Zmotion XPLC864E 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.

XPLC864E Motion Controller User 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........................................................................................4
Chapter II Product Specification .........................................................................................7
2.1. Basic Specification............................................................................................7
2.2. Order Information..............................................................................................8
2.3. Interface Definition............................................................................................9
2.4. Work Environment ...........................................................................................10
Chapter III Wiring, Communication Configuration ............................................................11
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 & Single-ended Encoder ...........................................20
3.4.1. Digital Input Specification & Wiring .....................................................22
3.4.2. Basic Usage Method ............................................................................23
3.5. OUT Digital Output ..........................................................................................24
3.5.1. Digital Output Specification & Wiring...................................................25

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3.5.2. Basic Usage Method ............................................................................27
3.6. AD/DA Analog Input / Output..........................................................................27
3.6.1. Analog Input / Output Specification & Wiring ......................................28
3.6.2. Basic Usage Method ............................................................................29
3.7. ETHERNET .......................................................................................................29
3.8. EtherCAT Bus Interface ...................................................................................31
Chapter IV Expansion 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 Inspection and Maintenance .............................................................52
6.2. Common Problems..........................................................................................53

XPLC864E Motion Controller User Manual V1.5
Chapter I Production Information
1.1. Product Information
XPLC864E is a kind of economical multi-axis motion controller that integrates Basic,
PLC and HMI programming methods.
XPLC864E economical multi-axis motion controller is a kind of standalone motion
controller that is compatible with EtherCAT bus and pulse type, and itself supports 8 axes
motion control, but 12 axes can be expanded to achieve some control requirements, such
as point to point, linear motion, electronica cam, etc.
XPLC864E economical 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 period of EtherCAT bus is 1ms.
◆Pulse output mode: directional/pulse or dual pulse.
◆Support encoder position measurement, which can be configured as handwheel
input mode.
◆The max output pulse frequency of each axis can reach 500kHz.
◆IO can be expanded through ZCAN and EtherCAT, and 512 isolated inputs and 512
isolated outputs can be extended at most.

XPLC864E Motion Controller User Manual V1.5
◆Axis position limit signal / origin signal port can be configured as any input at will.
◆The maximum output current of general digital outputs OUT28-31 can reach 500mA,
which can directly drive some kinds of solenoid valves.
◆Interfaces: EtherCAT, RS232, RS485, Ethernet.
◆Support 12 axes linear interpolation, any circular interpolation, helical 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 XPLC864E motion controller is installed horizontally with screws, and each controller
should be fastened with 4 screws.

XPLC864E Motion Controller User Manual V1.5
→Unit: mm →Mounting Hole Diameter 4.5mm
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:
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)

XPLC864E 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

XPLC864E Motion Controller User Manual V1.5
Chapter II Product Specification
2.1. Basic Specification
Item
Description
Model
XPLC864E
XPLC664E
Basic Axes
8
6
Max Extended Axes
12
Type of Basic Axes
EtherCAT bus axes/pulse axes/encoder
Digital IO
There are 32 inputs and 32 outputs.
Max Extended IO
512 inputs, 512 outputs
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
128MByte
Power Supply Input
24V DC main power input, 24V DC IO power input
Communication Interfaces
RS232, RS485, Ethernet, CAN, EtherCAT
Dimensions
219*135mm

XPLC864E Motion Controller User Manual V1.5
2.2. Order Information
Model
Description
XPLC664E
6 axes EtherCAT control, it supports linear interpolation, any
circular interpolation and helical interpolation.
XPLC664E2
6 axes EtherCAT control, it supports linear interpolation, but
doesn’t support circular interpolation and helical interpolation.
XPLC864E
8 axes EtherCAT control, it supports linear interpolation, any
circular interpolation and helical interpolation.
XPLC864E2
8 axes EtherCAT control, it supports linear interpolation, but
doesn’t support circular interpolation and helical interpolation.
XPLC1264E
12 axes EtherCAT control, it supports linear interpolation, any
circular interpolation and helical interpolation.
XPLC1264E2
12 axes EtherCAT control, it supports linear interpolation, but
doesn’t support circular interpolation and helical interpolation.

XPLC864E Motion Controller User Manual V1.5
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
conducted.
RUN
1
Run state: it lights when runs normally
ALM
1
Error state: 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

XPLC864E Motion Controller User Manual V1.5
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”
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 type, power is supplied by IO
24V power. OUT16-31 can be configured as
pulse axes.
AD
Analog input port
2
12-bit resolution, 0-10V.
DA
Analog output port
2
12-bit resolution, 0-10V.
2.4. 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

XPLC864E Motion Controller User Manual V1.5
Chapter III Wiring, Communication
Configuration
3.1. Power Input, CAN Communication Interface
The power supply input adopts 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. This terminal is the power supply of the controller, and it is shared with CAN
communication at the same time.
→Main Power Terminal Definition:
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
Main power ground / CAN public end
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
Name
Type
Function
EGND
Input
IO power ground
E24V
Input
Power 24V input
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.

XPLC864E Motion Controller User Manual V1.5
3.1.1. Power Specification
→Specification
Item
Main Power
IO Power
Voltage
DC24V(-5%~5%)
DC24V(-5%~5%)
The current to open
≤0.5A
≤0.3A
The current to work
≤0.4A
≤0.2A
Anti-reverse connection
Valid
Valid
Overcurrent Protection
Valid
Valid
3.1.2. CAN Communication Specification & Wiring
The CAN interface of the controller adopts the standard CAN communication
protocol, which 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
maximum of 100m is recommended.
→Wiring Reference
Connect the CANL and CANH of the standard CAN module to the CANL and CANH of
the other side correspondingly. And public ends of the CAN bus communication both

XPLC864E Motion Controller User Manual V1.5
parties are connected together. In CAN bus left and right sides, connect a 120Ωresistor
respectively (please see below graphic).
→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.
⚫Please connect a 120Ω terminal resistor in parallel to each end of 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
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.

XPLC864E Motion Controller User Manual V1.5
→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 ETHERNET or RS232 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 details.
(4) Correctly set the "address" and "speed" of the slave station expansion module
according to the manual of the slave station.

XPLC864E Motion Controller User Manual V1.5
(5) After all the settings are completed, restart the power supply of all stations to
establish communication.
(6) Note that the "speed" settings of each node on the CAN bus must be consistent, and
the "address" settings cannot cause conflicts, otherwise the "ALM" alarm light will be
on, and the communication establishment will fail or the communication will be
disordered.
3.2. RS485 Serial Port
The communication interface adopts 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 Specification & Wiring
The RS485 serial port supports the MODBUS_RTU protocol and custom
communication, mainly including 485A, 485B and public end.
→Specification
Item
RS485
Maximum Communication Rate (bps)
115200
Terminal Resistor
No
Topological Structure
Daisy Chain Topology

XPLC864E Motion Controller User Manual V1.5
The number of nodes can be extended
Up to 127
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.
→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.
⚫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 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.