Zmotion XPLC300 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.

XPLC300 Motion Controller Hardware Manual V1.5
Content
Chapter I Production Information........................................................................................3
1.1. Product Information ..........................................................................................3
1.2. Function Features..............................................................................................3
1.3. System Frame ...................................................................................................4
1.4. Hardware Installment........................................................................................5
Chapter II Product Specification .........................................................................................7
2.1. Basic Specification............................................................................................7
2.2. Nameplate Information .....................................................................................8
2.3. Order Information..............................................................................................8
2.4. Interface Definition............................................................................................9
2.5. Work Environment ...........................................................................................10
Chapter III Wiring, Communication Configuration & .........................................................11
3.1. User Terminal ..................................................................................................11
3.1.1. Power Specification..............................................................................11
3.1.2. RS485, RS232 Communication Specification & Wiring .......................12
3.1.3. Basic Usage Method ............................................................................14
3.1.4. Digital Input Specification & Wiring .....................................................15
3.1.5. Basic Usage Method ............................................................................17
3.2. U Disk ..............................................................................................................17
3.3. ETHERNET .......................................................................................................18
3.4. EtherCAT Bus Interface ...................................................................................19
Chapter IV Expansion Module ...........................................................................................22
4.1. Local Expansion ..............................................................................................22
4.2. Function Configuration....................................................................................23
4.2.1. Local IO Offset Configuration...............................................................23
4.2.2. Local Analog Offset Configuration.......................................................24
4.2.3. IO Offset Configuration for ZMIO Expansion (that comes with XPLC300
controller)............................................................................................................24
4.2.4. Analog Offset Configuration for ZMIO Expansion (that comes with
XPLC300 controller)............................................................................................24
Chapter V Program & Applications....................................................................................26

XPLC300 Motion Controller Hardware Manual V1.5
5.1. ZDevelop Software Usage...............................................................................26
5.2. PC Upper-Computer Program Application .....................................................31
Chapter VI Run and Maintain ............................................................................................34
6.1. Regular Inspection and Maintenance .............................................................34
6.2. Common Problems..........................................................................................35

XPLC300 Motion Controller Hardware Manual V1.5
Chapter I Production Information
1.1. Product Information
XPLC300 motion controllers is a kind of EtherCAT vertical fieldbus motion controller
that supports ladder diagram programming. The controller itself supports max 16 axes to
achieve point to point, linear interpolation, electronic cam and other control requirements.
This manual mainly describes XPLC300 series’ specification, property, usage, etc.
Please read this manual carefully for know more about the product and use more safely.
XPLC300 series 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
◆16 axes motion control at most.
◆IO can be expanded through EtherCAT, and 512 inputs and 512 outputs can be
extended at most.
◆Interfaces: EtherCAT, RS232, RS485, Ethernet.
◆Support point to point, synchronous motion, motion superposition, electronic cam,
linear interpolation, etc.
◆Support U disk file reading and writing and application program upgrading, it is
convenient to remote maintain on-site.
◆Support ZPLC, ZBasic and ZHMI programming.

XPLC300 Motion Controller Hardware Manual V1.5
◆Support secondary development on all kinds of PC platforms.
◆Support multi-file and multi-task programming in ZBasic, and PC program and
controller inner program can work at the same time.
◆A variety of program encryption methods to protect the intellectual property rights of
customers.
◆Support power failure detection and power failure storage. (It can detect and save
when power-off)
1.3. System Frame

XPLC300 Motion Controller Hardware Manual V1.5
1.4. Hardware Installment
→Unit: mm
→Installation Step:
➢Please use 35mm standard DIN guide rail.
➢Open guide rail buckle of ECAT communication module, then embed the controller in
the DIN guide rail.
➢Press fit guide rail buckle of ECAT communication module, then fix the controller in
the DIN guide rail.
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.

XPLC300 Motion Controller Hardware Manual V1.5
⚫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:
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

XPLC300 Motion Controller Hardware Manual V1.5
Chapter II Product Specification
2.1. Basic Specification
Item
Description
Basic Axes
There are 4/6/8/12 axes
Max Extended Axes
16
Type of Basic Axes
EtherCAT bus axes (no pulse axes and ecoder)
Digital IO
1 input and no output
Max Extended IO
512 inputs and 512 outputs
AD/DA
No
Max Extended AD/DA
128 ADs and 64 DAs
Pulse Bit
32
Encoder Bit
32
Speed and Acceleration Bit
32
Motion Buffer of Each Axis
128
Array Space
320000
VR
1024
Program Space
6144KByte
Flash Space
8192KByte
Power Supply Input
24V DC input
Communication Interfaces
RS232, RS485, Ethernet, EtherCAT
Power
2.5W
Internal power provides for
behind-level module
6W
Local expansion behind-
level interface ability
16 input/output modules can be expanded at most (max
256 Ios), or 8 AD/DA modules (max 32 analogs).

XPLC300 Motion Controller Hardware Manual V1.5
2.2. Nameplate Information
Here shows XPLC312E, others are the same rule.
→Model description:
2.3. Order Information
Model
Axes
Encoder
Total axes
IN/OUT
AD/DA
Description
XPLC304E
4
-
16
1/0
-
Point to point,
linear
interpolation,
electronic cam
XPLC306E
6
-
16
1/0
-
XPLC308E
8
-
16
1/0
-
XPLC312E
12
-
16
1/0
-

XPLC300 Motion Controller Hardware Manual V1.5
2.4. Interface Definition
→Interface Description
Mark
Interface
Number
Description
POW
The led that indicates the
current state.
1
Power state: green, it lights when power is
conducted.
RUN
1
Run state: green, it lights when runs normally
ALM
1
Error state: red, it lights when runs incorrectly
RS232
RS232 serial port (port0)
1
Use MODBUS_RTU protocol
RS485
RS485 serial port (port1)
1
Use MODBUS_RTU protocol
EtherCAT
EtherCAT bus interface
1
EtherCAT bus interface, connect to EtherCAT
bus drive and EtherCAT bus expansion
module
ETHERNET
Network port
1
Use MODBUS_TCP protocol, expand the
number of network ports through the
interchanger, and the number of net port
channels can be checked through “?*port”

XPLC300 Motion Controller Hardware Manual V1.5
command, default IP address is 192.168.0.11
UDISK
U disk interface
1
Insert U disk equipment
E+24V
Main power supply
1
24V DC power, it supplies the power for
controller.
2.5. Work Environment
Item
Parameters
Work Temperature
-20℃-60℃
Work relative Humidity
10%-95% non-condensing
Storage Temperature
-40℃～80℃(not frozen)
Storage Humidity
Below 90%RH (no frost)
Vibration
Below 4.9m/s^2
Shock
Below 19.6m/s^2
Degree of Protection
IP20

XPLC300 Motion Controller Hardware Manual V1.5
Chapter III Wiring, Communication
Configuration &
3.1. User Terminal
The user terminal adopts a 9Pin (there are all 3 terminals) screw-type pluggable wiring
terminal, and the interval (means the gap distance between two ports) should be 3.81mm.
And power, RS485 and RS232 communication all can be connected and used through
corresponding interfaces of this terminal.
→Terminal Definition:
Terminal
Name
Type
Function
232RX
Serial port
RS232 signal, receive signal
232TX
RS232 signal, send signal
GND
Public end
Public ends of 232, 485 and IN0 (cannot
be as negative pole of power supply)
485A
Serial port
485 differential data A
485B
485 differential data B
IN0
Input
Switch input 0
+24V
Power positive
Positive (+) terminal of DC power input
EGND
Power negative
Negative (-) terminal of DC power input
EARTH
/
case grounding protection
3.1.1. Power Specification
→Specification
Item
Description

XPLC300 Motion Controller Hardware Manual V1.5
Voltage
DC24V(-10%~10%)
The current to open
≤0.5A
The current to work
≤0.4A
Anti-reverse connection
Valid
Overcurrent Protection
Valid
3.1.2. RS485, RS232 Communication Specification &
Wiring
RS485 serial port supports MODBUS_RTU protocol and custom communication, mainly
including 485A, 485B and public end.
RS232 serial port supports MODBUS_RTU protocol and custom communication, mainly
including 232RX, 232TX and public end.
→Specification
Item
RS485
RS232
Maximum Communication Rate (bps)
115200
115200
Terminal Resistor
No
No
Topological Structure
Daisy Chain Topology
1 to 1
The number of nodes can be extended
Up to 127
1
Communication Distance
The longer communication distance is, the
lower communication rate is, and maximum
of 100m is recommended.
→Wiring Reference
Connect 485A and 485B of RS485 to 485A and 485B of the controller correspondingly,
and connect the public ends “EGND”of RS485 communication parties together.

XPLC300 Motion Controller Hardware Manual V1.5
Connect 232RX and 232TX of RS232 to 232RX and 232TX of the controller
correspondingly, and connect the public ends “GND”of RS232 communication parties
together.
→Wiring Notes:
⚫As above, the daisy chain 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.
⚫The wiring of RS232 is above, and cross-wiring is needed when receiving and
accepting signals, and it is recommended to use the cross-cable with double-female
head when connecting to the computer.
⚫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

XPLC300 Motion Controller Hardware Manual V1.5
weak current, it is recommended for the distance to be more than 20cm.
⚫It should be noted that the equipment grounding (chassis) on the entire line must be
good, and the grounding of the chassis should be connected to the standard factory
ground pile.
⚫When routing terminal wiring cables, avoid bundling them with cables with strong
interference signals such as power lines, and must route them separately.
→Cable Requirements:
Shielded Twisted Pair, and the shielded cable is grounded.
3.1.3. Basic Usage Method
(1) Please follow the above wiring instructions to wiring correctly.
(2) After powered on, please use any one interface among the three interfaces
(ETHERNET, RS232, 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) 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

XPLC300 Motion Controller Hardware Manual V1.5
“ZBasic Programming Manual” for details.
(5) According to their respectively instructions, correctly set the relevant parameters of
the third-party equipment to match the parameters of each node.
(6) Correctly set the "address" and "speed" of the slave station expansion module
according to the manual of the slave station.
(7) After all the settings are completed, restart the power supply of all stations to
establish communication.
3.1.4. Digital Input Specification & Wiring
→Specification
Item
General input (IN0)
Input mode
NPN leakage, input is triggered when it is 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)

XPLC300 Motion Controller Hardware Manual V1.5
Max current
-6mA (negative)
Isolation mode
optoelectronic isolation
Note: the above parameters are standard values when the voltage of controller power
supply (E+24V port) is 24V.
→Wiring Reference
→Wiring Note:
⚫The wiring principle of high-speed digital input IN (0) 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 "EGND" port on the 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.
⚫When routing terminal wiring cables, avoid bundling them with cables with strong
interference signals such as power lines, and must route them separately.