .............................................................................................6
Chapter III Wiring, Communication Configuration & Ethernet ............................................7
3.1. Power Input .......................................................................................................7
3.1.1. Power Specification................................................................................8
3.2. IN Digital Input...................................................................................................8
3.2.1. Digital Input Specification......................................................................9
3.2.2. Digital Input Wiring.................................................................................9
3.3. OUT Digital Output ..........................................................................................10
3.3.1. Digital Output Specification .................................................................10
3.3.2. Digital Output Wiring ............................................................................11
3.4. EtherCAT Bus Interface ...................................................................................12
3.5. Expansion Module Usage................................................................................14
Chapter IV Expansion Module ...........................................................................................16
4.1. EtherCAT Expansion Wiring Reference............................................................16
4.2. EtherCAT Bus Expansion Resource Mapping .................................................17
Chapter V Run and Maintain .............................................................................................19
5.1. Regular Inspection and Maintenance .............................................................19
5.2. Common Problems..........................................................................................20

EIO1616 Bus Expansion Module User Manual V1.5
Chapter I Production Information
1.1. Product Information
EIO1616 bus expansion module is used for EtherCAT bus controller, when IO and
other resources are not enough, the controller can link with multiple EIO1616 through
EtherCAT bus. And IO and axis resources of EIO1616 can be accessed by mapping No.
1.2. Function Features
◆Digital expansion: there are 16 inputs and 16 outputs (it can select PCB type, module
type or module cover type)
◆The fastest refresh cycle of EtherCAT is 250us.
◆It has IO status display led, which can check IO status conveniently.
1.3. System Frame
1.4. Hardware Installment
EIO1616 bus expansion module is installed horizontally with screws, and each controller
should be fastened with 4 screws.

EIO1616 Bus Expansion Module User Manual V1.5
→Unit: mm →Mounting Hole Diameter 3.5mm
Installation
attention
⚫Non-professionals are strictly prohibited to operate. Specifically,
professionals who had been trained related electrical equipment,
or who master electrical knowledge.
⚫Please be sure to read the product instruction manual and safety
precautions carefully before installation.
⚫Before installation, please ensure that the product is powered off.
⚫Do not disassemble the module, otherwise the machine may be
damaged.
⚫Avoid direct sunlight installation.
⚫In order to facilitate ventilation 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, please do not install the controller in the following
places:

EIO1616 Bus Expansion Module User Manual V1.5
a) places where the surrounding ambient temperature exceeds
the range of -20°C-60°C
b) places where the ambient humidity exceeds the range of 10%-
95% (non-condensing)
c) places with corrosive gases and flammable gases
d) places with many conductive powders such as dust and iron
powder, oil mist, salt, and organic solvents.

EIO1616 Bus Expansion Module User Manual V1.5
Chapter II Product Specification
2.1. Interface Definition
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
Main power state: it lights when main power
is conducted.
EtherCAT 0
EtherCAT bus
interface
1
Connect to main controller or former level
expansion module.
EtherCAT 1
1
Connect to drive equipment or behind level
expansion module.
Digital input
16
NPN type, IO power 24V
Digital output
16
NPN type, IO power 24V
Main power
1
24V DC power supplies for main control area

EIO1616 Bus Expansion Module User Manual V1.5
of expansion module.
2.2. Order Information
Model
Functions
EIO1616
Internal 16 digital inputs, 16 digital outputs
EIO1616M
Internal 16 digital inputs, 16 digital outputs, with module type
EIO1616MT
Internal 16 digital inputs, 16 digital outputs, with module cover type
2.3. Work Environment
Item
Parameters
Work Temperature
-10℃-55℃
Work relative 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

EIO1616 Bus Expansion Module User Manual V1.5
Chapter III Wiring, Communication
Configuration & Ethernet
3.1. Power Input
The power supply input adopts a 3Pin (there are all 3 terminals) screw-type pluggable
wiring terminal. IO power inputs are in digital IO outputs, power is supplied by 24V DC
power.
→Terminal Definition:
Main Power
Name
Type
Function
EARTH
Grounding
Shield layer
GND
Input
Power ground
+24V
Input
Power 24V inputs
Note: please use +24V and IO24V separately for power supply. It is not recommended
to use the same power supply. It is recommended to use two 24V output power
supplies or a power supply that can provide two isolated 24V output.
IO Power
Name
Type
Function
IO24V
Input
IO power 24V input
IOGND
Input
IO power ground
Note: please use +24V and IO24V separately for power supply. It is not recommended
to use the same power supply. It is recommended to use two 24V output power
supplies or a power supply that can provide two isolated 24V output.

EIO1616 Bus Expansion Module User Manual V1.5
3.1.1.Power Specification
→Specification
Item
Main Power
IO Power
Voltage
DC24V(-10%~10%)
DC24V(-5%~5%)
The current to open
≤0.5A
/
The current to work
≤0.4A
≤0.5A
Anti-reverse connection
Valid
Valid
Overcurrent Protection
Valid
Valid
3.2.IN Digital Input
→Terminal Definition
Terminal
Name
Type
Function 1
IOGND
/
IO power ground
IOGND
/
IO power ground
IN0
NPN type,
digital inputs
Input 0
IN1
Input 1
IN2
Input 2
IN3
Input 3
IN4
Input 4
IN5
Input 5
IN6
Input 6
IN7
Input 7
IOGND
/
IO power ground
IOGND
/
IO power ground
IN8
NPN type,
digital inputs
Input 8
IN9
Input 9
IN10
Input 10
IN11
Input 11
IN12
Input 12
IN13
Input 13
IN14
Input 14
IN15
Input 15

EIO1616 Bus Expansion Module User Manual V1.5
3.2.1. Digital Input Specification
Item
Digital input (IN0-15)
Input mode
NPN type, input is triggered when in low-electric level
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
optoelectronic isolation
Note: the above parameters are standard values when the voltage of expansion
module power supply (E+24V port) is 24V.
3.2.2. Digital Input Wiring
→Wiring Note:
⚫The wiring principle of digital inputs IN (0-15) is shown in the figure above. The
external signal source can be an optocoupler, a key switch or a sensor, etc., all can
be connected as long as the requirements on output of electric level can be achieved.
⚫For the public end, please connect the "IOGND" port on the 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 expansion module are in the same power

EIO1616 Bus Expansion Module User Manual V1.5
supply system, this connection also can be omitted.
3.3. OUT Digital Output
→Terminal Definition
Terminal
Name
Type
Function
IOGND
/
IO power ground
IO24V
/
IO power input DC24V
OUT0
NPN leakage,
digital outputs
Output 0
OUT1
Output 1
OUT2
Output 2
OUT3
Output 3
OUT4
Output 4
OUT5
Output 5
OUT6
Output 6
OUT7
Output 7
IOGND
/
IO power ground
IO24V
/
IO power input DC24V
OUT8
NPN leakage,
digital outputs
Output 8
OUT9
Output 9
OUT10
Output 10
OUT11
Output 11
OUT12
Output 12
OUT13
Output 13
OUT14
Output 14
OUT15
Output 15
3.3.1. Digital Output Specification
Item
Digital Output (OUT0-15)
Output mode
NPN leakage type, it is 0V when outputs
Frequency
＜8kHz

EIO1616 Bus Expansion Module User Manual V1.5
Voltage level
DC24V
Max output current
+300mA
Max leakage current when off
25μA
Respond time to conduct
12μs
Respond time to close
80μs
Overcurrent protection
Support
Isolation method
optoelectronic isolation
Note:
The times in the form are typical based on the resistive load, and may change
when the load circuit changes.
Due 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. And it is recommended to set below 8KHz.
3.3.2. Digital Output Wiring
→Wiring Note:
⚫The wiring principle of digital outputs OUT (0-15) is shown in the figure above. The
external signal receiving end can be an optocoupler or a relay or solenoid valve, all
can be connected as long as the input current does not exceed 300mA.

EIO1616 Bus Expansion Module User Manual V1.5
⚫For the connection of the public end, please connect the "IOGND" port on the IO power
supply to the negative pole of the DC power supply of the external input device. If the
DC power supply of the external device and the expansion module power supply are
in the same power supply system, this connection can also be omitted.
3.4. EtherCAT Bus Interface
EIO1616 bus expansion module has 2 100M EtherCAT communication interfaces,
and they support EtherCAT protocol. EtherCAT 0 is connected to main controller or former
level expansion module, but EtherCAT 1 is connected to drive equipment or next level
expansion module, they can not be mixed. The pin definition is as follows:
→Specification
Item
Specification
Communication protocol
EtherCAT protocol
Valid service
CoE(PDO, SDO), FoE
Synchronization method
IO adopts input and output synchronization / DC-
distributed clock
Physical level
100BASE-TX
Duplex mode
Full duplex
Topology
linear topology

EIO1616 Bus Expansion Module User Manual V1.5
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
→Communication Cable Requirements
EtherCAT communication interface adopts 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:
Item
Specification
Cable type
Flexible crossover cable, Category 5e
traverse
twisted pair
Line pairs
4
Isolation
cross skeleton
Connector
Crystal head with iron shell
Cable material
PVC
Cable length
Less than 100m
Use RJ45 network cable connection 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.

EIO1616 Bus Expansion Module User Manual V1.5
Please use tube-type pre-insulated terminals and cables with appropriate wire
diameters to connect the user terminals.
→Interface Indicator Led Definition
Item
Function
Color
Status
Description
Link /
Act
Yellow
OFF commonly
MAC is not connected
Shrink
MAC has been connected and
data has been sent & received.
ON commonly
MAC has been connected but
no data sent & received.
Link /
Act
Green
OFF commonly
PHY is not connected
Shrink
PHY has been connected and
data has been sent & received.
ON commonly
PHY has been connected but
no data sent & received.
3.5. Expansion Module Usage
1) Please follow the above wiring instructions to correctly complete the wiring of power
supply, EtherCAT bus, IO signal and other modules.
2) After the controller is powered on, please use the ETHERNET interface to connect to
ZDevelop.
3) Set the IO No. of the expansion module through the bus command NODE_IO, and
configure the input and output at the same time. The program on the controller can
access the resources on the expansion module only through the IO No. When IO
mapping, first check the maximum IO number of the controller itself (including the
external IO interface and the interface in the pulse axis), and then use the command
to set. The IO NO. mapping must not be repeated in the whole control system.
4) After the setting is completed, the communication can be established. If the
communication is successful, "controller status" - "Slot0Nodes " will display the
information of the expansion module.

EIO1616 Bus Expansion Module User Manual V1.5
5) The state value of the corresponding input port can be directly read through the "IN"
command, and the state of the input port can also be visually checked through the
"ZDevelop/View/IN" interface or the IO indicator light on the expansion module. For
details, see "ZBasic Programming Manual".
6) The port can be turned on or off directly through the "OP" command, or it can be
turned on or off by clicking directly on the "ZDevelop/View/OP" interface, or the IO
indicator on the expansion module can visually check the output port status. For
details, see "ZBasic Programming Manual".

EIO1616 Bus Expansion Module User Manual V1.5
Chapter IV Expansion Module
4.1. EtherCAT Expansion Wiring Reference
EIO digital expansion module is powered by the dual power. Except the main power,
one IO power is needs connecting additionally to supply power for IO independently. Main
power and IO power both use 24V DC power.
To prevent interference, the IO power supply is separated from the main power supply.
After the EIO1616 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 No. is set through the bus command NODE_IO,
and the program on the controller can access the resources on the expansion module
only through the IO number.
When wiring, pay attention that EtherCAT IN is connected to the upper-level module,
and EtherCAT OUT is connected to the lower-level module. The IN and OUT ports cannot
be mixed.
EIO expansion module wiring reference example (take ZMC408SCAN as an example):
Involved number concepts in above figure are as follows: the bus-related command
parameters will use the following numbers:
Slot number (slot):
The slot number refers to the number of the bus interface on the controller, and the