Zmotion ZMC004WEA 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.

ZMC004WEA 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..............................................................................................7
2.3. Interface Definition............................................................................................8
2.4. Work Environment .............................................................................................9
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. 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 Port & Single-ended Encoder ...................................21
3.4.1. Digital Input Specification & Wiring .....................................................22
3.4.2. Basic Usage Method ............................................................................23
3.5. OUT Digital Output, Single-ended Pulse.........................................................24
3.5.1. Digital Output Specification & Wiring...................................................25

ZMC004WEA Motion Controller User Manual V1.5
3.5.2. Basic Usage Method ............................................................................26
3.6. AD/DA Analog Input/Output............................................................................27
3.6.1. Analog Input / Output Specification & Wiring ......................................27
3.6.2. Basic Usage Method ............................................................................29
3.7. EtherCAT Bus Interface / Ethernet ..................................................................29
Chapter IV Expansion 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 and Maintenance .............................................................51
6.2. Common Problems..........................................................................................52

ZMC004WEA Motion Controller User Manual V1.5
Chapter I Production Information
1.1. Product Information
ZMC004WEA economical multi-axis motion controller is a stand-alone motion
controller that is compatible with EtherCAT bus and pulse type. The controller itself
supports 4 axes, but 6 axes can be expanded to achieve some simple trajectory control
requirements, such as, linear interpolation, circular interpolation, helical interpolation, etc.
ZMC004WEA economical multi-axis motion controllers can be applied in pulse
applications within 6 axes, electronic 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 pulse output frequency of each axis is 500KHz.
◆IO can be expanded through CAN and EtherCAT, and 512 inputs and 512 outputs can
be extended at most.
◆Axis position limit signal / origin signal port can be configured as any input at will.
◆The maximum output current of general digital outputs can reach 300mA, which can
directly drive some kinds of solenoid valves.

ZMC004WEA Motion Controller User Manual V1.5
◆Interfaces: EtherCAT, RS232, RS485.
◆Support up to 6 axes linear interpolation, arbitrary circular interpolation, helical
interpolation and spline 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.
◆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
controller should be fastened with 4 screws.

ZMC004WEA 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

ZMC004WEA Motion Controller User Manual 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

ZMC004WEA Motion Controller User Manual V1.5
Chapter II Product Specification
2.1. Basic Specification
Item
Description
Model
ZMC004WEA
ZMC004BEA
Basic Axes
4
4
Max Extended Axes
6
6
Array space
16000
2400
Flash space
8MByte
2MByte
Type of Basic Axes
EtherCAT/local pulse axes/encoder axes
Digital IO
There are 16 inputs and 16 outputs.
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
2.2. Order Information
Model
Description
ZMC004WEA
4 axes, point to point, electronic cam, linear, circular, continuous
trajectory motion.

ZMC004WEA Motion Controller User Manual V1.5
ZMC003WEA
3 axes, point to point, electronic cam, linear, circular, continuous
trajectory motion.
ZMC004BEA
4 axes, point to point, electronic 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

ZMC004WEA Motion Controller User Manual V1.5
→Interface Description
Mark
Interface
Number
Description
POW
The led that indicates the
current state.
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
RS232A
RS232A serial port (port0)
1
Use MODBUS_RTU protocol
RS232B
RS232B serial port (port1)
1
Use MODBUS_RTU protocol
RS485
RS485 serial port (port2)
1
Use MODBUS_RTU protocol
EtherCAT
EtherCAT bus interface /
Ethernet
1
EtherCAT bus interface, connect to EtherCAT
bus drive and EtherCAT bus 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-ended encoder function.
OUT
Digital IO output port
16
NPN type, the power is supplied by internal
24V power supply. There are 8 high-speed
outputs, OUT8-15 have single-ended pulse
function.
AD
Analog input
2
12-bit resolution, 0-10V.
DA
Analog output
2
12-bit resolution, 0-10V.
2.4. Work Environment
Item
Parameters
Work Temperature
-10℃-55℃
Work relative Humidity
10%-95% non-condensing

ZMC004WEA Motion Controller User Manual V1.5
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

ZMC004WEA 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
5.08mm. And this 5pin terminal is shared by main power and CAN communication.
→Terminal Definition (Main Power):
Terminal
Name
Type
Function
+24V
Input
Main 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
Type
Function
EGND
Input
IO Power Ground
+24V
Input
IO Power 24V input
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.

ZMC004WEA 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
CAN interface of the controller uses standard CAN communication protocol, there are
mainly 3 terminals, CANL, CANH and public 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 module to the CANL and CANH of
the other side correspondingly. And public ends of the CAN bus communication both
parties are connected together. In CAN bus left and right sides, connect a 120Ωresistor
respectively (please see below graphic).

ZMC004WEA Motion Controller User Manual V1.5
→Wiring Notes:
⚫As above, the daisy chain topology is used for wiring, so the star topology cannot be
used. When the use environment is ideal and there are few nodes, the branch
structure can also be considered.
⚫Please connect a 120Ω terminal resistor (when there is one to one connection or the
number of slave stations is few and the wiring is relatively short, the terminal resistor
can not be added) in parallel at the two 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 current and
weak current wiring, it is recommended 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.
→Cable Requirements:

ZMC004WEA Motion Controller User Manual V1.5
Twisted pair shielded wire, and shielded cable grounded.
3.1.3. Basic Usage Method
(1) Please follow the above wiring instructions for correct wiring.
(2) After power on, 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 details.

ZMC004WEA Motion Controller User Manual V1.5
3.2. RS232A Serial Port
RS232A is in one standard DB9 male socket and supports MODBUS_RTU protocol
and custom communication.
→Interface Definition:
Terminal
PIN
Name
Type
Function
1, 4, 6,
7, 8
NC
Spare
Reserved
2
232A-RXD
Input
RS232A (port0), receive signal
3
232A-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 Distance
The Longer communication distance is,
the lower communication rate is,
maximum 10m is recommended.

ZMC004WEA Motion Controller User Manual V1.5
→Wiring Reference:
→Wiring Notes:
⚫The wiring of RS232A is as above, it needs to cross-wiring for sending and receiving
signals, and it is recommended to use a double-female head cross 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 instructions to wiring correctly.